Gemco 2500 Series User manual

High-Speed Programmable Limit Switch
2500
High-SpeedPLS
Series956
ABSOLUTEPROCESSCONTROL
KNOWWHEREYOUARE...REGARDLESS
INSTALLATION MANUAL
2500Series

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
Preface
This manual is for the Installation
and Maintenance of the Gemco 2500
Programmable Limit Switch.
AMETEK has checked the accuracy of
this manual at the time it was printed.
Any comments you may have for
the improvement of this manual are
welcomed.
AMETEK reserves the right to revise
and redistribute the entire contents
or selected pages of this manual.All
rights to the contents of this manual are
reserved byAMETEK.
WARNING: Caution must be
taken when adjusting limit
outputs!
Disconnect power before servicing.
The Gemco 2500 PLS contains no
serviceable components other than
relays and fuses. Consult factory for
repair or replacement.

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
Contents
Chapter 1: Introduction.............................4
1.1 Mechanical Cams..................................5
1.2 Description.............................................5
1.3 Standard Features.................................7
Chapter 2: Hardware Overview................9
2.1 PLS Module...........................................9
2.2 Remote Operator Interface...................11
2.3 Expansion Modules..............................11
2.4 ResolverAssembly..............................12
2.5 Status Display/Programming Keys......14
2.6 Dimension Drawings............................16
Chapter 3: Mounting and Wiring............20
3.1 Mechanical Installation........................20
3.2 Electrical Installation............................21
3.3 Wiring Instructions...............................21
Chapter 4: Programming........................30
4.1 Main Controller Keypad.......................30
4.2 Programming Keys Defined.................31
4.3 Before You Start..................................32
4.4 Menu Tree...........................................33
4.5 User and Supervisor ModeAccess.....33
Chapter 5: Global Parameters................35
5.1 Quick Start...........................................35
5.2 Initialize System...................................36
5.3 Expansion Boards...............................37
5.4 Lockout Functions...............................38
5.5 Scale Factor........................................39
5.6 Customize Decimal Pt.
(Decimal Location)...............................40
5.7 Electronic Offset..................................41
5.8 Motion Detect......................................42
5.9 Enable Brake Input..............................43
5.10 Brake Monitor....................................43
5.11 Set Fault Clear Option.......................45
5.12 Customize Display.............................46
5.13 Define Title Screen............................47
5.14 Label Outputs....................................48
5.15 Label Inputs.......................................49
5.16 Define User Password.......................50
5.17 Define Supervisor Password.............51
5.18 Software Version...............................52
Chapter 6: Limit Switch Outputs............53
6.1 Setpoint Data.......................................54
Chapter 7: Multiple Program..................56
7.1 NamingAProgram..............................57
7.2 EditingAProgram................................58
7.3 CopyingAProgram..............................59
7.4AccessingAProgram...........................60
7.5 Initialize Program.................................61
Chapter 8: Linear Speed Compensation 62
8.1 Linear Speed Compensation...............64
8.2 Minimum Speed Disable......................65
Chapter 9: Time Based Outputs.............66
Chapter 10: Inputs...................................67
10.1 Input Configuration............................71
10.2 Input Configuration for No Input........73
10.3 Input Configuration for
Reset to Preset Continuous...............74
10.4 Input Configuration for
Reset to Preset Single.......................75
10.5 Input Configuration for
Output Enable One Shot...................76
10.6 Input Configuration for
Output Enable Level..........................77
10.7 Enable Brake Input............................78
Chapter 11: Die Protection Inputs..........79
11.1Applications for Die Protection Inputs 79
11.2 Input Configuration for
Die Protect Momentary......................82
11.3 Input Configuration for
Die Protect Maintain..........................83
11.4 Input Configuration for
Die Protect Partial..............................84
Chapter 12: Faults...................................85
AppendixA: Ordering Information ........89
Appendix B: Specifications....................90
B.1: Main Controller Specifications............90
B.2: Expansion Module Specifications......91
B.3: Remote Operator Interface
Specifications....................................91

