Lenord, Bauer GEL 104 User manual

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LENORD, BAUER & CO. GMBH, 04/99 Subject to change without notice
Programmable Preselect Counter
GEL 104
User Manual
P1
P2
SET
PSC
F1 F2
MOTOR TECHNOLOGY LTD
MOTEC HOUSE, CHADKIRK BUSINESS PARK,
STOCKPORT, CHESHIRE SK6 3NE
ENGLAND
TELEPHONE: [phone]
FAX: [phone]
E-MAIL: [e-mail]
WEB SITE: www.motec.co.uk

Lenord, Bauer & Co. GmbH
Dohlenstraße 32
D-46145 Oberhausen
Phone [phone] •Fax [phone]
Internet: http://www.lenord.de •E-Mail: [email protected]

OPERATOR'S MANUAL G E L 1 0 4
C o n t e n t s
1 Introduction................................................................................................ 1
1.1 Fundamental safety instructions.............................................................1
1.2 Designated use ......................................................................................2
1.3 Guarantee, liability and copyright...........................................................2
2 Control elements........................................................................................ 3
2.1 Keyboard................................................................................................3
2.2 Display....................................................................................................4
3 Programming.............................................................................................. 5
3.1 Operating parameters ............................................................................5
3.1.1 Preselections 1 (P1) and 2 (P2).............................................................6
3.1.2 Set value (SET)......................................................................................6
3.2 Display parameters ................................................................................6
3.2.1 Prescaler (PSC) .....................................................................................6
3.2.2 Decimal point..........................................................................................7
3.3 System parameters................................................................................7
4 Control signals......................................................................................... 10
4.1 Count inputs Input A and Input B ........................................................10
4.2 Reset ....................................................................................................10
4.3 Count gate Inhibit ................................................................................10
4.4 Display Hold .........................................................................................11
4.5 Keylock .................................................................................................11
4.6 Outputs Out1, Out2 ............................................................................11
5 Assembly, commissioning, diagnosis of errors................................... 13
5.1 Assembly instructions...........................................................................13
5.2 Commissioning.....................................................................................13
5.3 Diagnosis of errors...............................................................................14
6 Technical specification ........................................................................... 15
6.1 Mechanical data...................................................................................15
6.2 Electrical data.......................................................................................15
6.3 Environmental conditions.....................................................................17
6.4 Type code.............................................................................................17
6.5 Dimensions...........................................................................................18
7 Pin layout.................................................................................................. 19

1INTRODUCTION 1
1 Introduction
1.1 Fundamental safety instructions
▲ The programmable preselect counters type GEL 104 have been built in
accordance with state-of-the-art standards and the recognised safety
regulations. Nevertheless, its use may constitute a risk to life and limb of the
user or of third parties, or cause damage to the counter or to other compo-
nents property. The counters must only be used
− in accordance with their designated use
− in technically perfect condition.
In order to maintain this status and to ensure a safe operation of the
counters, only skilled personnel1are allowed to commission, connect and
service these components, while observing the current regulations for
prevention of accidents and safety instructions as well as the operating
instructions.
▲ If a break down or malfunctioning of the counter may cause injury or
damage works equipment, this must be prevented by taking additional
safety measures, such as, for example, installation of limit switches,
protective devices, etc.
▲ If a safe operation can no longer be ensured, the counter must be stopped
and secured against unintentional operation.
▲ When mounting and connecting, the counter and all other components
concerned, must be de-energised: voltages up to 250 VAC may occur!
Make sure that meanwhile the line cannot be switched on.
▲ To ensure the hand contact safety (VDE 0106) of the connecting terminals a
professional connection of the current-carrying cables is required. Terminals
not being assigned ('NC') must not be wired-up.
▲ The counter must only be repaired by LENORD+BAUER or a company/person
authorised by LENORD+BAUER.
1Skilled personnel does mean:
− persons being familiar with the safety principles of automation systems,
− persons being trained on commissioning and servicing,
− persons knowing how to operate the device and knowing the relevant instructions in the manual
which are vital for the proper functioning of the device.

