Synapius ECS 20 Series Operating manual

Electronic Code Switch
User and installation manual
ECS 20xx series
Last update
January 20, 2009

Copyright TMPhysics @2006
All right reserved by Synapius BV The Netherlands
Electronic Code Switches

Electronic Code Switches

Table of contents
Industrial version 7
General description 8
Features .......................................8
Electrical .......................................9
Getting started 10
Operating instructions 11
Indication lamps (LED’s) ...........................11
The users PIN codes .............................11
The mastercode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Supervisors instructions 12
Changing the master code...........................12
Programming user pincodes. . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clearing all the user pin codes . . . . . . . . . . . . . . . . . . . . . . . . 14
Reading the number of E-stops of an individual user.............14
Device configuration 16
Automaitic turn off delay ...........................16
Programming the automatic turn off delay . . . . . . . . . . . . . . . . . . 16
Disabling the automatic turnoff. . . . . . . . . . . . . . . . . . . . . . . . 16
Configuring the device for access control . . . . . . . . . . . . . . . . . . 17
Setting the polarity of the safety switch input signal .............18
Emergency stop...................................19
Setting the E-stop handling function .....................19
Setting the power off time after E-stop in mode 01. . . . . . . . . . . . . . 20
Emergency stop modes ...............................20
User default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
History of users 22
Maintenance of the installation 23
Engine out of operation...............................23
ON/OFF switching without pincodes. . . . . . . . . . . . . . . . . . . . . . . . 24
Resetting the master code using the PUC code 25
Installation 26
Technical data 27
Ordering Information 28
TMP order Numbers .............................28
Electronic Code Switches

Compatibility with the former models 29
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical ...................................29
Operation of the ECS .............................29
New features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
APPENDIX A 32
Configuration list ...............................32
CODE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix B wiring 37
Electronic Code Switches

Electronic Code Switches

Industrial version
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Electronic Code Switches

1General description
The electronic code switches are specially designed for safe engine control and to prevent
unauthorized personnel to handle or work with a specific engine or installation.
A choice of five functions can be pre-selected to handle emergency situations.
All the devices have an OR-wired sense input to switch the machine immediately off after detecting an
incoming signal from one of the connected devices. The emergency handling function determines the
way how to restart after an emergency stop.
If the engine cannot be used temporarily it is possible to block all functions except for the mastercode
to reactivate the device.
Another feature can be used to use the ECS as a simple switch without using pincodes.
The ON/OFF button functions in this mode to toggle the engine on and off. The emergency function
remains active and restart after an emergency stop needs the mastercode. (See restarting after E-stop)
This function is useful during maintenance of the installation.
For advanced engine control it is possible to connect the ECS to the SYNAPS12/24 to control
more device or switch specific operating levels. This last avoids multiple keys for different operating
levels.
Features
•Up to 99 individual programmable user (PIN) codes
•Mastercode (programmable)
•Personal unlock code (PUC)
•Automatic turnoff
•Emergency stop
•Emergency handling functions for restart
•Service and maintenance mode
•Out of operation mode
•Reading the last two users
•Reading the number of E-stops for each individual user
•Registration amplitude of E-stop signal (e.g. Shockwave) [optional]
•Reset to factory settings
•Clearing all user pincodes by a single command procedure
•Anti-condense and ice forming in cold climate or environment
(Device temperature control optional)
•Up to 9 operating levels or sub-relaisfor each individual user (optional)
As long as an incoming emergency stop signal is active all buttons are ignored.
If an emergency stop signal occurs during the machine is off all button activities are ignored, but the
red led will indicate the occurrence of the input signal.
Electronic Code Switches

Electrical
Wide power supply versions: 12 to 24 VDC or 12-24 VAC and 48 - 90VDC (see ordering codes for
powersupply ranges)
Power supply current is less then 60 mA.
Electronic Code Switches

2Getting started
Before installing you must get the PUC code to activate the device and register for warranty and
product service. This can be performed by register by internet or visiting synapius.com. The PUC code
will be sent short after the registration.
Install the ECS conform the installation guide. The ECS is factory preprogrammed to run in service
mode with the mastercode 0000. In this mode the ECS functions as a simple ON/OFF switch without
any code entry. The ON/OFF switch toggles the installation on or off by each tapping on the ON/OFF
button.
The status of the sense input of the emergency stop is shown by the red led. If the installation is turned
on and an emergency stop occurs the ECS must restart after entering the mastercode to put into
program mode and then enter one digit for the Emergency stop handling routine you want to choose.
(See emergency stop)
Dependent on the application you have to set some parameters.
•mastercode
•Automatic turn off
•Polarity of the safety switch (seat switch)
•Emergency stop
•User pin codes can be added or modified anytime after the device has been activated
Electronic Code Switches

