a= INSTALLATION “ane” | AND OPERATION 953-5 Rev B 4793 microwiz MODEL MWB136B MULTI-FUNCTION COUNTER INSTRUCTION MANUAL953-SB MICRO-WiZ MODEL MWB136 Table of Contents GENERAL DESCRIPTION . SPECIFICATIONS ....2.5550++ INSTALLATIONS INSTRUCTIONS ...... Pane! Mounting lastroctions .. Wiring Instructions .......+ Scrial Communications Options insialiat MODEL MWB136 PROGRAMMING AND KEYBOARD OPERATIONS Set-Up Function Programmi ‘Set-Up Function Codes nad Options: Programming Presets ‘Viewing and Resetting Counters. BACK PANEL TERMINAL ASSIGNMENTS AND DESCRIPTIONS .... DIP Switth eee eeescssssessceeeeeeee MODEL MWB13 OPERATING MODES . SERIAL COMMUNICATIONS OPTION . MWB-RS422 Serial Communications Option . . MWB-RSZ32 Serial Commanications Option . . MWB-20MA Serial Communications Option . . S Commands. P Commands. R Commands. DIAGNOSTICS AND TROUBLESHOOTING ..........-0+s2eeeeeee ‘Appendix A: MWBI36 Programming Chart... ‘Appeadix B: Rate Indicator Prescaler Values. ‘Application Note: Counter Input Prescaler Programming. . ‘pteion Ye: Scien MWB Rate Ino BS SIS YR LKBRSSSSS BRSVIBBRBYSN RSL BRSIR Gaus w953-SB GENERAL DESCRIPTION MODEL MWB136 THREE PRESET, DUAL COUNTER WITH RATE INDICATOR The Model MWB136 dual bidirectional counter is a versatile six-digit preset counter with a Rate Indicator. This microprocessor-based counter is programmed through a fourteen-key membrane keyboard to function in a variety of modes. The large, six-digit .56" red LED display allows the unit to be viewed as far as thirty feet away. Five LED status lamps are used to indicate what data is being displayed at any time. The two counters in the Model MWBI36 can be programmed to operate in many modes, The main counter is used as a control counter and may be programmed to count in eight different modes, including both unidirectional and bidirectional inputs. The second counter (Batch/Totalizer) can count in parallel to the main counter (functioning as a total footage counter, for example), or it may count occurrences of Output 2 (batch-counting). Each counter has its own input prescaler. ‘Two of the Model MWBI36's three presets are assigned to Counter 1 (main counter) so it may be used asa two-level control. ‘This counter may function as a Reset-to-0 or a Reset-to-Preset control. Auto-resetting when Counter 1 equals a preset is also available. A third preset can be tied to either Counter or the Rate Indicator, enabling it to be used as part of a three-level controller, a batch-count preset, or as an over-speed switch. Each preset has both a Form-C relay output and open-collector transistor output, which are available for switching external control devices (solenoids, valves, switches, te), ‘The Rate Indicator employs a half-second update time and is able to sample input rates as low as a few hertz to as high as 30,000 hertz. ‘The Rate Indicator has an input prescaler used to convert the input pulses into any desired unit. Counter 1, Counter 2, or the Rate Indicator may be programmed as the default display, leaving the remaining two to be viewed as de.ired. All options are programmed through 19 set-up functions. This data may be viewed at any time, but may only be changed when an external control input is active. This prevents accidental or unauthorized changes to the data. All preset, set-up function, and counter values are stored in a non-volatile memory. This data, once written, will remain valid for the life of the unit. Unit may be programmed to either retain the displayed count or reset when power is lost. The Model MWB136 has three optional serial munications boards that are easily installed inside the unit by the customer. No external boards or wiring, except for the serial link cable, are needed, An RS-232C, an RS-422 and a 20 Milliampere Current Loop are standard options. oo ECCI953-5B SPECIFICATIONS COUNTER 1 - (MAIN) Count Range: -999999 to +999999 Presets: Two 6-digit presets, -999999 to +999999 Preset 3 may be assigned to Counter 1 Count Inputs: Quadrature X1, X2, or X4 Add/Add (Summation) X1 or X2 Add/Subtract (difference) X1 or X2 Count and Direction X1 Count Modes: Count to Preset 2, Reset to 0 Count to 0, Reset to Preset 2 Toggle - Count to Preset 1, Reset to 0 Count to Preset 2, Reset to 0 Count Speed: High Range - 30,000 Hz.* Low Range - 30 Hz. Prescaler: Presettable from 0.00001 to 9,99999 COUNTER 2 - (BATCH/TOTALIZER) Count Range: +999999 to -999999 Presets: Preset 3 may be assigned to Counter 2 Programmable from -999999 to +999999 Count Inputs: Same input as Counter 1 Occurrences of Output 2 (batch counting) Count Speed: High Range - 30,000 Hz.