21
INTRODUCTION
1.2 Designated use
The GEL 104-type counters have been exclusively built for measuring and
controlling purposes in industry. In conjunction with an incremental pulse
generator, e.g. positions, lengths or angles may be measured and displayed or
cutting and dosing jobs may be performed.
The counters should not be put into operation unless being built in.
Designated use also means that the user follows all instructions given in this
manual.
Using the device for purposes other than those mentioned above is considered
contrary to its designated use. LENORD, BAUER & CO. GMBH cannot be held
liable for any damage resulting from such use.
1.3 Guarantee, liability and copyright
In principle, our general 'Terms of delivery and payment' apply which are part
of the sales contract and are made available to the Buyer upon signing of the
contract at the latest. LENORD, BAUER & CO. GMBH will not accept any claim
under guarantee nor any other responsibility in case of injury to persons or
damages, if they are due to one or several of the following reasons:
• non-designated use of the counter
• improper mounting, commissioning and operation of the counter
• operation of the counter when the safety devices of the line are defective or
not operative
• non-observance of the instructions supplied in the manual regarding
storage, assembly, commissioning and operation of the counter
• unauthorised modifications of the counter's design
• improper repair
• disasters caused by foreign objects and Force Majeure
This manual was prepared with utmost care. We do, however, not assume any
liability with regard to faultlessness.
LENORD+BAUER hold the copyright of this operating manual. The manual is
only intended for the buyer or the machine builder and their personnel. All
instructions, notes and other data supplied must not be copied, distributed or
communicated neither partially nor entirely.
Violations might be prosecuted.

2CONTROL ELEMENTS 3
2 Control elements
2.1 Keyboard
The function of these five keys depends on the current mode of operation of
the counter.
F1 F2
123 4 5
1 store key
• in counting mode:
in conjunction with another key only: start programming mode (see
further below)
• in programming mode:
save last entry and
− terminate programming mode or
− selection of subsequent parameter (depending on the programming
plane)
2 sign key
• in counting mode:
− programming of the 1st preset value P1 (F1)
− together with the store key: programming the set value SET ( +
F1)
• in programming mode:
change sign ( )
3 cursor key 'left'
• in counting mode:
− programming of the 2nd preset value P2 (F2)
− together with the store key: programming of a prescaler PSC
(prescaler) or decimal point ( + F2)
• in programming mode:
activate next input position of a value ( )
X1104055

42
CONTROL ELEMENTS
4 cursor key 'up'
• when switching on:
together with the store key: activate system programming mode
(+ )
• in counting mode:
together with the delete key: reset = set count to set value and reset
outputs ( + = )
• in programming mode:
increment value at active input position ( )
5 delete key
• in counting mode:
together with the cursor key 'up': reset, see above
(+ = )
• in programming mode:
delete current value, i.e. set to zero ( )
2.2 Display
The LED-type display consists of two areas:
P1
P2
SET
PSC
AB
A function indicators
• in counting mode:
switching state of outputs
Out1 (P1) and Out2 (P2)
• in programming mode:
parameter active at present: preselection 1(P1), preselection 2 (P2),
set value (SET), prescaler (PSC) or decimal point (–)
B value display
• in counting mode: current count of the counter
• in programming mode: parameter to be modified
X1104022

3PROGRAMMING 5
3 Programming
Several programming planes are available for programming the counter.
Via the 1st programming plane the user is provided with access to the
operating parameters, i.e. preselection 1 / 2 and set value, which are
frequently changed.
In the second programming plane the display parameters, the prescaler and
the decimal point can be set.
Access to the operating and display parameters can be locked by means of the
control input
Keylock (terminal 28).
In the third programming plane the general mode of operation of the counter
and all plant or machine relevant system parameters will be fixed. Normally,
this is only necessary on commissioning or after a retrofit.
3.1 Operating parameters
Enter this programming plane by a short pressing of a certain key or key
combination (see below). The active parameter is indicated by flashing of the
respective indicator (P1, P2 or SET) and the lowest digit of the pertaining value.
To return to the counting mode either
− press the store key or
− it is carried out automatically approx. 15 seconds after actuation of a key
(without saving a modified value).
Programming is performed as follows:
• if required, cancel a value using the delete key (you may only erase an
entire value, i.e. you may not erase it digit by digit)
• use the cursor key to go to position of the value to be changed (the
activated digit flashes)
• use the cursor key to increment the figure concerned
• modify all remaining digits of the value as described above
• in case of a negative value press the operational sign key
• save value by pressing the key

