AMCI ANS1 ANYNET-I/O User manual

MICRO CONTROLS INC.
ADVANCED
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Manual #: 940-0A090

ADVANCED MICRO CONTROLS INC.
GENERAL INFORMATION
Important User Information
The products and application data described in this manual are useful in a wide variety of different applica-
tions. Therefore, the user and others responsible for applying these products described herein are responsible
for determining the acceptability for each application. While efforts have been made to provide accurate infor-
mation within this manual, AMCI assumes no responsibility for the application or the completeness of the
information contained herein.
UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS, INC. BE RESPONSIBLE OR
LIABLE FOR ANY DAMAGES OR LOSSES, INCLUDING INDIRECT OR CONSEQUENTIAL DAM-
AGES OR LOSSES, ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS
MANUAL, OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN.
No patent liability is assumed by AMCI, with respect to use of information, circuits, equipment, or software
described in this manual.
The information contained within this manual is subject to change without notice.
This manual is copyright 2014 by Advanced Micro Controls Inc. You may reproduce this manual, in whole or
in part, for your personnal use, provided that this copyright notice is included. You may distribute copies of
this complete manual in electronic format provided that they are unaltered from the version posted by
Advanced Micro Controls Inc. on our official website: www.amci.com. You may incorporate portions of this
documents in other literature for your own personal use provided that you include the notice “Portions of this
document copyright 2014 by Advanced Micro Controls Inc.” You may not alter the contents of this document
or charge a fee for reproducing or distributing it.
Standard Warranty
ADVANCED MICRO CONTROLS, INC. warrants that all equipment manufactured by it will be free from
defects, under normal use, in materials and workmanship for a period of [18] months. Within this warranty
period, AMCI shall, at its option, repair or replace, free of charge, any equipment covered by this warranty
which is returned, shipping charges prepaid, within eighteen months from date of invoice, and which upon
examination proves to be defective in material or workmanship and not caused by accident, misuse, neglect,
alteration, improper installation or improper testing.
The provisions of the "STANDARD WARRANTY" are the sole obligations of AMCI and excludes all other
warranties expressed or implied. In no event shall AMCI be liable for incidental or consequential damages or
for delay in performance of this warranty.
Returns Policy
All equipment being returned to AMCI for repair or replacement, regardless of warranty status, must have a
Return Merchandise Authorization number issued by AMCI. Call [phone] with the model number and
serial number (if applicable) along with a description of the problem during regular business hours, Monday
through Friday, 8AM - 5PM Eastern. An "RMA" number will be issued. Equipment must be shipped to
AMCI with transportation charges prepaid. Title and risk of loss or damage remains with the customer until
shipment is received by AMCI.
24 Hour Technical Support Number
24 Hour technical support is available on this product. If you have internet access, start at www.amci.com.
Product documentation and FAQ’s are available on the site that answer most common questions.
If you require additional technical support, call [phone]. Your call will be answered by the factory dur-
ing regular business hours, Monday through Friday, 8AM - 5PM Eastern. During non-business hours an auto-
mated system will ask you to enter the telephone number you can be reached at. Please remember to include
your area code. The system will page an engineer on call. Please have your product model number and a
description of the problem ready before you call.
We Want Your Feedback
Manuals at AMCI are constantly evolving entities. Your questions and comments on this manual are both wel-
comed and necessary if this manual is to be improved. Please direct all comments to: Technical Documenta-
tion, AMCI, 20 Gear Drive, Terryville CT 06786, or fax us at [phone]. You can also e-mail your
questions and comments to [email protected]

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Tel: [phone] Fax: [phone] http://www.amci.com 3
TABLE OF CONTENTS
General Information
Important User Information ..................... 2
Standard Warranty ................................... 2
Returns Policy .......................................... 2
24 Hour Technical Support Number ........ 2
We Want Your Feedback ......................... 2
About this Manual
Audience .................................................. 7
Applicable Units ...................................... 7
Trademark Notices ................................... 7
Revision Record ....................................... 7
Navigating this Manual ............................ 7
Manual Conventions ................................ 8
Where To Go From Here ......................... 8
Chapter 1: Introduction to the ANS1
AnyNET-I/O ............................................ 9
The ANS1 ................................................ 9
Physical Description ................................ 10
Front Panel ..................................... 10
Status LED’s .................................. 11
I/O Connectors ............................... 12
Power Connector ........................... 12
Web Interface Connector ............... 12
Network Connections .................... 13
Compatible Transducers .......................... 13
Compatible AMCI Transducers .... 13
Compatible AMCI Encoders ......... 13
Compatible Foreign Transducers .. 13
Programming Web Interface .................... 14
Web Page Access Levels ............... 14
Module Specifications ............................. 14
Electrical Specifications .......................... 15
Connectors ............................................... 15
Chapter 2: Limit Switch 
Functionality
Global Machine Position ......................... 17
Advanced Parameter Use .............. 18
Global Machine Speed ............................. 18
Chapter 2: Limit Switch 
Functionality 
(continued)
Limit Switch Outputs ............................... 19
Limit Switch Offset ...................... 19
Stitch Programming ...................... 20
Limit Advances ............................. 21
Fixed Delays ............................. 21
Variable Delays ........................ 22
Timed Limits ................................. 22
Limit Output Enabling ............................. 23
Machine Speed Enabling .............. 23
Simple ANDing ............................ 23
Pulse ANDing ............................... 24
Window ANDing .......................... 24
Shift Register ANDing .................. 25
Shift Register Programming ..... 25
Limit Switch Programming ...... 25
Application Example ................ 25
Chapter 3: Additional Functionality
Brake Monitor .......................................... 27
Stop Time Monitoring .................. 27
Start Time Monitoring .................. 28
Die Protection Monitors ........................... 28
Normally True Check ................... 28
Normally False Check .................. 28
Cyclic Check ................................. 29
Constant Check ............................. 31
Quick Check ................................. 33
Production Counters ................................. 34
Part Cycle Counter ........................ 34
Batch Counters 1, 2, 3 ................... 35
Good Part Counter ........................ 35
Machine Revolutions .................... 35
Using Batch Counter Outputs ....... 35
Chapter 4: Installing the ANS1
Module Installation .................................. 37
Module Location ........................... 37
Safe Handling Guidelines ............. 37
Prevent Electrostatic Damage ... 37
Prevent Debris From Entering
the Module ............................. 37
Remove Power Before Servicing
in a Hazardous Environment . 37