* Low Range - 30 Hz. Prescaler: Presettable from 0.00001 to 9.99999 * Counter 1 and Counter 2 are limited to 26,000 Hz. if both input prescalers are set for some value other than 1,00000. RATE INDICATOR Speed Range: 0 Hz. to 30,000 Hz. Presets: Preset 3 may be assigned to the Rate Indicator Prescaler: Presettable from 0.00001 to 9.99999 Update Time: 0.5 seconds INPUT SIGNAL LEVELS Count Inputs: Logic Level inputs = (Pins 11,12) Vy = +3.5 VDC min, +30 VDC max. Vi = +0.8 VDC max., -30 VDC min. Low Level Inputs = Vq = +150 mVDC min, +30 VDC max. Vy =_ -150 mVDC max, “30 VDC min. Input Filter = High Range = 30,000 Hz. Low Range = 30 Hz. ECCI ee953-5B SPECIFICATIONS (cont) Control Inputs: (Pins 1-610) Vy = +30 VDC max, +2.5 VDC V4 = +125 VDC max, -V supply, mi Control Inputs are internally pulled up. Control Inputs must remain stable for 30 milliseconds. ‘The following control inputs are activated by a contact closure to ground: Pin Set-Up Program Enable (ENB) Pin 2 Reset Counter 1 (RST1) Pin 3: Reset Counter 2 (RST2) Pin 4: Unlatch Output 3 (UNL3) Pin 5: Unlatch Output 2 (UNL2) Pin 6: Unlatch Output 1 (UNL1) Pin 10: Stop Count (STOP) OUTPUTS Relays: 3 Relays, each controlled by a Preset Form-C Contacts rated 220 VAC at 10 amps, resistive. All contacts are RC are-suppressed. Open-Collector: ‘Three Darlington NPN Open-Collector Transistor Outputs, each controlled by a Preset. Vey = +30 VDC max, Vg = +1.0 VDC at 150 ma,, typ. +0.6 VDC at 20 ma, typ. Maximum Current = 150 milliamperes, sink to D.C. ground Operating Modes: a. Latched b. Toggle ¢. Momentary, .01 to 99 seconds d. Follow All Transistor and Relay Outputs may be either initially energized or initially de-energized in all four modes. FRONT PANEL 6, .56" LED Display S'LED Status Lamps 14-Key Membrane Switch Keyboard Splashproof Polyester Overlay, resistant to solvents such as acetone, ketone, etc, 3. ECCI953-5B SPECIFICATIONS (cont.) ENCLOSURE DIN Case Dimensions: 5.35" W x 2.62" H x 5.90" D Bezel Dimensions: * 5.15" W x 3.05" H x 0.30" D DIN Panel Cut-out Dimensions 5.43" W x 2.68" H USER POWER SUPPLIES: +5 VDC, 250 milliamperes max. -V Supply* (Approx. -8 VDC), 100 milliamperes max. unregulated ENVIRONMENT: Opera +32 to +130°F Storage: -40 to +160°F Operating Humidity: 90% non-condensing. POWER REQUIREMENTS: MWBI36 - 117 VAC, 150 milliamperes + 10%, -20%, 47 to 63 Hertz MWB136/220VAC - 220 VAC, 150 milliamperes + 10%, -20%, 47 to 63 Hertz MWBI36/12VDC - +12 VDC, 0.9 amperes 20% MEMORY: Program Memory: 4K x 8 EPROM Non-volatile Memory: 128 x 4 NOVRAM DIAGNOSTICS: ‘Checksum Test on Non-volatile Memory RAM Bit Test on both External Static RAM and CPU Internal RAM. Watch Dog Timer. SERIAL COMMUNICATIONS OPTIONS: RS-422, RS-232C®, and 20 Milliampere Current Loop available. Baud Rate is user selectable from 150 to 4800 baud. Half Duplex, odd parity, 1 stop bit and 1 start bit. * Not available on the MWB136/12VDC models. ECCI 4+953-5B INSTALLATION INSTRUCTIONS Panel Mounting Instructions The Micro-Wiz counter is designed to be panel mounted in an existing housing. The unit should be mounted away from sources of electrical noise. Adequate air circulation should be allowed so that the heat generated inside the unit may be dissipated through its heat Figure 1 shows the mounting instructions and panel cutout dimensions. If it is desired to space the units close together or close to an enclosure wall, the optional mounting brackets (part no. 267-290) can be used. These brackets allow the unit to be installed within 0.5 inches of the wall. pr 5.37 =R 7 oI a 5.43% 2 oh ia PANEL CUT QUT sto. Top me! =] Pe ‘ 02 FRONT Le 5.675 = 1875 577 1) CUT OUT PANEL WHERE UNIT IS TO BE MOUNTED. 2) PLACE GASKET OVER END OF UNIT AND SLIDE BEHIND BEZEL. 3) INSERT UNIT INTO CUT OUT. 4) ATTACH PANEL MOUNTING CLIPS TO OUTSIDE OF UNIT. STANDARD CLIP 1344-91 OPTIONAL CLIP 267-290 5) ‘TIGHTEN SCREWS IN CLIPS UNTIL UNIT IS SECURED. Figure 1: Micro-Wiz Panel Mounting Instructions 5. Eccl953-5B INSTALLATION INSTRUCTIONS (cont.) Wiring Instructions ‘The Model MWB136 can interface with a variety of different transducers. Figures 2A - 2L show how to wire the most commonly used transducers. When wiring the unit, be sure to set the DIP switch on the back panel to its proper setting for the transducer. Depending on the application, the user will determine the proper setting of the input filter switches. Only when using the Contact Closure Input (Figure 21) should this switch be set to 30 Hertz. Figure 3 shows the back panel with the terminal designations and wiring instructions for all other remote inputs and outputs. Some general wiring rules to follow: 1 2 ECCI Before attempting any wiring, make sure power is not being supplied to