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
Chapter 1: Introduction
The 2500 PLS is a high speed resolver
based Programmable Limit Switch that
monitors rotary machine position and
provides discrete limit switch outputs.
These outputs are updated at a much
faster rate than can be accomplished
using any conventional PLC.
The single turn resolver is usually
coupled to the machine shaft at a 1:1
ratio so that one resolver shaft rotation
corresponds to one machine cycle.
As the resolver rotates it generates a
ratiometric analog signal representing an
absolute rotary position. The ratiometric
signal is converted to a digital signal
at the 2500 PLS. Resolvers have no
brushes, contacts, or any frictional parts
to wear out.
As the resolver passes through the user
programmed dwell settings, the 2500
PLS turns electrical switches, known as
outputs, on and off. Outputs can energize
solenoids, relays, or solid-state circuitry
to control external devices. Because the
2500 PLS is completely electronic and
has no frictional parts, it offers several
advantages over mechanical cam
switches:
• Long life with no parts to wear out.
• Easy to use menu driven displays.
• Setpoints can be adjusted instantly
from the controller.
•Adjustments can be made while the
machine is running.
• Programmable inputs allow for complex
output functions that are impossible
with mechanical cams.
• Operating speeds up to 2,000 RPM.

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
1.1 Mechanical Cams
The 2500 Programmable Limit Switch
electronically simulates mechanical cam
switches.Amechanical cam consists
of a mechanical limit switch and a roller
follower whose roller follower rides on
the cam assembly as shown in Figure 1.
The camshaft is driven by the machine
at a 1:1 ratio so that the cam limit switch
turns ON and OFF at specific positions
in the machine cycle. Cam limit switches
have the following disadvantages:
• The roller follower and limit switches
wear out.
• The machine must be stopped during
adjustment.
• On/off patterns are limited to typically
one on and one off per cam. Multiple
on and off points require custom cams.
• The mechanical cam switches are
typically not installed in an easily
accessible location.
• They cannot run at high speeds
because of contact bounce and
mechanical wear.
1.2 Description
The 2500 is a family of PLS’s that
offer unparalleled flexibility. The main
controller is a resolver-based controller
that consists of 8 input and 8 output
relays, one fault check output relay and
one optional brake monitor input relay.
The optional expansion module will
provide 8 additional inputs and outputs
per module. Up to 7 expansion modules
can be driven by the controller for a total
of 64 inputs and 64 outputs.
The 2500 PLS uses a unique, easy to
understand programming sequence. The
traditional number buttons have been
replaced with a rotary knob and the main
controller has a 2x24 vacuum fluorescent
display along with 4 pushbutton keys for
programming.
The keys have been defined as MENU,
ÕÖ and  . The rotary knob scrolls
you easily through the menu drive
alphanumeric display. On-line help
screens have been added to aid in the
setup and troubleshooting of the unit.
System parameters are entered through
a scrolling menu, which is accessed
through the main display. The rotary
knob is used to scroll through the
selections and the  key is used to
select the menu item. The user can view
any system value without entering a
password. However, if the user wants to
change a value, a password is required.
All the parameters are password
protected. Once the password is entered,
the user will be allowed to edit any value
as long as the user does not return to the
main display and the program input is in
the correct state.
System data such as position, RPM, and
brake monitor status will be shown on the
main display. This data can be toggled
through using the rotary knob.
Figure 1-1:
1980 Rotating Cam Limit Switch