Table of Contents
ADVANCED MICRO CONTROLS INC.
4
Chapter 4: Installing the ANS1 
(continued)
Module Mounting ......................... 38
Dimensions ............................... 38
Compatible DIN Rail ................ 38
Installing IC-5 Connectors ....... 39
Mounting the AnyNET-I/O 
Module ................................... 39
Stack Addressing .......................... 39
Powering the Module ............................... 40
Required Power ............................. 40
Wiring ........................................... 40
Transducer Installation ............................. 40
AMCI Engineering Data
Download Location ....................... 40
AMCI Transducer Mounting 
Guidelines ................................... 41
Transducer Cabling .................................. 41
Suggested Cable ............................ 41
Installation Guidelines .................. 42
Single Resolver Transducers ........ 42
Single Resolvers ........................... 43
Foreign Transducers ................................. 43
Quadrature Encoder Installation ............... 44
AMCI Compatible Encoders ........ 44
Differential Wiring ....................... 44
Single Ended Wiring ..................... 45
Relay Board Installation ........................... 45
DIN Rail / Panel Mount
Conversion .................................... 46
RB-7 Outline Drawing .................. 46
RB-8 Outline Drawing .................. 47
Compatible Relays ........................ 47
Connections to the ANS1 ............. 48
Powering the RB Boards ............... 48
I/O Wiring ................................................ 49
Relay Board Inputs ....................... 49
Relay Board Outputs ..................... 49
ANS1 Inputs ................................. 50
ANSI Outputs ............................... 51
Encoder Output Wiring ................. 52
Slave Module Wiring .................... 52
HTTP Interface ......................................... 52
Chapter 5: Output Data Format
Command Word ....................................... 53
Command Block 0: Clear Errors Only ..... 53
Command Block 1: Define Return Data 
and I/O Forces ........................................ 54
Command Word Bits ..................... 54
Return Data Attribute Number ...... 55
Output Force Words ...................... 55
Input Force Words ......................... 55
Command Block 2: 
Global Machine Configuration ... 56
Command Word Bits ..................... 56
Global Machine Bit Parameters 
(Word 1) ..................................... 57
Command Block 3: 
Program Limit Setpoints ........................ 58
Command Word Bits ..................... 58
LS Setpoint Pair Data Format ....... 59
Command Block 4: 
Adjust LS Setpoint Positions .................. 60
Command Word Bits ..................... 60
Command Block 5: 
Program LS Timing Parameters ............. 61
Command Word Bits ..................... 61
Command Block 6: 
Program LS Enabling Parameters .......... 62
Command Word Bits ..................... 62
Command Block 7: 
Program Die Protection Parameters ....... 65
Command Word Bits ..................... 65
Command Block 8: 
Program Brake Monitor Parameters ....... 67
Command Word Bits ..................... 67
Command Block 9:
Program Shift Register Parameters ....... 68
Command Word Bits ..................... 68
Command Block 10: 
Program Production Cycle Parameters ... 69
Command Word Bits ..................... 69
Command Block 11: Program 
Production Counter Parameters .............. 70
Word 1: Counter Number .............. 70
Word 0: Command Word Bits ...... 71
Command Block 15: 
Save/Restore Program ............................ 72
Command Word Bits ..................... 72
Word 1 Values ............................... 72

20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786
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Table of Contents
5
Chapter 6: Input Data Format
Available Data Attribute Blocks .............. 73
Data Attribute Number .................. 73
Status Word 0 ........................................... 73
Bit Values ...................................... 74
Data Attribute 0: 
Global Setup Data ................................. 75
Data Attribute 1: 
LS Setpoint Programming Data ............ 76
Data Attribute 2: 
LS Output Adjustments Data ................ 77
Data Attribute 3: 
Enabling Input Programming Data ....... 78
Data Attribute 4: 
Die Monitor Setup Data ........................ 79
Data Attribute 5: 
Brake Monitor Setup Data .................... 80
Data Attribute 6: 
Shift Register Setup Data ...................... 81
Data Attribute 7: 
Production Cycle Setup Data ................ 81
Data Attribute 8: 
Counter Setup Data ............................... 82
Data Attribute 16: 
Machine Status Data ............................. 83
Data Attribute 17: 
Counter Value Data .............................. 85
Data Attribute 18: 
Die Monitor Data .................................. 86
Data Attribute 19: Brake Monitor 
and Output Advance Data ..................... 87
Data Attribute 20: 
Shift Register Data ................................ 88