the uni For all inputs, use shielded cable and keep alll lines as short as possible. Also keep these lines away from any source of electrical noise, such as motors and solenoids. Do not bundle or route any line, either input or output, with other power lines. Use some type of are suppression on the contacts and coils of power relays that are near or interface directly with the unit. The terminals on the back pane! will accept lugged or unlugged wires up to AWG 14. Whenever only one transducer input is used, the unused input should be set for TTL logic, 30 Hz. input filtering, and the pull-up resistor active using the DIP switch settings in Figure 10. If this is not done, the unused input could produce count pulses.953-5B INSTALLATION INSTRUCTIONS (cont.) Figure 2A: PU7928A/PU7928B END SENSITIVE PICKUP SVITCH SETTINGS T2s456 eawabud PU7928A, T2sase EAOW ACA pu7928B PULL ee oer elalolalo olelejola SVITCH SETTINGS T2esas6 PaGWBa ECCI953-5B INSTALLATION INSTRUCTIONS (cont.) Figure 2C: PU785A PROXIMITY PICKUP SWITCH SETTINGS aaa Figure 2D: PU863 UNIDIRECTIONAL PULSE GENERATOR, swrtew sertines selsiele WAUBGA 2 solo ECCI -8-INSTALLATION INSTRUCTIONS (cont.) 953-5B Figure 2E: PU871/PU880 UNIDIRECTIONAL PULSE GENERATOR Pua7t PuB80 Fug71 - cus PUBBO - CLA Cas itil acd sw SWITCH SETTINGS elelolefefofo}a}o] @ ewe 8 2 8 e[ofo[e[o]o[e] T2sase puBWSOE SWITCH SETTINGS T2s4s56 SaB abe ECCI953-5B INSTALLATION INSTRUCTIONS (cont.) Figure 2G: OPEN COLLECTOR TRANSISTOR INPUT (OPEN COLLECTOR OUTPUT PH TRANSISTOR MUST SEW Sua @ SVDC ‘SWITCH SETTINGS Tessse EWAWBUA Vth = 43.5 vain. Vil = 40.8 Veax, VALUE OF 'R' 15 DEPENDENT on INPUT DEVICE CHARACTERISTICS svt SWITCH SETTINGS pesase LAW WBE ECCI -10-953-5B INSTALLATION INSTRUCTIONS (cont.) Figure 21: PU752A LOW LEVEL INPUT PICKUP at >< Yih +1sorDe ata, ‘+30¥0C ax. PU7324, VAL = -150—v0C max. cu caste, =30v0¢ ain. SWITCH SETTINGS Tesase CAWWAGE conacr wt snvca S¥DC @ Sau WTaT ‘SWI «ose es fll S¥ITCH SETTINGS elofofe[e[o IUAQAAA e]o]efele “le ECCI953-5B uses. Pusse Pug76 Puss: ECCI INSTALLATION INSTRUCTIONS (cont.) Figure 2K: PU866 BIDIRECTIONAL PULSE GENERATOR sui SUITCH SETTINGS 5 SHTELD resas6 pu AWAY Pus6s=cLs PUa76=cL5 Pugas=cL4 VI SWITCH SETTINGS QO S/S} oO} @/S|@]ojo]o elefofe] Tesas6 VAWAHH‘953-5B INSTALLATION INSTRUCTIONS (cont.) UNLATCH RELAY 3 = aa unvaren aauar 2] a 1. RESET COUNTER 2 REFER TO. SIX CUSTOMER SUPPLIED NORMALLY OPEN Contacts. asta Reva, UNL a, UNL2; UNL, ARE ACTIATED ON CLOSURE OF CONTACTS. TO GROUND. SET-UP ENABLE HELD 10 GROUND, ALLSWS USER TO PREPROGRAM SET-UP FUNCTION ALL INPUTS ARE SWITCHED TO £.€.C.T, SUPPLIED B.C. GROUND. SHIELDED CABLE MUST BE USED ALL OPEN couLecton OUTPUTS ARERATED S0VOE © 150mA ‘OUTPUT 5 OPEN COLLECTOR ‘OUTPUT 2 OPEN COLLECTOR [— OUTPUT 4 OPEN COLLECTOR, ‘STOP COUNT INPUT = INPUT WELD RT B.C, GROUND ZNIBITS counTinG . CUSTOMER Suppuieo suo. CONTACT TRANSDUCER INPUT A TRANSDUCER INPUT B De GROUND. USER SUPPLY +3 oe REGULATED @ 250 mA, swiren SEMTINGS, 3) TPUT A Losic Lever ofr -TTy ONS BCROSSING 2) INPUT A PULL-UP ONTACTIVE RANUAL FoR INPUT CURRENT 3) INPUT 8 LOGIC LeveL. OFF- TTL REQUIREMENTS. ON-BCROSSING 4) INPUT B PULL-UF ONTACTIVE s) INPUT A FILTER Mw8 136 127 VAC HOT ‘ove 136)/220¥0:220VAC HOT hwe aa4/az voc: #120 Mw 1361117 VAC NEUTRAL, Mw 134/220VAC; 220 YAC NEUT. mwa 136/12 VDC: OC. GROUND BUILDING GROUND (MUST BE ‘WIREE FOR PROPER OPERATION) UNREGULATED USER SUPPLY “BVOC @ 100nn (NOT 4 AVAILABLE ON MW 136/12VBC D.C. cROUND Figure 3: BE eRa Sou Jo sueurg riuten oa BOKNZ,ON- 30N2 RELAY 1 COMMON RELAY 1 NORMALLY OPEN RELAY 1 NORMALLY CLOSED RELAY 2 COMMON RELAY 2 NORMALLY OPEN RELAY 2 NORMALLY CLOSED. RELAY 3 COMMON RELAY 3 NORMALLY OPEN RELAY 3 HORMALLY CLOSED NOTE RELAYS 1 AND 2 ARE CONTROLLED BY PRESETS, LAND 2 COMPARED TO COUNTER 1. RELAY 3 Ts CONTROLLED BY PRESET S WHICH CAN BE ‘Tie 70 COUNTER 2, COUNTER 2, OR THE. RATE INDICATOR. ALL RELAYS “1 AMES, RES. 220 AC Back Panel Wiring “13. ECCI953-SB INSTALLATION INSTRUCTIONS (cont.) cover — counter 1.64 HOOK UP Space micko- wuz Ep] “counvex Figure 4: MWB Desk Top Enclosure ECCI “14.953-5B INSTALLATION INSTRUCTIONS (cont.) Serial Communications Option Installation There are three different Serial Option boards available for the Micro-Wiz counters. Each option is available as a separate unit, which is to be installed in the unit by the user. A manual and customer interconnect drawing is supplied with the unit. ‘The available options are: 1, Model MWB-RS232 RS-232C Serial Option. 2. Model MWB-RS422 RS-422 Serial Option. 