3Operating instructions
Indication lamps (LED’s)
In the normal operation mode the red LED will flash each time a correct keystroke occurs.
To indicate the switch is ON, the green LED is on.
When the ECS is in the programming mode, the red LED is on. Now the green LED indicates a correct
keystroke.
The users PIN codes
Users are registered into a user list and are indexed from 1 to 99 (user ID). A normal user does not
have to remember his user ID just only his pincode.
The user pincode must be at least 4 digits and maximum 8 digits.
The pincode 00000000 (8 zero’s) is reserved for clearing an existing pincode, so that this is not a valid
pincode.
The User ID is used in the following cases:
•Entering a new user pincode
•Removing a user pincode from the list
•Reading the last users
•Reading the number of emergency stops of a user
•The user ID 00 is used for the location of the mastercode
The mastercode
The mastercode is used for programming and configuring the ECS. With the mastercode you cannot
turn the switch on. The mastercode is also used to initiate for restart after an emergency stop.
The master pincode must be at least 4 digits and maximum 8 digits and must be kept in a safe place.
In page
Electronic Code Switches

4Supervisors instructions
Changing the master code
The master code is factory set to 0000. For safety reasons, change first this factory setting to your own
desired master code.
Press CE to clear existing keystrokes
0000 the factory set master code
now, the red LED goes on, which means the device is in programming mode
00 this is the location of the master code
xxxxxxxx Now enter your new personal master code (min. 4 - max. 8 digits)
Write down this code (see code list appendix A) and keep it at a safe place.
xxxxxxxx Re-enter the new code
Now the green LED goes on, without switching the relay on.
This means that your new master code has been accepted.
If this doesn’t happen, you will have to start from the beginning.
pg
Electronic Code Switches

Programming user pincodes
All the user pin codes are stored into a user pincode list having a specific location number between 1
and 99. The user identity is represented as the location were his pincode is registered. It is advised to a
note the user number and the pincode in a separate list (see appendix A)
To enter a new user pincode follow the next instructions.
Press CE to clear existing keystrokes
xxxxxxxx enter the master code
now, the red LED goes on, which means the device is in programming mode
xx enter the location (user ID number always 2 digits)
xxxxxxxx Now enter your new personal master code (min. 4 - max. 8 digits)
Write down this code (see code list appendix A) and keep it at a safe place.
xxxxxxxx Re-enter the new code
Now the green LED goes on, without switching the relay on.
This means that your new master code has been accepted. If this doesn’t happen, you will
have to start from the beginning.
xenter one digit 0-9 to assign the operating level for this user
Omitting or zero assigns the lowest operating level
Press agian to clear the program mode, green LED goes off
Electronic Code Switches

Clearing all the user pin codes
The user pin codes from 1 to 99 can be cleared in a single procedure.
Follow the next procedure to perform this.
Press CE to clear existing keystrokes
xxxxxxxx enter the master code
now, the red LED goes on, which means the device is in programming mode
00000000 enter eight zero’s
Confirm clearing the user codes otherwise press to cancel
Clearing the user codes takes a little time thus wait until the green LED turns off before proceeding.
Clearing a single user
To clear a single user position and the corresponding pincode you must store 00000000 (eight zero’s)
as user pincode. This will replace the user ID number with blank. For this reason a user pincode
consisting of eight zero’s is a non valid pincode for normal usage.
Reading the number of E-stops of an individual user
If the E-stop handling function 2 is active (re-start by the user code) the number of E-stops are
recorded for each individual user. This number of E-stops can be read out. To do this follow the next
procedure.
To clear existing keystrokes
xx user number (2 digits)
The Red and green LED’s flashes to indicate the number of E-stops.
The red flashes the ten’s and the green flashes the one’s. Also, multiplying the red flashes by ten and
then adding the number of green flashes gives the total of E-stops.
For example: If a user caused 23 E-stops, reading out results in two red flashes and three green flashes.
To clear the E-stop counter, for a user xx, just reprogram the user pincode at the same user xx place.
This might be the same or a new pincode.
Note:
Although the user numbers 98 and 99 are valid user numbers, the recording of E-stops is not applicable
to this two user numbers for this numbers are reserved for reading the two last users.
Electronic Code Switches