Table of Contents
ADVANCED MICRO CONTROLS INC.
6
Notes

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Tel: [phone] Fax: [phone] http://www.amci.com 7
ABOUT THIS MANUAL
Audience
This manual explains the set-up, installation, and operation of AMCI’s ANS1 AnyNET-I/O Programmable
Limit Switch module. It is written for the engineer responsible for incorporating these modules into a design,
as well as the engineer or technician responsible for its actual installation.
Applicable Units
This manual applies to all ANS1 modules, including those that have an integral network connection. Exam-
ples of these modules includes the ANS1E with an integral Ethernet port. Integral network connections allow
the ANS1 to connect itself, and up to five other modules, to an industrial network.
If you have an ANS1 module with a network interface, you will have to refer to the appropriate AnyNET-I/O
Network Interface manual for information on connecting the module to your network. These manuals can be
found in the PDF document section of our website at www.amci.com/documents.asp
The AnyNET-I/O product line is constantly evolving. Check our website, www.amci.com for
the latest information on available modules and network interfaces in the AnyNET-I/O line.
Trademark Notices
The AMCI logo is a trademark of Advanced Micro Controls Inc.
All other trademarks contained herein are the property of their respective holders.
Revision Record
This manual, 940-0A090, is the first revision of this manual. It was released December 18th, 2014.
Navigating this Manual
This manual is designed to be used in both printed and on-line formats. Its on-line form is a PDF document,
which requires Adobe Acrobat Reader version 7.0+ to open it. The manual is laid out with an even number of
pages in each chapter. This makes it easier to print a chapter to a duplex (double sided) printer.
Bookmarks of all the chapter names, section headings, and sub-headings were created in the PDF file to help
navigate it. The bookmarks should have appeared when you opened the file. If they didn’t, press the F5 key
on Windows platforms to bring them up.
Throughout this manual you will find blue text that functions as a hyperlink in HTML documents. Clicking
on the text will immediately jump you to the referenced section of the manual. If you are reading a printed
manual, most links include page numbers. You will also find red text that functions as a hyperlink. These
links will bring you to the AMCI website. Note that after clicking on a red link, the program may ask for con-
firmation before connecting to the Internet.
The PDF file is password protected to prevent changes to the document. You are allowed to select and copy
sections for use in other documents and, if you own Adobe Acrobat version 7.0 or later, you are allowed to
add notes and annotations.
Read this chapter to learn how to navigate through this manual and familiarize
yourself with the conventions used in it. The last section of this chapter high-
lights the manual’s remaining chapters and their target audience.

ABOUT THIS MANUAL
ADVANCED MICRO CONTROLS INC.
8
Manual Conventions
Three icons are used to highlight important information in the manual:
NOTES highlight important concepts, decisions you must make, or the implications of those
decisions.
CAUTIONS tell you when equipment may be damaged if the procedure is not followed
properly.
WARNINGS tell you when people may be hurt or equipment may be damaged if the proce-
dure is not followed properly.
The following table shows the text formatting conventions:
Where To Go From Here
This manual contains information that is of interest to everyone from engineers to operators. The table below
gives a brief description of each chapter’s contents to help you find the information you need to do your job.
Format Description
Normal Font Font used throughout this manual.
Emphasis Font Font used the first time a new term is introduced.
Cross Reference When viewing the PDF version of the manual, clicking on
the cross reference text jumps you to referenced section.
HTML Reference When viewing the PDF version of the manual, clicking on
the HTML reference text will open your default web
browser to the referenced web page.
CHP
Num. Chapter Title Intended Audience
1Introduction
to the ANS1 Anyone new to the ANS1. This chapter gives a basic overview of
the features available on the unit, typical applications, and electri-
cal specifications.
2Limit Switch
Functionality
Anyone that needs detailed information on the limit switch features
available on the ANS1, including how the ANS1 calculates
machine position, limit switch programming, and how to use the
output enable features.
3Additional
Functionality Anyone that needs detailed information on the additional function-
ality available on the ANS1, including brake monitoring, die pro-
tection, and production counters.
4Installing the ANS1 Anyone that needs detailed information on installing the ANS1,
transducers, relay boards, and I/O wiring.
5Output Data Format Anyone that needs information on the format of the data written to
the ANS1.
6Input Data Format Anyone that needs information on the format of the data retrieved
from the ANS1.