3. Model MWB-20MA 20 Milliampere Current Loop Option. Refer to the Serial Option manual for installation and wiring instructions, ‘The Serial Communications section later in this manual describes how these options are used.953-SB MODEL MWB136 PROGRAMMING AND KEYBOARD OPERATIONS. The Model MWBI36 front panel, Figure 5, has a fourteen-key membrane keyboard with a six-di LED display which is used for viewing, programming, and resetting the counters, presets, and Set-Up Functions data. A polyester overlay is used to provide the maximum resistance to chemicals and abrasion. Five LED status lamps are used to indicate what data is currently being displayed. se” ‘The MWB136 has an internal timer that is activated whenever the keyboard is used which prevents data other than the two counters or the Rate Indicator from being latched on the display. ‘The user must continuously press keys within ten seconds of each other to prevent the unit from reverting back to the default display. This timer is active when programming Set-Up Functions or presets, and when resetting a counter. It is not active while in the Quick Scan Mode. During normal operation, the MWB136 will be displaying the default device. This device is either Counter 1, Counter 2, or the Rate Indicator. It is assigned by the user in Set-Up Function 16. For all sections on Programming and keyboard operations, it is assumed that the default device is currently displayed. CE Cn CRC) Figure S$: MWB136 Front Panel ECCI a6.953-5B PROGRAMMING AND KEYBOARD OPERATIONS (cont.) Set-Up Function Programming ‘The Model MWB136 may be operated in a variety of ways. The Set-Up Functions enable the user to Program the unit for the desired operation. Of the 23 Set-Up Functions, 19 are used for this Programming. The remaining 4 functions are used in diagnostic routines which are discussed in later sections. All 19 of these functions should be programmed before the unit is used to insure proper operation, The Set-Up Functions are addressable through the front panel. The functions may be viewed at any time by the operator, but the back panel input labelled ‘ENB’ must be connected to D.C. ground before any data can be changed. This feature insures that data cannot accidentally be altered. All Set-Up Function data, as well as the counters and the presets, are stored in non-volatile memory so they need only to be programmed once. To Select a Set-Up Function for Viewing - Press - Set-Up Key the display will go to and the LED on the Set-Up Key will light. xx where 'XX’ represents the two-digit code of the desired Set-Up Function, Enter Key the current option code programmed for the Set-Up Function will be displayed. All functions, except for Code 00, are addressed for either viewing or programming in this manner. If the back panel input "ENB" is not connected to D.C. ground, pressing any other key will cause the unit to revert back to the default display. If no keys are pressed within ten seconds, the unit will automatically revert to the default display. To Select and Reprogram a Set-Up Function - (The back panel input ENB’ must be connected to D.C. g.ound.) Press “Set-Up Key display goes to "00. XX where XX’ is the desired Set-Up Function number. Enter Key the current option code is displayed. X(XXXXX) where ’X’ is any VALID option code for the selected Set-Up Function. Refer to Figure 6 for valid codes, Enter Key the new data is stored in the unit. The 'Reset’ key may be used at any time to escape from this mode without altering the currently programmed data. “7 ECCI953-5B PROGRAMMING AND KEYBOARD OPERATIONS (cont.) Quick Sean Mode - For Set-Up Function 00 (Quick-Scan mode), the ENB’ input must be closed in order for this function to be called. When called, the display will jump to '01' for Set-Up Function 01 and the LED lamp on the *Set-Up’ key will light. Pressing the "Enter’ key will cause the data for that function to be displayed. Each time the ’Enter’ key is pressed the unit will alternately display a Set-Up Function number and then the data for that function. New data may be entered at any time, The unit will revert to the default display after Set-Up Function 19 data is viewed, or the 'Reset’ key may be used at any time to escape from this mode. The Counters are not updated while in this mode. The machine must be stopped before calling this Set-Up Function. While in the Quick Scan Mode, the user may jump around to any Set-Up Function, Whenever the unit is currently displaying the two-digit Set-Up Function number, the user may enter the two-digit number of the desired function. When the Enter key is pressed, the data for that function will be displayed. Pressing the Enter key again will cause the unit to continue to sequence up through the Set-Up Functions from the point just jumped