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
Tel: [phone] Fax: [phone] http://www.amci.com
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

20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786
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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Tel: [phone] Fax: [phone] http://www.amci.com 9
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