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CHAPTER 1
INTRODUCTION TO THE ANS1
AnyNET-I/O
The ANS1 is an expansion to the AnyNET-I/O product line from
AMCI. The concept of this product line is simple: specialty and/or
high speed I/O that can be attached to any popular industrial net-
work; hence the name AnyNET-I/O.
AnyNET-I/O is designed for a broad range of applications, from
small machines with a single control enclosure, to large machines
that use distributed I/O extensively to minimize wiring costs.
What makes the AnyNET-I/O line different is that all of the mod-
ules are available with or without a network interface. Eliminating
the need for a separate networking module lowers the total cost of
ownership for all applications, but especially for the cost sensitive
small machines that only require one or two sophisticated func-
tions.
Like many modern controllers, AnyNET-I/O modules are
designed to be DIN rail mounted. Up to six AnyNET-I/O modules
can be stacked together and accessed over a single network inter-
face. “Stacking” is accomplished through a small backplane con-
nector that snaps into the DIN rail before the AnyNET-I/O
modules are installed. These connectors allow the AnyNET-I/O
modules to communicate with each other. To the network, the
stack of modules appear as one continuous block of I/O words.
The ANS1
The ANS1 is a Programmable Limit Switch module that accepts 12 to 24 Vdc as its power source. The
ANS1 offers the following functionality:
A total of forty programs that can be stored on the ANS1. If the ANS1 is attached to a host controller,
additional programs can be stored on the host.
Eight relay and eight DC outputs. These outputs can be configured as limit switch, fault, counter over-
flow, or general purpose outputs.
Sixteen DC inputs. Inputs can be used to condition the outputs (Enable ANDing), preset machine or
limit switch positions, or as general purpose inputs.
Four setpoint pairs per limit switch as well as On/Off advances and timer output functionality.
Three different Enable ANDing tests for conditioning the limit switch outputs.
RPM ANDing to condition the outputs based on the speed of the machine.
256-bit Shift Register for machines that require multiple turns to create a single part.
Sixteen programmable Die Protection Monitors with fault counters that can monitor five different types
of events to guarantee proper machine operation.
Brake Monitor that reports both starting and stopping time of the machine.
A total of six counters that include three batch counters, a total machine revolutions counter, a total
parts counter, and a total good parts counter.
This manual is designed to get you quickly up and running with the ANS1 Pro-
grammable Limit Switch Module. It is possible to purchase an ANS1 with or with-
out a network interface. This manual only covers the functionality unique to the
ANS1. Information on connecting to the network interface is available in the
appropriate AnyNET-I/O Network Interface manual available on the AMCI website.
Figure 1.1 AnyNET-I/O Module Stack

Introduction to the ANS1
ADVANCED MICRO CONTROLS INC.
1
10
The ANS1 (continued)
It offers a single transducer input for position feedback that can either be a resolver based transducer or an
incremental encoder. If additional I/O points are needed, multiple ANS1 modules can be slaved together.
One ANS1 interfaces with the position transducer and broadcasts the position value to the remaining ANS1
modules over a high speed serial link.
An AMCI AnyNET-I/O Stack is limited to six modules, and all of them can be ANS1 modules. This gives
you up to ninety-six I/O points in a single AnyNET-I/O Stack. The slave interface is an RS485 serial link that
can conservatively drive sixty-four modules. If your application require more than six modules, you can
slave them together, but you will need multiple network connections to program them.
Like all AnyNET-I/O modules, the ANS1 can
be attached to a host controller through vari-
ous industrial networks including:
EtherNet/IP
Modbus TCP
Modbus RTU
Profibus-DP
The ANS1 is the first AnyNET-I/O module to
include an integral web server, which allows
you to program the ANS1 from any web
browser. This allows you to run the ANS1 as
an independent product, without the need of a
host controller. If slaving multiple modules
together, each module has to be programmed
separately. The IP address of the web server is
programmable, so all of the modules can be
brought into one ethernet switch and pro-
grammed from one web browser connection.
Physical Description
Front Panel
Figure 1.3 shows the layout of the front panel. Compared
to most of the other AnyNET-I/O modules, the ANS1 is a
double width module. Even though it is twice the width, it
only takes one slot in the AnyNET-I/O stack.
Relay Board Connector. Allow the ANS1 to be con-
nected to AMCI RB-7 or RB-8 relay boards. These
relay boards give you access to all sixteen input and
output points. I/O on the relay board are numbered
1 through 8 when programming the ANS1.
Relay Cable Ground Lug. Use this point to ground
the shields on the relay board cable.
Stack Address DIP Switch. Used to set the address
of the ANS1 in an AnyNET-I/O Stack. If the ANS1
is used as the network host, then the module must
have an address of zero. (All switches off.)
Figure 1.2 ANS1 Web Interface
ADDRESS
PLS
PWR FUSE
IN OUT
09 09 13 13
10 1014 14
11 1115 15
12 1216 16
Relay
Board
Connector
I/O Status
LED’s
Relay
Cable
Ground
Lug
Stack
Address
DIP Switch
Module Status LED
Figure 1.3 ANS1 Front Panel Callout

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Introduction to the ANS1 1
11
Physical Description (continued)
Status LED’s
Figure is a close up of the front of the module that shows the locations of the
ANS1 Status LED’s.
Power. States are off or solid green. If off, the module is without
power or a hardware error has occurred. If on, the module and outputs
are working normally.
Fuse. States are off or solid red. If off, the output drivers on the ANS1
are operating normally. If on, the one or more of the outputs are in an
overload condition, and the internal resettable fuse has opened.

Note that none of the outputs will conduct current if the FUSE LED is
on.
Inputs 9 - 16. States are off or solid orange. If off, the input on the
ANS1 is not receiving power. If on, the input is receiving power. 