to. Figure 6 lists the Set-Up Function code numbers and the options for each. All invalid inputs are ignored by the unit. Appendix A is a programming form that should be used before any data is entered. It lists all Set-Up Functions and presets so the desired data for each may be written down and saved for future reference. It also aids in providing a check list for the information that needs to be entered into the unit before it is operated. WARNING THESE SET-UP FUNCTIONS ALTER THE OPERATION OF THE UNIT ‘AND THEY SHOULO NOT BE PROGRAMMED WHILE THE MACHINE IS RUNNING. SINCE THE OUTPUTS MAY BECOME ACTIVATED DUR- ING THE REPROGRAMMING, THE UNIT SHOULD BE LOCKED OUT FROM THE PROCESS IT 1S CONTROLLING. ECCI -18-953-5B PROGRAMMING (cont.) * indicates factory-programmed data. CODE _FUNCTION __OPTIONs o1 Counter 1 Input Configuration ery AUEene DESCRIPTION Quadrature X1 Quadrature X2 Quadrature X4 Add/Add X1 (Summation) Add/Add X2 Add/Subtract X1 (Difference) Add/Subtract X2 ‘Count and Direction Q Counter 2 Input 1 Configuration Input same as Counter 1. Direction is opposite. Output 2 (always counts up). Input same as Counter 1, Direction is the same. 03 Counter 1 Operating * Mode ue Reset to 0. Count up or down Reset to Preset 2. Count up or down. Reset to 0. Count to Preset 1 Reset to 0. Count to Preset 2 Reset to Preset 1. Count to 0 Reset to Preset 2. Count to 0 04 Counter 1 Reset ie Options ene awe Manual reset from front and back panels. Manus: reset, back panel only Manual reset from front and back panels. Auto-reset when Counter 1 equals Preset 2. Manual reset from back panel only. Auto-reset when Counter 1 equals Preset 2. Manual reset from front and back panels. Manual reset causes crop on Output 2. Manual reset from back panel only. Manual reset causes crop on Output 2. Manual reset from front and back panels, Auto-reset when Counter 1 equals Preset 2. Manual reset produces crop on Ouiput 2. Manual reset from back panel only. Auto-reset when Counter 1 equals Preset 2. Manual reset produces crop on Output 2. Figure 6: Set-Up Function Codes -19- ECCI953-5B PROGRAMMING (cont. CODE __ FUNCTION _OPTIONS__DESCRIPTION 05 Counter 2 Reset . Manual reset from back and front panel. 1 Options 2 Manual reset from back panel only. 3 Manual reset from back and front panels. Reset does not affect Output 3. 4 Manual reset from back panel only. Reset does not affect Output 3. Note: Option Codes 3 and 4 assume Preset 3 is assigned to Counter 2 (Set-Up Function 12). 06 Counter 1 Input, 0.00001 to Refer to the Applications note at end of manual. Prescaler 9.99999 Unit shipped with prescaler set at 1.00000. C7 Counter 2 Input 0.00001 to Refer to the Applications note at end of Prescaler 9.99999 manual. Unit shipped with prescaler set at 1,00000. 08 Rate Indicator 0.00001 to Refer to Appendix B for examples. Input Prescaler 9.99999 Unit shipped with prescaler set at 1.00000. o Counter 1 Decimal = 1 +000000 Point Location 2 +00000.0 10 Counter 2 Decimal 3 +0000.00 Point Location 4 +000.000 uu Rate Indicator Decimal 5 +00.0000 Point Location 6 +0,00000 7 +.000000 Functions 09, 10, and 11 are all factory-programmed at 1. 2 Preset 3 Assignment "1 Preset 3 assigned to Counter 1 2 Preset 3 assigned to Counter 2 3 Preset 3 assigned to the Rate Indicator Note: This function also assigns the output associated with Preset 3 to the indicated device. Figure 6: Set-Up Function Codes ECCI -20-953-5B PROGRAMMING (cont.) CODE __ FUNCTION OPTIONS _ 13 Output 1 Options 1000 NO. Toggle 2000 N.C. Toggle 4 Output 2 Options 3000 NO. Latch 4000 N.C. Latch 15 Output 3 Options 5XXZ_ ——_N.O. Momentary 6XXZ N.C, Momentary 7000 N.O. Follow 8000 NCC. Follow For Momentary Outputs, XXZ sets the time out. XX = Momentary Mantissa, Preset 01 10 99. Z = Momentary Multiplier, 0 = X 0.01 seconds 1 = X 0.10 seconds 2 = X 1.00 seconds Example: Unit is shipped at 5250 = 25 second momentary signal Functions 13, 14, and 15 are all factory-programmed at 3000. Note: Refer to MODEL MWB136 OPERATING MODES Section for restrictions when using the Follows Output options. 16 Default Display “1 Counter 1 (Display returns to 2 Counter 2 default selection) 3 Rate Indicator 4 Last Counter or Rate Indicator viewed. 7 Power-On-Reset ai Both Counters are restored to the count previous Options to the power outage. 2 Counter 1 is reset per the option set in Function 03. Counter 2 is restored. 3 Counter 1 is restored, Counter 2 is reset to 0. 4 Counter 1 is reset per the option set in Function 03. Counter 2 is reset to 0. 18 Preset Programming = * 1 Presets may be programmed at any time. Disable 2 Presets may only be programmed when the Set-Up Enable control input (ENB) is closed. 