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
2500 Stand Alone Main Controller
Clawson, MI 48017 U.S.A.
NP0197900
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ENTER
SCROLL
MENU
2500 SERIES PLS
• 8 Isolated DC Inputs and 8 Solid-StateAC or DC Outputs,
Expandable to 64 (in groups of 8) using 2500E Expansion
Modules
• Rotary Knob with Simple, Menu Driven Programming and Help
Menus
• Brake Monitor
• 2 x 24 Vacuum Fluorescent Display
• Panel Mountable
2500R Remote Operator Interface
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
• Keypad only, used with 2500C Blind Main Controller Units
• 2 x 24 Vacuum Fluorescent Display
• Panel Mountable, up to 25 feet from Main Controller
• Simple RJ45 Connections to Main Controller
• Rotary Knob, with Scrolling, Menu Driven Programming
2500C Blind Main Controller Units
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INPUT STATUS
OUT6 OUT8OUT7OUT5OUT4
IN8IN7IN5 IN6IN4
OUT1 OUT2 OUT3BK IN
AC POWER
50/60 Hz
INTERNALLY FUSED
100-240 VAC
IN3IN2IN1
GND
L2
L1
2500CBXXXX
2500 SERIES PLS
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
R
• 8 Isolated DC Inputs and 8 Solid-StateAC or DC Ouptuts,
Expandable to 64 (in groups of 8) using 2500E Expansion
Modules
• Brake Monitor
• Panel or DIN Rail Mountable
2500E Expansion Modules
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IN4
INPUT STATUS
IN1 IN2 IN3 IN6IN5 IN7 IN8
INTERNALLY FUSED
L1
100-240 VAC
50/60 Hz
AC POWER
GND
L2
OUT4OUT1 OUT2 OUT3 OUT6OUT5 OUT7 OUT8
SERIAL No. >>>>>> D/C >>>>
2500EXXXXX
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
R
• 8 Isolated DC Inputs and 8 Solid-StateAC or DC Outputs
• Panel or DIN Rail Mountable
• Up to 7 Expansions Modules can be Driven From the Main
Controller
• Simple Depluggable Connections
2500 PLS configurations include:

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
1.3 Standard Features
Scale Factor
The Scale Factor is the number of
increments that the PLS counts through
over one rotation of the resolver. For
example, a PLS with a Scale Factor of
360 will count from 0 to 359 over one
revolution.
Offset
The Offset feature is used to electronically
synchronize the PLS displayed position
with the actual machine position. Valid
values are 0 to (one less than the
programmed Scale Factor).
Supervisor Menu
Two levels of programming access are
provided: User and Supervisor. In the
Supervisor Menu, display screens can
be customized and outputs and functions
can be locked out. Each level can be
assigned a password that must be entered
to program the locked out functions. This
can provide key personnel the flexibility
they need while protecting settings against
accidental or unauthorized changes.
Onboard Help
Onboard Help is available from the
2500 PLS 2x24 alphanumeric vacuum
fluorescent display. Each programming
screen has easy to follow English
programming screens.
Multi-program
The Multi-program feature allows
the storage of multiple sets of output
sequences that are pre-programmed
based on various requirements of different
jobs. When jobs are changed, the new
program is simply called up from the
Interface or remote inputs and all outputs
and inputs are automatically set to the
new output sequences. The 2500 PLS is
capable of storing 15 different programs.
Program Name
The Program Name feature allows the
user to assign a name to each program.
Program Copy
The Program Copy feature copies all
parameters from one program to another.
This is useful when inputting data from
one program to another where only minor
changes are needed.
Brake Monitor
The Brake Monitor checks the stopping
time of the machine against a selected
preset stopping time in milliseconds.A
user defined output remains energized
when the stop time parameters are within
tolerance.An excessive stop time will
cause the relay to de-energize, which
could be used to stop further machine
operation.
Motion Detector
Aprogrammable Motion Detector output
will energize a user selected relay when
the transducer speed meets or exceeds
the user programmed RPM value.
Fault Check
The 2500 PLS offers an on-line Fault
Check which provides an automatic,
in-process mechanism to verify that all
major programmable limit switch functions
are operating properly. The fault check
output can be energized by activating
the fault check enable input. The output
is a mechanical relay, which remains
energized during normal operation.