Note that the input status LED’s only display the powered state of the
inputs. They do not show the logical state of the input. If an input is
programmatically forced on or off, this state will not be reflected in the LED’s.
Outputs 9 - 16. States are off or solid orange. The LED reflects the logical state of the output, including
whether or not the output is forced on or off.
As shown in figure 1.3 on page 10 and figure 1.6 on page 12, a Module Status LED is located on the bottom
of the module, below the relay board connector. This LED gives additional information on the state of the
ANS1.
Table 1.1 Module LED States
LED State Module State
Solid Green Module and Transducer are operating normally.
Blinking Green One or more outputs are being forced on or off.
Solid Red
1) Non-Clearable Transducer Fault. (Most common occurrence)
Signals from the resolver cannot be decoded. Most common cause is a
wiring issue.
2) Module Fault. (Rare occurrence)
Remove power, and remove all I/O connections. Restore power. If the
error remains, contact AMCI for technical assistance. If the error clears,
begin the process of removing power, installing one I/O connector, and
applying power to the ANS1. Repeat the process until you discover the
connector with the problem.
Blinking Red Clearable Resolver Transducer Fault. The transducer fault latch has been
enabled on the ANS1. A Clear Errors command must be issued to clear the fault.
ADDRESS
PLS
PWR FUSE
IN OUT
09 0913 13
10 10
14 14
11 1115 15
12 1216 16
Figure 1.4 Status LED’s

Introduction to the ANS1
ADVANCED MICRO CONTROLS INC.
1
12
Physical Description (continued)
I/O Connectors
Figure shows the pinout of the Main and I/O connectors located on the top of the ANS1. Mating connectors
are supplied with the ANS1. Additional connectors can be ordered from AMCI under the part number 
MS-2x11.
Figure 1.5 I/O Connector Pinout
Power Connector
As shown in figure 1.6 below, the power connector is located on the bottom of the module. The mating con-
nector is included with the ANS1. Spares are available from AMCI under the part number MS-4M. They are
also available from Phoenix Contact under their part number 187 80 37.
Figure 1.6 ANS1 Bottom View
Web Interface Connector
Figure 1.6 also shows the location of the Web Interface Connector. This RJ45 Ethernet connector accepts any
standard CAT5 or CAT6 network cable and allows you to monitor and program the ANS1 over its built in
web server. This allows you to program and use an ANS1 without a host controller.
11
10
9
8
7
6
5
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
-Ref (R2)
+Sin (R3)
Shield
-Z In/Out
-B In/Out
-A In/Out
QuadDir
-RxD (Slave)
-TxD (Slave)
Reserved
Reserved
Reserved
Shield
N.C.
Input 9
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Input 16
+Ref (R1)
+Cos (S4)
Com (S1,S2)
+Z In/Out
+B In/Out
+A In/Out
Ground
+RxD (Slave)
+TxD (Slave)
Reserved
Reserved
Reserved
Common
+Vdc In
Output 9
Output 10
Output 11
Output 12
Output 13
Output 14
Output 15
Output 16
11
10
9
8
7
6
5
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
J2 J4
J2 J4J1 J3
J1 J3
Power Connector
Web Interface
Connector
Module
Status LED

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Introduction to the ANS1 1
13
Physical Description (continued)
Network Connections
Figure 1.6 on the previous page also shows the location on the ANS1 that is reserved for network connec-
tions. If your ANS1 has a network connection, such as the ANS1E for Ethernet networks, connection to the
network will be made here. Refer to the appropriate AnyNET-I/O Network Interface manual for additional
information.
Compatible Transducers
The ANS1 is compatible with resolver based transducers as well as quadrature incremental encoders.
Resolver based transducers offer absolute position feedback and will survive the harshest of industrial envi-
ronments. Encoders offer the ability to easily change the length of a single machine cycle. Note that the
ANS1 does not decode the Z-channel of the encoder.
AMCI offers broad lines of transducers that are compatible with the ANS1.
Compatible AMCI Transducers
All R11X-J resolvers
All R15X-J resolvers
The HT-6 single turn transducer with the standard AMCI resolver
All members of the H25 family of single turn transducers with the standard AMCI resolver
All members of the HT-20 family of single turn transducers with the standard AMCI resolver
All members of the HT-20-(x) family of multi-turn transducers with the standard AMCI resolver
All members of the HT-400 family of single turn transducers with the standard AMCI resolver
All members of the HT-400-(x) family of multi-turn transducers with the standard AMCI resolver
Further information on AMCI transducers can be found on our website starting at:
http://www.amci.com/resolvers.asp
Compatible AMCI Encoders
All DC25 incremental encoders with differential outputs
Further information on AMCI incremental encoders can be found on our website starting at:
http://www.amci.com/rotary-encoders/incremental-rotary-encoder.asp
Compatible Foreign Transducers
Popular resolver transducers from other manufacturers can be used with the ANS1. Most of them will require
a Reference Module from AMCI to make the resolver compatible with the ANS1. The Reference Module is a
single ended transformer that either raises or lowers the reference going out to the resolver so the return sig-
nals are in the proper range for the ANS1.
Any incremental encoder with 5 volt differential output drivers is compatible with the ANS1. The ANS1 can
also be used with encoders that use a higher voltage driver or have single ended outputs with the use of appro-
priate current limiting resistors.