19 Follows Output 7 Follows output active when the + counter = +preset or the - counter < - preset. 2 Follows output is active when the counter Is 2 Preset. Figure 6: Set-Up Function Codes ECCI953-SB PROGRAMMING (cont.) CODE __ FUNCTION OPTIONS. DESCRIPTION . 20 Machine Number 00 10 99 Serial Port Identification Note: Refer to the Serial Communications Manual on how to program this function, Unit shipped set at 20, Programming Presets The Model MWB136 has three presets that are all programmed in the same manner. Each preset may be set from -999999 to +999999. The decimal point location for the preset is determined by the Counter or Rate Indicator it is assigned to. To View a Preset - Press - 1/Preset 1 Key _to view Preset 1. 2/Preset 2 Key _to view Preset 2. 3/Preset 3 Key _to view Preset 3. The presets are displayed as long as the key is pressed and for 10 seconds after it is released. The LED on the Program key will light whenever a preset is displayed. To Program a Preset - (Example is for Preset 1.) Press - Program Key the LED on the Program Key begins to flash. The main display is not affected. 1/Preset 1 Key _the current value for the preset is displayed. X(XXXXX) the new data for the preset. Leading zeroes need not be entered. Set-Up Key to toggle the polarity between +/-. Enter Key to store the new data. To program Preset 2 or 3, that preset’ to be pressed if the preset's polarity ig ce Preset programming may be disabl disabled through Set-Up Funct ith this functi i Presets may only be modified if the back panel npet Re eco ais function set for option code set's key is substituted in the second step. The Set-Up Key needs only larity is changed. The MWB136 always defaults to +. ECCI953-SB PROGRAMMING (cont.) Viewing and Resetting the Counters and Rate Indicator To View a Counter or Rate Indicator - Press - 6/Counter 1 Key to view Counter 1. 7/Counter 2 Key to view Counter 2. 8/Rate Key to view the Rate Indicator. The device selected will be displayed as long as the key is pressed and for 10 seconds after it is released. The LED to the right of the display associated with the device will also light, If Set-Up Function 16 has been programmed for code ’4’, the device selected will become the new default device. To Reset a Counter - (Examples shows how to reset Counter 1) Press - Reset Key the main display will begin to flash. This flashing is to indicate to the user that a counter can be reset. 6/Counter 1 Key the counter will be reset per the option in Set-Up Function 03 and it will be displayed, To reset Counter 2, the "7/Counter 2° key is pressed. If the front panel reset has been disabled through Set-Up Function 04 for Counter 1 or Set-Up Function 05 for Counter 2, nothing will happen when the counter’s key is pressed after the Reset Key. If the Reset Key has been pressed accidentally, the user may wait 5 seconds for the unit to clear the flashing without affecting the counters, or the Reset Key may be pressed again. ECCI953-5B BACK PANEL TERMINAL ASSIGNMENTS AND DESCRIPTION@ ‘The Model MWB136 has 28 terminal pins and 6 switches on the back panel. Figure 7 gives a detail of the back panel. All control inputs are activated when they are connected to DC ground through a jumper, switch, Termi Pint - Pin 2 - Pin 3- Pin 4- Pin - Pin 6 - transistor or relay. al Assignments Set-up Function Enable (ENB) When connected to the DC ground, this input enables the user to change any of the set-up data. Since the set-up data determines how the unit operates, it is important to limit access to it. ‘When this input is left open, the set-up data may still be viewed but cannot be changed. This input may also be used to prevent reprogramming of the presets. Reset Counter 1 (RST 1) Reset Counter 2 (RST 2) These two inputs are used to reset the counters. When closed, the counter associated with the input will be reset. Any output associated with the counter that is reset will also be returned to its normal status (unlatched) unless told not to by Set-Up Function 05. Opening the contact has no effect. Unlatch Output 3 (UNL 3) Unlateh Output 2 (UNL 2) Unlatch Output 1 (UNL 1) These inputs are used to unlatch the outputs. When closed, the output will be set to its normal status. Pin 7 - Open-Collector Output 3 (OC 3) Pin 8 - Open-Collector Output 2 (OC 2) Pin 9 - Open-Collector Output 1 (OC 1) ECCI These outputs are the open-collector Darlington transistors associated with Presets 1, 2 and 3. They are energized at the same time as the relays. Soar SLopane ise } @ ENS ASTTASTEUM SUM2UMLI OCS OC2 0C1 STO cap sv ee ens OF Ge ESS is ie HOT NEUT oy =v GND | NC A NO COM NC # NO RCO NC ® NO RCOM 15 16 7 18 19 | 205 213 22 | ase 248 25 | 261 271 28 Figure 7: Model MWB136 Back Panel 24953-5B TERMINAL ASSIGNMENTS (cont.) Pin 10 - Stop Count (STOP) This input stops the two counters when closed to ground. It has no effect on the Rate Indicator. Counting resumes as soon as it opens. Pin 11 - Input A (IN A) Pin 12 - Input B (IN B) These two transducer inputs are programmed to count in a variety of ways. Figure 8 shows what each input's function is for different count input modes. The DIP switch (described later in this section) controls the input logic levels and filtering for these inputs. [_counrmope [_ineura | inrura Add/Subtract X1, Decrement Counter Increment Counter cant Low_= Counts Up Figure 8: Count Input Functions Pin 13 and 19 - DC Ground (GND) DC ground must be used as the common return for all the switch inputs, encoder inputs and open-collector outputs. It is also the power supply common for both the +5V and -V (approx. -8V) supplies. Pin 14 - +5V DC (+5V) Main regulated power supply rated at 250 milliamperes. This supply may be used for powering encoders, photoscanners, and other devices. Pin 15 and 16 - Primary Power Inputs These pins are used to connect the primary power source for the MWB136. The following table lists the various inputs for the different MWB136 models and how the back panel is labeled for each. NoDes. [xe wis anne rte tse [rvac Prvacun [wor nrvac nouns ee ee eae lc a ree pees Figure 9: Input Power Terminals ECCI953-5B TERMINAL ASSIGNMENTS (cont.) Pin 17 - Building Ground It is recommended that the building ground always be connected. This will provide reliable noise-reduction and filtering inside the unit, It is also suggested that all inputs use shielded cable, with the shield connected to building ground at the counter end only. Pin 18 - -V DC (approximately -8V) Secondary unregulated supply rated at 100 milliamperes. This supply is only available on the MWBI36 and MWB136/220VAC models. Pin 20 - Relay 3 Normally Closed Contact (NC) Pin 21 - Relay 3 Normally Open Contact (NO) Pin 22 - Relay 3 Common (COM) Pin 23 - Relay 2 Normally Closed Contact (NC) Pin 24 - Relay 2 Normally Open Contact (NO) Pin 25 - Relay 2 Common (COM) Pin 26 - Relay 1 Normally Closed Contact (NC) Pin 27 - Relay 1 Normally Open Contact (NO) Pin 28 - Relay 1 Common (COM) All relays are rated 10 amperes resistive at 220 VAC. All contacts are RC suppressed. DIP Switches The six DIP switches located on the back panel select the input logic levels and input filtering. They also supply an input pull-up resistor that can be used for contact closure inputs. Figure 10 lists the settings for these switches. [_swircn | FUNCTION OFF (DOWN) ON (UP) Input A Pulleup Not Connected Input B Logic Level TTL Input [o Crossing nput_ Input B Pull-up Not Connected Active Input A Filter 30 KHz 30 Hz Input B Filter 30 KHz 30 Hz Figure 10: DIP Switch Settings ECCI953-SB MODEL MWB136 OPERATING MODES COUNT INPUTS: ‘The Model MWB136 has eight different i modes ii unidirectional and bidirectional inputs, =?" “OUntn"B modes. These include botn Unidirectional ‘Add/Add X1 and X2 These modes are actually summation inputs. Two asynchronous, unidirectional inputs can be summed together, counting the trailing edges only (X1) or counting both the trailing and leading edges (X2). This mode should be used if a single unidirectional input is to be counted. Bidirectional Quadrature X1, X2 and X4 These modes accept two encoder inputs that are phase shifted by 90 degrees. The phase shift, either leading or lagging, determines the count direction. The X1 mode counts at the line count given by the encoder. X2 doubles this count while X4 doubles it again. ‘This enables the unit to count 2400 pulses per revolution from a 600 line count encoder when programmed for Quad X4, ‘Add/Subtract X1 and X2 These modes allow the user to increment the counters through one input while decrementing the counters through the other. Two asynchronous inputs can be counted at X1 or X2; Input A decrements the counters while Input B increments them. Count and Direction X1 In this mode Input A accepts count pulses, while the logic level on Input B determines their direction. If Input B is low, the pulses are added to the counters. If Input B is high, the pulses are subtracted from the counters. COUNTER 1 - (MAIN COUNTER) OPERATION Counter 1 Operating Modes Reset-to-Preset - Counter 1 can be programmed to reset to Preset 2, and then count up or down. The outputs are activated when Counter 1 equals Preset 1 and at 0. The output associated with Output 2 is activated at 0. Both an auto-reset and a manual reset will cause the counter to reset