KEPCO POSITROL PM2A3 Manual

POSITROL
INSTALLATION & OPERATING INSTRUCTIONS
MODELS
PM2A3
PM2A5
PM2A9
PM2B3
PM2B5
PM2B9
99321 05/02/02
KESSLER-ELLIS PRODUCTS
10 Industrial Way East
Eatontown, NJ 07724
800-631-2165 • 732-649-7100
Fax: [phone]
http://www.kep.com

Proprietary Notice
Theinformationcontainedinthispublicationisderivedinpartfromproprietaryandpatentdata.
This information has been prepared for the expressed purpose of assisting operating and
maintenance personnel in the efficient use of the instrument described herein. Publication of
thisinformationdoesnotconveyanyrightstouseorreproduceitortouseforanypurposeother
thaninconnectionwiththeinstallation,operationandmaintenanceoftheequipmentdescribed
herein.
Copyright 1990
Printed in USA. All Rights Reserved.
WARNING
This instrument contains electronic components that are susceptible to damage by static
electricity. Properhandling* proceduresmustbeobservedduringtheremoval,installation,or
handling of internal circuit boards or devices.
*Handling Procedure
1. Power to unit must be removed.
2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any
printed circuit board or other internal device is installed, removed or adjusted.
3. Printedcircuitboardsmustbetransportedinaconductivebagorotherconductivecontainer.
Boardsmustnot beremovedfromprotectiveenclosureuntil theimmediatetimeofinstallation.
Removedboards must beplaced immediately inprotective container fortransport, storage, or
return to factory.
Comments
This instrument is not unique in its content of EDS (electrostatic discharge) sensitive
components. Most modern electronic designs contain components that utilize metal oxide
technology (NMOS, CMOS, etc.). Experience has proven that even small amounts of static
electricity can damage or destroy these devices. Damaged components, even though they
appear to function properly, exhibit early failure.

TABLE OF CONTENTS
DESCRIPTION........................................................................................................1
TYPICAL APPLICATION ........................................................................................1
MOUNTING.............................................................................................................2
WIRING...................................................................................................................3
WIRING CONNECTIONS .......................................................................................3
JUMPER OPTIONS ................................................................................................3
DEFINITIONS .........................................................................................................4
CALCULATING THE K FACTORS .........................................................................4
FRONT PANEL OPERATIONS ..............................................................................5
PROGRAMMING FLOW CHART ...........................................................................5
PROGRAMMING ....................................................................................................6
SETTING THE PRESETS & PANEL LOCK............................................................7
TROUBLESHOOTING GUIDE................................................................................8
WARRANTY