Introduction to the ANS1
ADVANCED MICRO CONTROLS INC.
1
14
Programming Web Interface
The ANS1 has an internal web server that allows you to program and use the module without a host control-
ler. The web server is accessed through the RJ-45 pot on the bottom of the ANS1, below the relay board con-
nector. The location of the connector is shown in figure 1.6 on page 12. The RJ-45 is an auto-sensing port.
A computer can be directly connected to the port with a standard ethernet cable. A crossover cable is not nec-
essary.
Programming the ANS1 from the web interface is password protected. There are four levels of access:
Visitor: (No password) Read only access
Operator: (Default password = ‘123’) Can clear faults, reset/preset counters, and increment/decre-
ment limit setpoints.
Supervisor: (Default password = ‘456’) Can perform all Operator functions as well as full limit
switch programming, counter setup, and die protection setup.
Master: (Default password = ‘987’) Access to all functions, including brake monitor setup, IP set-
tings, and password settings.
Passwords are made up of alphanumeric characters and can be up to twelve characters in length.
Web Page Access Levels
If you attempt to use a function that is not allowed for your access level, the ANS1 will bring you to the User
Log In screen and wil either present you with the password screen, or with a button that allows you to logout.
Table 1.2 Web Page Access Levels
Screen Description Master Supervisor Operator
Stored Programs All Functions All Functions Load Only
Machine Status All levels can clear a transducer fault.
I/O States All Functions All Functions View Only
Counters All Functions All Functions Cannot Preset
Program Cycles
Faults All Functions All Functions All Functions
Shift Register View Only Screen
Limit Positions All Functions All Functions View Only
Limit Adjust All Functions All Functions All Functions
Anding/Enable All Functions All Functions View Only
Timing/Advances All Functions All Functions View Only
Counters All Functions All Functions Only Batch
Counter
Programming
Shift Register All Functions All Functions View Only
Die Protection All Functions All Functions View Only
Net Config All Functions View Only View Only
Machine Config All Functions View Only View Only
Password Admin All Functions No Access No Access
Brake Monitor All Functions View Only View Only

20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786
Tel: [phone] Fax: [phone] http://www.amci.com
Introduction to the ANS1 1
15
Module Specifications
Number of I/O Words (16 bits each)
20 input words and 20 output words
Physical Dimensions
Width: 1.8 inches max.
Depth: 4.5 inches max.
Height: 3.9 inches
5.0 inches min. with mating connectors
Weight
0.50 lbs. (0.23 kg.) with mating connectors
Position Sensor
Resolver or Quadrature Encoder (4X decode)
Multiple units can be slaved together over a serial
link.
Number of Outputs
(16) 8 Relay Outputs, 8 DC Sourcing Outputs
Number of Inputs
16 DC inputs. 
(8) DC Sourcing Inputs on relay board
(8) DC Sinking Inputs on module
Throughput Time
Master ....... 10 to 20 microseconds
Depending on load and programming
Slave ......... 50 microseconds
Web Interface Default IP
192.168.0.40 (Programmable from interface.)
Limit Switch Functionality
Maximum of sixteen outputs 
Four on/off setpoint pairs per output
Separate on/off advances per output
Fixed and Variable advances available for
brake/clutch control
Timer functionality (Interval On)
... 1 to 32,767 milliseconds
Enable ANDing 
Output can be tied to one or more inputs
Speed Enable (RPM between setpoints)
High Enable (Input must be active)
Pulse Enable (Input must pulse within 
output’s setpoint pairs.)
Window Enable (Input must pulse within
programmable window’s setpoint pairs.)
Shift Register (Associated bit position in shift
register must equal ‘1’.)
Shift Register
256 bits. Updated once per machine cycle.
Logic ‘1’ placed in register’s first bit if input
active during programmed sensing window.
Die Protection Monitors
(16) Monitors. 
Activated when an input is assigned to it.
Normally True Check
Normally False Check
Cyclic Check
Constant Check
Pulse Check
Each monitor has an 8 bit fault counter.
Output can be assigned to monitor to signal fault
condition.
Brake Monitor
Monitors starting & stopping times of the machine
Resolution ............ 1 millisecond
Range ................... 1 to 32,767 milliseconds
Reports:
Starting Position
Starting Time
Brake Applied Position
Stopping Time
Production Counters
Machine Revolutions
Program Cycles
(3) Batch Counters
Good Part Counter
Range ................................. 0 to 999,999,999
Counters can be preset to any value within their
range.
Batch Complete Outputs
Separate outputs can be assigned to the Machine
Cycle counter and each of the three batch coun-
ters to signal when the counter has reached its
programmable setpoint.
Part Cycle Counter
Good Part Counter
Machine Revolution Counter
Programmable Fault Outputs
Die Protection Fault
Start Time Fault
Stop Time Fault
Status LED’s
See Status LED’s starting on page 11.