63
PROGRAMMING
3.1.1 Preselections 1 (P1) and 2 (P2)
Key: F1 for preselection 1 (P1)
F2 for preselection 2 (P2)
P1 may be interpreted either as absolute or relative value (see para. 3.3,
system parameter F20).
P2 is the main preselection by means of which an automatic reset is initiated in
the counter, provided that it had been programmed accordingly (see para. 3.3,
system parameters F4).
As soon as the count reaches the programmed value of P1 or P2 (via counting
pulses counted upwards or downwards), the respective relay switch
Out1 or
Out2 ( Out1 is reset by P2).
3.1.2 Set value (SET)
Key: + F1
In case of a reset the count of the counter will be set to this value (via
keyboard, terminal or automatically).
3.2 Display parameters
Key: + F2
The parameter last modified is the active one: prescaler (prescaler, indicator
PSC) or decimal point. By briefly pressing the store key you may switch
back and forth between the two parameters.
To return to the counting mode either
− press the store key longer than 2 seconds or
− it is performed automatically approx. 15 seconds after having last actuated
any key (modified parameters will not be saved)
A reset is always performed.
3.2.1 Prescaler (PSC)
Values must be entered as described in para. 3.1.
By means of the prescaler the number of counting pulses (= encoder pulses ∗
edge evaluation) may be converted in such a way, that the count will be dis-
played in the required unit. A residual value processing is not performed.

3PROGRAMMING 7
Setting range: 0.0005 … 99.9999 (standard setting: 1.0000)
If you enter a value less than 0.0005 the error message
Error0
will be
emitted. To enter a new value press the store key.
3.2.2 Decimal point
Use the cursor key to select one of the 4 possible variants:
–.= display without decimal point
–.–= display with one decimal
–.––= display with two decimals
–.–––= display with three decimals
3.3 System parameters
To enter this operating plane press the store key and the cursor key
simultaneously upon switching on the supply voltage. The following parameters
and their variants are available (standard settings are printed in boldface):
Parameter Variant Description
1. Count inputs A, B
In dIF A, B as differential inputs: A accumulative, B subtractive
Input A
+
Input B
-
1
0
-1
1
0
1
0
Count
E110401A
ud A is the count input, B is the counting direction input
(up/down)
1
0
-1
1
0
1
0
Count
Input A
count pulses
Input B
up/down
E110401B

83
PROGRAMMING
Ph1
Ph2
Ph4
phase discriminator mode with edge evaluation
once,
twice,
quadruple
1
0
1
0
5
0
5
0
8
5
0
down
Input A
90°
Input B
0°
Count
eval.: x4
eval.: x2
eval.: x1
up
E110401C
2. Input frequency
Fr 0.03
40
input damping
30 Hz (bounce-proof),
40 kHz
3. Mode
F4 0
1
count = P2 ⇒
no automatic reset
automatic reset
4. Switching duration of output Out1
F5 oFF no output signal
bI bistable output signal
0.02
0.05
0.10
0.50
1.00
20 ms
50 ms
100 ms
500 ms
1 s
5. Switching duration of output Out2
F6 same as F5
6. Reset-signal
F13 0
1
signal processing
static,
dynamic
7. Function of preselection 1 (P1)
F20 0
1
value is effective
absolute (count = P1 → Out1 ),
in relation to preselection 2 (presignal for preselection 2,
count of counter = P2 + P1 → Out1 )