THIS PAGE IS BLANK

1
DESCRIPTION
Application:
Any position monitoring application
where 2 alarm setpoints and a 6
digit LED display is needed. Such
as blade positioning, box making
and many other machine shop and
industrial applications.
Description:
Featuring 6 digits of bright,
7-segment LED displays, this unitl
is a position monitor which accepts
signal inputs up to 30 KHz. A 5
digit floating decimal scale factor
allows a readout in true engineer-
ing units. The unit has two, pro-
grammable alarm set points from -
99999 to 99999 and a selectable
start point. These setpoints con-
trol two 5 Amp relays. A two stage
panel lock prohibits menu changes
from unauthorized personnel.
Specifications:
Display
6 digit, .55" high, 7 segment, red
orange, LED.
Input Power:
24, 110, 220 VAC ±15% or 12 to
15VDC.
Current: maximum 300 mA DC or
8.0 VA at rated AC voltage.
Output Power:
(AC powered units only) + 12VDC
@ 50mA unregulated -10 +50%
Temperature:
Operating:+32°F (0°C) to +130°F
(+54°C).
Storage:-40°F (-40°C) to +200°F
(93°C).
Memory:
EEPROM stores data for ten years
if power is lost.
Inputs:DC pulse input open or 0-1
VDC (low), 4-30 VDC (high),
30KHz speed max.
Reset:
Front Panel: resets display to view
(start) value.
Remote: 4-30VDC positive edge,
Resets display to view (start) value.
Lockout:
Unauthorized front panel changes
can be prevented by entering a
user selected, 5 digit code. The
lockout feature can be programmed
to lock the entire front panel or lock
the menu items and leave the pre-
sets and reset accessable. In ei-
ther mode the locked items can be
viewed but not changed.
Control Outputs:
2 each N.O. Relays - 5Amp @ 120/
240 VAC or 28 VDC. (N.C. Relay
contacts or NPN sink from 10 VDC
to .5 VDC @ 100 mA available with
solder jumpers). The output will
remain active when the display is
equal to or greater than the set
point. If the display falls below the
set point, the output becomes in-
active.
Set Points:
Two control set points are provided.
The set points can be programmed
for any number from minus 99999
to plus 99999. The position moni-
torl will recognize new set point val-
ues without the need to reset the
unit. The unit also has a starting
point which can be viewed or
changed by pressing the "view" but-
ton. When the reset is activated,
the display will reset to the view
(start) value.
Shipping Weight:
2 pounds.
TYPICAL APPLICATION:
The position monitor can be used in many position
applications. When two units are used, both X and Y axes
positions can be monitored. The application below in-
volves monitoring of the X axis only.
In this application the STOP position on a sheet
metal shear must be monitored. A quadrature encoder
was placed on the screw drive shaft. The Encoder outputs
100 pulses per revolution. Each revolution of the screw
drive equals a .15 inch movement of the STOP. To calcu-
late the scale factor simply divide 100 by .15 (100 ÷.15) =
666.66 pulses per inch. This would be the scale factor if
the display was to be read in inches. In this application the
STOP movement must be accurate to .01 inches. There-
fore the factor 666.66 must be divided by 100 (666.66 ÷
100) = 6.6666 pulses per .01 inch.
The unit has two alarm set points which activate
two relays. The unit also has a programmable preset start-
ing point. At any time the preset start point can be viewed
or changed by pressing the view button. The two relay
outputs can be used to signal alarms when the desired
position has been reached.
This unit is the perfect solution for position moni-
toring applications where a low cost, scalable monitor is
needed.
HOLLOW SHAFT
QUADRATURE ENCODER
CHANNEL A
CHANNEL B
+ DC (RED)
COMMON (BLK)
ELECTRICAL
CONNECTIONS
1
2
3
4
5
6
7
8
9
10
11
12
N.O.(N.C. / NPN)
COMMON
N.O.(N.C. / NPN)
COMMON
A INPUT
B INPUT
12V OUTPUT/+DC INPUT
-DC (GROUND)
RESET INPUT
NOT USED
A.C. INPUT
A.C. INPUT
POSITION
MONITOR
ENCODER

2
MOUNTING
HOW TO MOUNT:
Slide the body of the unit through the rubber
gasket. Inserttheunitintothepanel.Slidethe
brackets up the groove to press against the
backofthepanel,asshownin"FIG.A". Insert
the screws into the rear of the brackets.
Tighten the screws evenly and alternately. A
panellessthan.1"maydistortiftheclampsare
screwed too tightly. Do not over tighten! A
normal level of torque is required. Maximum
torque should be 3" pounds.
FIG. A
4.437
(112.7)
2.625
(66.68)
3.925
(99.7)
3.622
(92)
1.772
(45)
.587 4.245
(107.8)
BEZEL
GASKET
CUSTOMER PANEL
Panel Thickness 0.062" (1.5)
to 0.187" (4.7) max.