Introduction to the ANS1
ADVANCED MICRO CONTROLS INC.
1
16
Electrical Specifications
Module Power
ANS1 Power ..... 12 to 24 Vdc ± 20%, surge to
30Vdc without damage to 
module.
ANS1 Current ... 225 mA @ 24 Vdc (5.4 watts)
All DC Inputs
Nominal Voltage Range ..... 12 to 24 Vdc
On State .............................. 10 to 30 Vdc
Off State ............................. 0 to 5 Vdc
Input Impedance ................ 3.3 Kohm
Encoder Outputs
DS26LS31 Driver. 5 Vdc @ 20 mA output
Onboard Limit Switch Outputs
Nominal Voltage Range .... 12 to 24 Vdc
(ANS1 power supply)
Current per Output ............ 1 Adc @ 30°C
0.5 Adc @ 60°C
Current Limit for 2 ............ <4A 
(Overload condition)
Short Circuit Protection .... Electronic. (Cycle
power to restore.)
Inductive Spike ................. Current Limited
Relay Outputs
KD-6 ........... 3 to 60 Vdc
3 Adc
KA-3 ........... 120 Vac
3 Aac
Environmental Specifications
Ambient Operating Temperature
........... -4° to 122°F (-20° to 50°C)
Storage Temperature
........... -40° to 185°F (-40° to 85°C)
Humidity ........... 0 to 95%, non-condensing
Connectors
Mating connectors are included with the ANS1 and 
are available separately under the following 
AMCI part numbers.
Connector AMCI Part # Wire Strip Length Min. Tightening Torque
I/O MS-2X11 28 - 16 AWG 0.275 inches Spring Cage Connector
Power MS-4M 28 - 12 AWG 0.394 inches 4.43lb-in (0.5 Nm)
Backplane IC-5 Not Applicable

20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786
Tel: [phone] Fax: [phone] http://www.amci.com 17
CHAPTER 2
LIMIT SWITCH FUNCTIONALITY
Global Machine Position
The Global Machine Position is the position value that all limit switches are based on. Limit switch positions
can be offset from the Global Machine Position, but all position values increase and decrease in step with this
position. The ANS1 uses one of two types of sensors to determine the Global Machine Position.
Resolver: An absolute position sensor that is designed for harsh industrial environments. The resolver
is also an absolute sensor and will retain machine position through power cycles. The ANS1 decodes
the resolver position to 4,096 counts per turn.
Quadrature Encoder: An incremental position sensor. The ANS1 is compatible with all encoders that
have industry standard A-quad-B outputs. This includes the incremental DuraCoders that are available
from AMCI. The advantage of the incremental encoder is the fact that it is easy to change the length of
a machine cycle by reprogramming the ANS1. The ANS1 always uses 4X decoding when using a
quadrature encoder, so the counts per turn is equal to the number of lines of the encoder.
Three programmable parameters are used when calculating the Global Machine Position.
Counts per Cycle: [Range of 2 to 4,096, Default of 4,096] Sets the number of counts the position sen-
sor generates for a single cycle of the machine. Most applications have a one to one ratio of sensor
turns to machine cycles. In these applications, this parameter should be set to 4,096 when using a
resolver or four times the number of encoder lines when using a quadrature encoder. (The ANS1 always
uses 4X decoding when using an encoder. This limits the resolution of the encoder to 1,024 lines.)
If your application does not have a one to one ratio of sensor turns to machine cycles, see the
Advanced Parameter Use section below.
Full Scale Count: [Range of 1 to (Counts per Cycle), Default of 360] Used to scale the Counts per
Cycle value to engineering units. The scaled value is reported as the Global Machine Position and is
used while programming limits. If a resolver is used and the Counts per Cycle and Full Scale Count
parameters are left at their default values, the ANS1 will report 360 counts per sensor rotation.
Scaled Machine Offset: [Range of -(Full Scale Count-1) to +(Full Scale Count-1)] Used to offset the
Global Machine Position without physically rotating the shaft of the position sensor. The Scaled
Machine Offset is applied after the position is scaled using the Full Scale Count parameter. This offset
is a circular offset. It offsets the position without changing its range of values. For example, with a Full
Scale Count of 360 and a position value of 10, programming a Scaled Machine Offset of -20 will result
in a Global machine Position of 350.
One additional parameter is available to simplify setting the machine position. This value allows you to pre-
set the Global Machine Position.
Machine Preset Value: [Range of 0 to (Full Scale Count -1), Default of 0] This parameter defines the
value that you want the Global Machine Position to become when you issue a preset command. The
ANS1 presets the Global Machine Position by recalculating the value of the Scaled Machine Offset.
The ANS1 can be preset through a bit on the network output data. The module also give you the ability to
program one of the sixteen inputs as a Machine Preset Input. Once programmed, an inactive-to-active transi-
tion on the input will preset the Global Machine Position to the programmed Machine Preset Value.
This chapter covers the ANS1 functionality and parameters needed to have the
ANS1 act as a programmable limit switch. Parameter that affect position and
velocity feedback are covered, as well as the parameters that set limit switch set-
points and advances. Finally, this chapter also covers limit switch ANDing func-
tionality.