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
Input
Each Input can be configured as either
a reset to preset input, an output
configuration enable input, or a die
protection input.
Output Enabler
The output enable input will enable the
setpoints for one revolution when the input
is activated in a programmed window. The
user can program the window.
Reset to Preset
The Reset to Preset feature allows the
user to reset a pre-defined output to any
preprogrammed position. This feature can
be used to compensate for mechanical
slippage. NOTE: Each output has its own
independent reset input.
Reset Single Shot
The Reset Single Shot feature allows the
user to reset a pre-defined output to any
pre-programmed position. However, with
this feature the output associated with
this input waits for the input signal before
it allows the output to fire. Once the input
is made, the output will only fire one time
and wait for the next input signal.
Die Protection
Die Protection is used in stamping
applications where it is necessary to
monitor a part as it is progressing through
the die. If the part is not detected in the
location, an output will signal the press to
stop.
Output Enable
Output Enable is used in conjunction with
an input. If the input is not seen within a
programmed range, the output associated
with that input will not fire. Output enables
are typically used in gluing applications
where if a product is not present, the
gluing output does not fire.
Setpoint Data
There are up to eight setpoint pairs
available per revolution for each output.
The user can add, delete, or change a
setpoint in the list. Valid setpoints range
from 0 to a value (one less than the
current scale factor). For example, if the
scale factor is set at 1000, then valid
setpoint values range from 0 to 999.
Timed Outputs
Time Based outputs are programmed
like standard outputs to turn on at a
specific resolver position and stay on for a
programmable amount of time.
Minimum Speed
The Minimum Speed Disable will disable
the selected outputs when the Disable
actual RPM falls below the minimum
speed programmed by the user. Valid
minimum speed values range from 0 to
2048.Avalue of zero will disable this
feature. The default value is zero.
Linear Speed
Linear Speed Compensation allows for
setpoints to be adjusted to compensate
for mechanical lag at higher speeds. Each
output can be programmed with its own
adjusted values. The user will program an
on offset and an off offset and the RPM
that is associated with that offset. The unit
will linearize the offset values and adjust
the setpoints for that output based on the
actual RPM value.
Software Version
The software version can be viewed
through the Software Version menu
item. The version number will follow our
standard numbering system with two
digits before the decimal indicating major
releases and the two digits after the
decimal indicating minor releases.

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1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
This section contains mechanical and
electrical information on the 2500 PLS
main controller, expansion modules,
remote operator interface, and resolver
assembly. For specifications, see
Appendix B.
2.1 PLS Module
The 2500 PLS module is an electronic
assembly that can be configured many
different ways.The three main parts are
described in Chapter 1. The following are
features found on the module:
•Arotary knob replaces the standard
number buttons.As the knob is
rotated, it helps guide you through the
programming process. Convenient help
screens guide you through the entire
programming process.
•A2 line x 24 character vacuum
fluorescent display indicates all PLS
functions.
• Eight depluggable solid-state output
relays are located on the back of the
controller. Each output has its own
input located on the opposite side of
the controller.
•An optional depluggable Brake monitor
input relay is located on the back of the
controller. This input can be used to
determine stopping time of the
machine.
• The auxiliary communication port
currently supports ModbusASCII
protocol.
• Resolver input terminals allow
connection to a Gemco resolver or
compatible equipment.
• Expansion ports allow for further
relay expansion. The main controller
is capable of driving 64 outputs and
inputs.
• Fault check.Amechanical relay output
is held closed as long as the PLS is
working properly. If the PLS resolver
circuitry or microprocessor fails, the
relay will open.
• Universal input power. The 2500 PLS
can operate over a wide input range,
100 - 240 VAC, 50/60 Hz.
Chapter 2: Hardware Overview

10
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax [phone] • www.AMETEKAPT.com
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
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INPUT STATUS
IN8IN7IN5 IN6IN4
100-240 VAC
INTERNALLY FUSED
IN1
50/60 Hz
IN3IN2
AC POWER
GND
L2
L1
OUT4 OUT6OUT5 OUT7 OUT8OUT2 OUT3OUT1BK IN
Figure 2-1: 2500CF Main Controller
Figure 2-2: 2500CB Blind Main Controller
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EXPANSION OUT
INPUT STATUS
OUT6 OUT8OUT7OUT5OUT4
IN8IN7IN5 IN6IN4
OUT1 OUT2 OUT3BK IN
AC POWER
50/60 Hz
INTERNALLY FUSED
100-240 VAC
IN3IN2IN1
GND
L2
L1
2500CBXXXX
2500 SERIES PLS
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
R