3
WIRING
AC / DC CONNECTIONS:
NOTE: Connect power only after other connections
are finished. Do not touch the live AC power termi-
nals. The unit has been designed with an isolated
AC input, therefore polarity is not a concern for the
AC power. The chasis is plastic, therefore earth
ground is not used. For DC operation, connect +DC
to terminal 7 and -DC to terminal 8.
Although the unit is designed to be immune from line
or RF interference, the unit is controlled by a micro-
processor and an electrically "noisy" environment could
cause operating problems. The input power lines
should not be common to power lines for motors,
pumps, contactors, etc.
Four sources of noise can occur:
1) AC power line noise- If the unit cannot be con-
nected to an electrically clean power source, an in-
ductive load supressing device (MOV as GE#V130LA1
or Resistor Capacitor as Paktron# .2uf/220 ohm @
400V) can be installed. Although locating the sup-
pressor across the AC supply at the unit should help,
best results are obtained by connecting the suppres-
sor across the leads of the "load" at the device caus-
ing the spikes.
2) Input line noise- The noise is carried on the input
and DC ground lines. Make sure the input wires are
not run into the unit in a bundle with power input
lines. We recommend using shielded cable. Con-
nect the shield to DC ground of the unit and "earth" at
one point in the circuit preferably at the DC ground
terminal of the unit.
3) Output lines- The unit has Two relay outputs. When
these outputs are used to run external relays or sole-
noids, spikes can be generated upon activation. This
noise can spread through the instrument causing op-
erating problems. If the source is a D.C. operated
device, a general purpose diode (IN4004) placed
across the solenoid prevents electrical noise spikes.
Connect the cathode (banded side) to the more posi-
tive side of the coil. If the source is an A.C. operated
device, use a Resistor Capacitor or MOV across the
coil.
4) 12 VDC output supply- Noise can be generated on
the 12 VDC output supply if it is used to drive induc-
tive loads or if the current draw exceeds 50 mA. In-
sure that all inductive loads have a diode (such as
IN4004) across the coil and that the current does not
exceed 50 mA.
WIRING CONNECTIONS
1. COMMON
2. N.O. (N.C. / NPN)
3. COMMON
4. N.O. (N.C. / NPN)
5. A INPUT
6. B INPUT
7. 12 V OUTPUT / +DC INPUT
8. -DC (GROUND)
9. RESET INPUT
10.NOT USED
11. AC INPUT
12. AC INPUT
A
B
Output Jumper Selections
Before making any board modifications, be sure power is
disconnected and locate the plastic extender to the case at
the rear of the unit. To remove the extender locate and
remove the two screws which hold it in place. After the
extender is removed the PC board will be exposed.
The unit must be removed from the case to access jumpers
C & F, all other jumbers can be accessed by removing the
plastic extender.
FUNCTION
"A" RELAY
N.C. OUTPUT
"B" RELAY
N.C. OUTPUT
"A" PRESET
TRANSISTOR (NPN)
"B" PRESET
TRANSISTOR (NPN)
MODIFICATION
CUT JUMPER
AT "A" "B" TO "2"
CUT JUMPER
AT "D" "E" TO "4"
CUT JUMPER
AT "A" "C" TO "2"
CUT JUMPER
AT "D" "F" TO "4"
BOTTOM VIEW AT TERMINAL
DE
G
H
20192
12 11 10 9 8 7 6 5 4 3 2 1
L4AB2
FC