Limit Switch Functionality
ADVANCED MICRO CONTROLS INC.
2
18
Global Machine Position (continued)
Advanced Parameter Use
If your transducer completes less than one rotation for every part cycle on the machine, the Counts per Cycle
parameter can be used to force the Global Machine Position to return to zero before the transducer completes
a full rotation. Table 2.1 shows how the Counts per Cycle parameter affects the roll over position for a
resolver transducer.
Table 2.1 Roll Over Example 1: 4096 Count Transducer
The resolver will remain an absolute sensor if the Counts per Cycle parameter is programmed
to be a power of 2. (2, 4, 8, ... 1024, 2048, 4096). If any other value is used, the machine posi-
tion may be incorrect if the resolver shaft is rotated while power is removed from the machine.
Table 2.2 shows how the Counts per Cycle parameter affects the roll over position for a 2,000 count (500 line)
encoder.
Table 2.2 Roll Over Example 2: 2000 Count Encoder
Global Machine Speed
Global Machine Speed is the shaft speed in RPM. Global Machine Speed is updated every 14.6 milliseconds
and is averaged using an exponentially weighted moving average. A single parameter sets the smoothing fac-
tor for the filter.
RPM Filter: [Range of 0 to 65,535, Default of 40,960] The smoothing factor (kbelow) is a value that is
equal to the RPM Filter / 65,536. The formula below shows how the smoothing factor is used when cal-
culating the Global Machine Speed: 
Where: St= Next Global Machine Speed to be reported
St-1 = Last reported Global Machine Speed
k= RPM FIlter / 65,536
Xt= Measured RPM Value
When the RPM Filter value, and therefore k, is near zero, the last reported Global Machine Speed is almost
completely eliminated and the latest Measured RPM Value is primarily what is reported. This is a signal
without much filtering and it quickly responds to changes in the machine speed.
As the RPM Filter approaches its maximum value, and kapproaches 1, the latest Measured RPM Value is
attenuated more and more. The Global Machine Speed in more heavily filtered and more slowly responds to
changes in machine speed.
The default RPM Filter value yields a smoothing factor of 0.625.
Counts per Cycle Full Scale Count Results
4096 360 360 counts (0 to 359) over one turn of the transducer
3072 2700 2700 counts (0 to 3699) over 3/4 of a turn of the transducer
2048 360 360 counts (0 to 359) over 1/2 of a turn of the transducer
1024 90 90 counts (0 to 89) over 1/4 of a turn of the transducer
Counts per Cycle Full Scale Count Results
2000 1440 1440 counts (0 to 1439) over one turn of the transducer
1500 810 810 counts (0 to 809) over 3/4 of a turn of the transducer
1000 360 360 counts (0 to 359) over 1/2 of a turn of the transducer
500 90 90 counts (0 to 89) over 1/4 of a turn of the transducer
StkS
t1–
1k–Xt +=

20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786
Tel: [phone] Fax: [phone] http://www.amci.com
Limit Switch Functionality 2
19
Limit Switch Outputs
The ANS1 has a total of sixteen outputs, all of which can be used as limit switch outputs. (When using the
additional features described in chapter 3, outputs can be used to indicate faults or overflow conditions.) At
their most basic level, each output can be programmed to turn on and off up to four times within each trans-
ducer cycle based on the Global Machine Position. Four Setpoint Pairs, each with a From Setpoint and a To
Setpoint, define the positions where the output changes state.
Figure 2.1 Basic Limit Switch Output
Limit Switch Offset
Each limit switch has a Limit Position Offset that allows you to offset where the limit switch fires in relation
to the Global Machine Position. You can program this offset directly, or through a Limit Position Preset
Value. Figure 2.2 below shows two limit switches with identical programming. The second has a positive
Limit Position Offset applied to it.
Figure 2.2 Offset Limit Switch Output
When using the Limit Position Preset Value functionality, you can preset the limit switch using a bit in the
network data. You also have the option of programming one of the sixteen inputs as a Limit Position Preset
Input. Multiple limit switches can be associated with a single Limit Position Preset Input so they can be preset
as a group. You can also have multiple Limit Position Preset Inputs, each associated with one or more limit
switch outputs.
One Machine Cycle
From1 From2To1 To2
From4From3 To4To3
Limit
Switch
One Machine Cycle
Limit Position Offset
Limit
Switch 1
Limit
Switch 2

Limit Switch Functionality
ADVANCED MICRO CONTROLS INC.
2
20
Limit Switch Outputs (continued)
Stitch Programming
Stitching allows you to create a regular on/off pattern within a setpoint pair. One application of stitching is
placing a glue pattern on a box before it is sealed. Figure 2.3 shows a single limit switch where the first set-
point pair uses a stitching pattern and the second setpoint pair does not.
Figure 2.3 Stitched Limit Switch Output
The most common way of programming a stitched output is to determine the required On Distance, the
required Off Distance, and the number of times the output must be on. Once the From Setpoint is determined,
the To Setpoint is then calculated as:
When programming a stitched output, you do not enter the number of times the output turns on and off. The
ANS1 calculates the number of times the output changes state based on the programmed On Distance, Off
Distance, and From and To Setpoints. The ANS1 will give a programming error if the four programmed
parameters do not allow the On Distance to occur at least twice and the Off Distance to occur at least once.
Figure 2.3 shows Stitch ON and Stitch OFF distances that were chosen to fit evenly within the From and To
setpoints. It is possible to program the parameters so that the distances do not fit evenly. Two examples are
shown in figure 2.4.
If the remaining distance in the From/To setpoint pair is greater than or equal to one half of the Stitch
ON distance, the output will come on at the end of the limit for the remaining distance.
If the remaining distance in the From/To setpoint pair is less than one half of the Stitch ON distance, the
output will be off at the end of the limit for the remaining distance.
Figure 2.4 Additional Stitched Limit Switch Examples
One Machine Cycle
Stitch ON Distance Stitch OFF Distance
From1
From2To1 To2
Limit
Switch
To Setpoint (On Distance * {Times On}) + (Off Distance * {Times On -1})=
One Machine Cycle
Stitch ON
Distance
Stitch ON
Distance
½ Stitch ON
½ Stitch ON
Stitch OFF
Distance
Stitch OFF
Distance
From1
From1
From1
From1
To1
To1
To1
To1
Limit
Switch
Limit
Switch
Limit
Switch
Limit
Switch