Electronic Code Switches

5Device configuration
Automaitic turn off delay
The ECS is provided with a function to switch the power off when the system is not used for a certain
period. This function looks to the voltage level of the sense input line (grey wire).
A sense input (grey wire,) when connected to the GND wire (blue) via a switch, is used to indicate the
need for automatic switch off.
If properly connected through the seat switch, the ECS will shut down the programmed delay after the
driver has left the seat.
If the ECS is installed on a pallettruck, the gray wire can be connected through an unused contact on
the accelerator.
Programming the automatic turn off delay
Note: for normal use (not for access control) the access control register must be set to zero.
To clear existing keystrokes
xxxxxxxx Enter the master code
The red LED goes on to indicate the program mode
01xx enter four digits starting with 01 followed by two digits >0 for the number of minutes
E.g. for 5 minutes delay enter 0105
To save this delay
Disabling the automatic turnoff
If the switch off delay is set to zero the automatic turnoff is disabled
To clear existing keystrokes
xxxxxxxx Enter the master code
The red LED goes on to indicate the program mode
0100 disables the automatic turnoff
To save
Electronic Code Switches

Configuring the device for access control
In access control mode the ECS must activate the switch for a short period (seconds or minutes).
If the access seconds register is >0 the ECS is automatically set in access mode. If the number of
seconds is less or equal then 60 the this number is treated as hold time in seconds.
If a number greater then 60 is entered then the current number of minutes in the turnoff delay is used
as hold time. The grey wire is used in the same way so that this input line can be used to hold the
switch ON as long as this input signal is active
Clear exsisting keystrokes
xxxxxxxx Enter the mastercode for programming mode
The red LED goes on to indicate the program mode
Electronic Code Switches

Setting the polarity of the safety switch input signal
The factory setting of the input signal from the safety switch (e.g. seat switch) ia active low level. This
means that if the input (grey wire) is switched to 0V ( blue wire) the installation is supposed to be in
save operating state. When released (disconnected or switched to the supply plus) the engine will be
automatically switched off if the turnoff delay time is not zero.
If the ECS is turned off and the turnoff delay is not zero it is not possible to start the engine as long as
the safety switch is not closed.
If the safety switch is a seat switch on a verhicle it is not possible to start when the driver is not on his
seat.
If for any reason the input polarity must be reversed then follow the next instruction to set the device
for reverse polarity.
Clear exsisting keystrokes
xxxxxxxx Enter the mastercode
The red led will go on to indicate the progeramming mode
0501 Code to set reverse polarity enter 0500 to set normal polarity
confirm
Pg
Electronic Code Switches

Emergency stop
The basic principle of the emergency stop is based upon a common input sensing line triggering on a
low voltage level or a negative edge coming from one or more switches or sensors. The sense line is
normally kept at a high voltage level. All the devices, attached to this line, are connected parallel to
each other forming an OR-wired circuit. Each device switches the sense line to the ground wire (blue
wire of the ECS) if an emergency stop must be evoked.
On detecting a signal, from one or more devices, the selected emergency stop procedure is started.
The main purpose of selected an E-Stop procedure is to determine how to restart the engine.
The ECS provides three programmable E-stop functions which will determine what to do after an
emergency stop (E-stop).
•E-stop code 0: No action. The signal will be ignored.
•E-stop code 1: Immediate switch off. Restart after a preset delay with the normal user pin code.
•E-stop code 2: Immediate switch off. Restart only after resetting with the master code
Setting the E-stop handling function
The E-stop handling code must be set after each re-start after an emergency stop.
Or any time you want to change the E-stop function for some reason.
Follow the next procedure to re-start or to change the E-stop function.
To clear existing keystrokes
xxxxxxxx Enter the master code
The red LED goes on to indicate the program mode
xenter the single digit of the E-stop code (0,1,2,3 or 4)
To save this E-stop code
pg
Electronic Code Switches

Setting the power off time after E-stop in mode 01
In E-stop mode 01 the power will be switched off for a specified period so that it is not possible to
power on within that period. This period can be adjusted by programming the desired dead-time as
follows:
To clear existing keystrokes
xxxxxxxx enter the master code
The red LED goes on to indicate the program mode
03xx where xx are the minutes for dead-time after an E-stop
E.g. if a dead-time of 12 minutes is wanted enter 0312
To accept
Emergency stop modes
E-stop
mode Turnoff Dead- time
after
stop
Restart by
user pin-
code
Restart by
mastercode
0- - - -
1yes yes yes yes
2yes no no yes
3always -no yes
4yes no no yes
Electronic Code Switches