4
DEFINITIONS
COUINT - COUNT; This portion of the programming menu sets up the count input data.
dp loc - DECIMAL POINT LOCATION; This sets a fixed decimal for the count and preset
values.
lo cps - LOW COUNTS PER SECOND; This sets the input for a low count speed input (0
to 40Hz).
hi cps - HIGH COUNTS PER SECOND; sets the input for a high count speed input (0 to
30KHz).
DP f a - DECIMAL POINT FOR FACTOR A; This sets a decimal point for factor A.
loc - LOCK; This portion of the programming menu sets up the panel lock configuration and
code.
lc all - LOCK ALL; This sets the unit to lock the entire front panel when the lock is "on".
Preset values can be viewd but not changed.
lc prg - LOCK PROGRAM; This sets the unit to lock the program when the lock is "on".
Presets values can be viewd and changed.
code - CODE; This message flashes for approximately 3 sec. and is followed by the existing
lock code.
The K factor (divider) is the number of pulses per the
desired unit of measure. The K factor can be any 5
digit number from .0001 to 99999. The K factor can
be easily calculated by following two simple steps.
STEP 1 - Calculate a base K factor:
The base K factor is the number of pulse per the
known unit of measure. Calculate the base K factor
using:
Pulses = Base K factor
Known Units value
EXAMPLE #1:
An Encoder with 100 pulses per revolution is sensing
material. 1 Revolution of the shaft equals 1 foot of
material.
Base K factor = 100 (pulses) = 100
1 (foot)
EXAMPLE #2:
An inductive proximity sensor is sensing a notch on a
paper roll (1 pulse per revolution). Each revolution of
the paper roll equals 3 meters of paper.
Base K factor = 1(pulse) =.3333
3 (meters)
STEP 2 - Calculate the count K factor:
The count K factor is the actual number to be pro-
grammed into the unit. Caculate the count K factor
using:
Count K factor = Base K factor
Units conversion factor
UNITS CONVERSION FACTORS
To convert: Divide by:
ft to in 12
in to ft 0.0833
ft to m 0.3048
ft2 to m20.0929
ft3 to m30.0283
m to ft 3.2808
m2 to ft210.763
m3 to ft335.315
EXAMPLE #1:
Using the base K factor from example #1 above, the
desired reading is meters.
Count K factor =100 (base K factor) = 328.08
0.3048 (units factor)
EXAMPLE #2:
Using the base K factor from example #2 above, the
desired rate reading is Feet
Count K factor = .3333 (base K )= 0.1016
3.2808 (units factor)
The Count K factor is the number to enter in the
factor section of the program menu (see Program-
ming Step 1).
CALCULATING THE K FACTORS

5
A B C D E
RST
ENTER LOCK PRE A PRE B VIEW PRGM
Press to RESET
to view value in
operating mode;
Press to "ENTER"
in programming
mode.
Press to view or
change Preset A.
FRONT PANEL OPERATIONS
PROGRAMMINGFLOWCHART
count
DP LOC
RUN MODE
DP F A
#####
ENTER
ENTER
ENTER
ENTER
LO CPS HICPS
PRGM
ENTER
LOC
LC ALL LCPG
CODE
RUN MODE
#####
ENTER
ENTER
PRGM
ENTER
PRGM
PRGM
START HERE
Press to view or
change the start
(view) value.
Press to cycle
through PROGRAM
choices; Press to
step through set up
choices in pro-
gram mode.
Press to "enter
LOCK code for
panel lock.
Press to view or
change Preset B.

6
PROGRAMMING
DISPLAY
count
DP loc
LO CPS or HI CPS
DP F a
#####
count
LOC
LC ALL
or
LC PRG
CODE
flashes
followed by...
#####
REMARKS
Thissectionofthemenuisusedtoset
the counter parameters.
Key in the desired decimal location
and press ENTER.
Press the PRGM key to step through
choices. Press ENTER to "enter" dis-
played choice..
Keyinthedesireddecimallocationfor
K factor A and press ENTER .
Key in the desired scaling K factor for
input A and press ENTER .
Press the PRGM key to step through
choices. Press ENTER to "enter" dis-
played choice.
This is the security lock code. To
changepressthekeysunderthedigits
to be canged and press ENTER to
"enter" displayed value. RECORD
THIS NUMBER FOR FUTURE USE!!
STEP
1
SETTING
THE
COUNTER
PRESS
PRGM
ENTER
ENTER
ENTER
ENTER
STEP
2
SETTING
PANEL
LOCK
PRGM
PRGM
ENTER
ENTER
THE PROGRAMMING IS COMPLETE !