3PROGRAMMING 9
8. Output signal memory
F21 0 outputs reset after having switched on the power supply
1 same switching status as prior to switching on the power
supply, monostable times, however, being started anew
9. Input signal level
F24 0 npn: active level: Low
1
pnp: active level: High
10. Lock keyboard reset
F26 0
1
if the signal Keylock is active, the keyboard reset is
not locked,
locked
11. Programming lock for the set value
F27 0
1
if the Keylock signal is active, the key combination is + F1
unlocked,
locked
12. Programming lock for display parameters
F28 0
1
if the Keylock signal is active, the key combination is + F2
not locked,
locked
13. Programming lock for preselection
F29 0
1
2
3
if the Keylock signal is active, the key(s)
F1 and F2 are not locked
F1 is locked (preselection P1)
F2 is locked (preselection P2)
F1 and F2 are locked (both preselections)
14. Standard settings
F30 0 no function
1 all parameters are set to standard (upon pressing the store
key)
Use the cursor key to select the requested option and confirm by pressing
the key; thus the subsequent parameter will be automatically activated.
To return to the counting mode
− press the store key longer than 2 seconds or
− this is performed automatically approx. 40 seconds after having last
actuated any key (modified parameters will not be saved).

10 4 CONTROL SIGNALS
4 Control signals
4.1 Count inputs
Input A
and
Input B
The count inputs (terminals 30 and 29) are controlled with the positive or
negative signal edge (pnp / npn, see system parameter F24). The maximum
counter frequency is 40 kHz.
You may use all commercial electronic pulse generators, whose High level is
> 8 V.
Signals emitted by mechanical, potential-free switches are processed (bounce-
free, max. 30 Hz).
Use the first system parameter ‘In’ to determine the function of the counting
inputs, i.e. the counting mode (see para. 3.3, 1st point).
4.2
Reset
If a reset is carried out the count of the counter will be set to the programmed
value (standard: 0) and outputs
Out1 and Out2 will be reset. The following
options are available:
a)keyboard reset
By simultaneously pressing the delete key and the cursor key
(can be locked by means of the Keylock signal, provided that the system
parameter F26 had been programmed accordingly)
b)terminal reset
At terminal 26 High or Low level will be applied (the active level is fixed via
system parameter F24 and its processing – either static or dynamic – via
F13)
c) automatic reset
The count of the counter reaches the preselection value P2 (provided that
the system parameter F4 had been programmed accordingly)
d)programming reset
is effected when leaving the 2nd programming plane where the display
parameters can be changed.
4.3 Count gate
Inhibit
As long as High (or Low) level is applied to the control input Inhibit (terminal
25), both counting inputs are locked (to determine the active level use system

4CONTROL SIGNALS 11
parameter F24). Thus you can interrupt the counting mode, although the
counting pulses continue.
4.4 Display Hold
As long as High (or Low) level is applied to the control input Hold (terminal 27),
the current count of the counter is 'frozen' without loosing any pulse (the active
level is fixed by system parameter F24); when changing the level the current
count will be shown again. Thus, especially where rapid counting operations
are concerned, the counter can comfortabely be read at any time without
having to interrupt the current counting operation.
4.5 Keylock
As long as High (or Low) level is applied to the control input Keylock (terminal
28) (use system parameter F24 to determine the level), certain programming
planes cannot be activated and/or a keyboard reset cannot be carried out.
(depending on system parameters F26 … F29).
4.6 Outputs Out1, Out2
The outputs Out1 and Out2 are available as transistor outputs (pnp) and as
potential-free change-over contacts. To protect the counter against harmful
voltage spikes we recommend external measures for spark prevention.
Some fundamental characteristics are:
• The outputs can be locked individually or can be switched to monostable or
bistable operation; for this purpose use system parameters F5 and F6.
• The switching status prevailing prior to switching off the voltage supply may
be reactivated upon switching on, provided that system parameter F21 had
been programmed accordingly; monostable times will be started anew.
• As soon as the count has reached the preselection P2,
Out1 will be reset;
the same also applies to the count provided that system parameter F4 has
been programmed accordingly (automatic reset).
• If a reset is performed
Out1 and Out2 will be reset.
Examples:

12 4 CONTROL SIGNALS
1. Monostable outputs
a) without automatic reset
t
Count
P2
P1
Out 2
E110401D
b) with automatic reset (negative set value)
t
Count
P2
P1
0
SET
Out 1
Out 2
E110401E
2. Bistable outputs
t
Count
P2
P1
Out 1
Out 2
Reset
E110401F

5ASSEMBLY, COMMISSIONING, DIAGNOSIS OF ERRORS 13
5 Assembly, commissioning, diagnosis of errors
5.1 Assembly instructions
1. Before incorporating the counter into the control panel the installation frame
(see dimensioned drawing in chapter 6) must be pulled off the counter
housing. For this purpose slightly lift the 4 catch brackets (alternately on top
and at the bottom, and pushing them forward catch by catch).
2. Turn back the screws of the installation frame by approx. 5 mm.
3. Insert counter into the cut-out of panel and snap installation frame into place.
4. Fix the counter with the screws against the panel (free from play).
5.2 Commissioning
Before setting the counter into operation check whether you can answer the
following questions with yes:
✔ Does the supply voltage rating correspond to the voltage specified at the
counter?
✔ Has the supply voltage been connected to the correct terminals and is the
polarity correct for DC supply?
✔ The maximum counter frequency will not be exceeded?
✔ Have the control pulses for the counter got the necessary switching
thresholds (see para. 6.2)?
✔ Has programming been performed properly, i.e. according to the specific
requirements?

14 5 ASSEMBLY, COMMISSIONING, DIAGNOSIS OF ERRORS
5.3 Diagnosis of errors
Problem Possible cause
no display • supply voltage OFF or improperly connected
all display segments are ON • short-time: self-test after having switched on
the supply voltage
• sporadic: contact of supply voltage
connections not in perfect condition or
voltage fluctuates under the minimum value
keyboard reset not possible • locked (system parameter F26) and signal
Keylock active
input of preselection or other
programming not possible • programming lock(s) switched on (system
parameter F27 … F29) and signal Keylock
active
counter does not count • counting input not connected properly or
bridged
• earth connection counter – pulse generator
defective
• incorrect level (npn/pnp, system param. F24)
• contact/pulse generator does not switch
properly
• max. counting frequency is exceeded
• input
Reset , Hold or Inhibit activated
• pulse or pause width too small
• prescaler too small
counter does not count correctly • bounce/disturbing pulses, vibrations at the
encoder
• incorrect prescaler
outputs without function • signal duration programmed "off" (system
parameter F5 or F6)
• faulty relay
• contacts welded because of overload
Error0
message • programming of prescaler < 0.0005
confirm error message with the store key
Error1
message • counted value limits exceeded (< -99999,
> 999999)
use keyboard reset to delete error message

6TECHNICAL SPECIFICATION 15
6 Technical specification
6.1 Mechanical data
dimensions (W×H×D)
fastening
control panel thickness
electrical connection
lead cross section
screws
weight
display
colour
digits
digit height
indicator LEDs
data storage
data conservation
read cycles
write cycles
96×48×108 mm (acc. to DIN 43700)
in the panel cut-out 92×45 mm with clamping
frame, screws M3
max. 11 mm
2 plug-in-type connecting terminals, 10 and 8
poles, 5 mm grid
1…1,5 mm2with end splices
M2.6
DC version: approx. 200 g
AC version: approx. 420 g
7-segment-LED with leading zero elimination
and programmable decimal point
red
6
14 mm
4
non-volatile memory
> 10 years
unlimited
> 100000
6.2 Electrical data
Voltage supply
a) DC Ub
overload protection
12…24 V= -5% / +10%
external fuse:
12 V= : 0.25 A fast-blow / 0.25 A slow-blow
(IEC 127 / UL 198)
24 V= : 0.16 A slow-blow / 0.20 A slow-blow
(IEC 127 / UL 198)