7
SETTING THE PRESETS & PANEL LOCK
PRESS DISPLAY REMARKS
VIEW
SETTING
THE
PRESETS
This value is the reference point (preset) that the
unit will reset to when the "Reset" is activated.If
the displayed value is not the desired preset,
press the key(s) under the digit to be changed.
A negative preset can be entered by pressing
the A button until the digit passes nine and steps
through -0 to -9.
PRE A = Preset A; The set point at which output
A will trigger. If the displayed value is not the
desired preset, press the key(s) under the digit
to be changed. A negative preset can be en-
tered by pressing the A button until the digit
passes nine and steps through -0 to -9.
PRE B = Preset B; The set point at which output
B will trigger. If the displayed value is not the
desired preset, press the key(s) under the digit
to be changed. A negative preset can be en-
tered by pressing the A button until the digit
passes nine and steps through -0 to -9.
Key in the lock code (see programming step 3)
by pressing the keys under the digits to be
changed. Each time a key is pressed the digit
will increment one. Press the ENTER key to
enter the displayed code.
After the code is entered the unit will display
LOC (unit is locked) or UN LOC (unit is un-
locked). This message will be displayed for
approximately 3 seconds before the unit returns
to the run mode.
PRE A
PRE B
SETTING
THE
LOCK
STATUS
LOCK
ENTER
preset
Followed by...
#####
(Start value)
PRE A
Followed by...
#####
( Preset A value)
PRE B
Followed by...
#####
( Preset B value)
CODE
Followed by...
0
LOC
or
UN LOC

8
TROUBLESHOOTING GUIDE
Power is applied to unit but
the display does not light.
Unit works but occasionally
the display freezes or skips
counts.
Input signal is connected but
the unit does not count.
1. Recheck power wiring.
1. Use a different power sup-
ply or install a surge suppres-
sor.
1. Recheck input wiring.
2. Recheck K factor settings.
3.Replacetransmittingdevice.
4.Recheckdebouncefiltering
selection ("HI CPS" or "LO
CPS").
5.Toconfirm,setKfactor@1.
Connect a wire to pin 7 (12V
out)andtouchittopin5(Input
A). Each time pin 5 is pulsed
thecountershouldcountonce.
IfnotcallfactoryforanRMA#.
PROBLEM POSSIBLE CAUSES SOLUTIONS
1. AC or DC power wiring is
incorrect.
1. Line noise is effecting the
processor due to a current
spike or surge.
1. Input wiring is incorrect
2.ScalingKfactorisincorrect.
3. Transmitting device is de-
fective.
4. Wrong debounce filtering
setting selected.
5. Unit is defective.
IF YOU HAVE ANY OTHER PROBLEMS, PLEASE CALL THE FACTORY.

Wehope youwillbe pleasedwith ourproduct. Ifyouhave anyquestionsconcerningour
warranty,repair,modificationorreturnedgoodsprocess,pleasecontactyourlocal distributor.
HOW TO ORDER:
Kessler - Ellis Products Co.
10 Industrial Way East
Eatontown, NJ 07724
800-631-2165 • 732-649-7100
Fax: [phone]
www.kep.com
WARRANTY
This product is warrantied against defects in materials
and workmanship for a period of two (2) years from the date
of shipment to Buyer.
The Warranty is limited to repair or replacement of the
defectiveunitattheoptionofthemanufacturer.Thiswarranty
is void if the product has been altered, misused, dismantled,
or otherwise abused.
ALL OTHER WARRANTIES, EXPRESSED OR IM-
PLIED, ARE EXCLUDED, INCLUDING BUT NOT LIMITED
TO THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE.
Series
PM2
Position Monitor
Operating Voltage
A = 110 VAC ±15% or 12 to 15 VDC
B = 220 VAC ±15% or 12 to 15 VDC
C = 24 VAC ±15% or 12 to 15 VDC
Inputs
3 = Separate Up / Down Inputs
5 = One Count Input, One Up / Down Control
9 = Quadrature Input
Accessories
Separate non keyboard panel order # 34235
Separate keyboard panel order # 34237
SAMPLE: PM2 A 3