to Preset 2. Reset-to-0 - In this mode, Counter 1 will reset to 0 and count up or down. Outputs occur when Counter 1 equals the two presets. -27- ECCI953-SB OPERATING MODES (cont.) Toggle Modes - These modes enable Counter 1 to alternate between the two presets. It is recommended to have Counter 1 set for an auto-reset option in order for these modes to work properly. In the Reset-to-0 Toggle Mode, Counter 1 is Hy reset to 0 with a manual reset. It counts up to Preset 1, actuating Output 1. It then auto-resets to 0 and counts up to Preset 2, actuating Output 2 when Counter 1 equals Preset 2. In the Reset-to-Preset Toggle Mode, Counter 1 is initially reset to Preset 1 with a manual reset. When Counter 1 equals 0, Output 1 is actuated and the counter auto-resets to Preset 2. When Counter 1 equals 0 again, Output 2 is actuated and the counter auto-resets back to Preset 1. Note that, in this mode, Preset 3 could be used as a common prewarn for both outputs. Counter 1 Reset Modes Manual Resets - Counter 1 can be reset from either the front panel or a back panel input. Since it is sometimes desirable to prevent a machine operator from resetting the counter, the front panel reset key operation for Counter 1 can be d:sabled. The back panel input is always active, The unit also has a reset with a crop output option. A reset signal from either the front panel or remote input will produce a crop signal on Output 2. If the crop option is selected, do not set Output 2 for the Follows option, Auto-Reset - An Auto-Reset option is available for Counter 1. When Counter 1 equals Preset 2 in the Reset-to-0 mode, or 0 in the Reset-to-Preset and the Reset-to-Preset Toggle modes, or when it equals either Preset 1 or 2 in the Reset-to-0 Toggle mode the counter will automatically reset without loss of count, All manual reset options are available when the Auto-Reset option is selected. Again, it is not recommended to set Output 2 for the Follows option when Counter 1 is set for auto-reset. When Counter 1 is auto-reset, the outputs assigned to Counter 1 are not unlatched, It is up to the user to make sure the outputs are restored to their normal status after an auto-reset so they may be activated again. Counter 1 Input Prescaler ECCI Counter 1 has its own six-digit input prescaler. All uni 1.00000. It is programmable from 0.00001 to 9.99999, for wear or inaccuracies in Application Note at the e factors other than 1.00000. are shipped with this prescaler set to prescaler may be used to compensate the measuring device, or to convert to a different unit of measure. An nd of this manual describes how the input prescaler is determined for953-5B OPERATING MODES (cont.) COUNTER 2 - (BATCH/TOTALIZER) OPERATION Input Configurations and Operating Modes Counter 2 may either count in parallel with Counter 1 or count occurrences of Output 2. When counting in parallel with Counter 1, this counter functions as a total-quantity counter. When counting occurrences of Output 2, it is used as a batch counter. When counting in parallel with Counter 1, Counter 2 can be selected to count either in the same direction as Counter 1, or in the opposite direction. This option is useful when counting unidirectional pulses and Counter 1 is programmed in the Reset-to-Preset mode (counting down). In this situation Counter 2 is programmed to count up so it may be used as a total-footage counter. Counter 2 Reset Options Counter 2 is manually reset from either the front panel or a remote input. As with Counter 1, the front panel reset may be disabled allowing only reset signals from the remote control input to reset it. Counter 2 is always reset to 0 and does not have an auto-reset option. If Preset 3 is assigned to Counter 3, the user may also select whether the reset will restore Output 3 to its normal status or not affect it (see Set-Up Function 05). This allows the user to use Output 3's open-collector output to reset Counter 2 without unlatching Output 3 in the process. Counter 2 Input Prescaler Counter 2 has its own input prescaler programmable from 0.00001 to 9.99999. Refer to the Applications Note at the end of this manual for programming instructions. RATE INDICATOR OPERATION ‘The Rate Indicator available with all Micro-Wiz counters is used to monitor the speed of the incoming pulses. The Rate Indicator samples the inpu, pulses for 0.5 seconds, converts the sample to pulses per second and then multiplies this result by its input prescaler. The final result may then be displayed. The Rate Indicator is continuously updating its result, Even when it is not displayed, current data is always available for viewing. ‘The input prescaler portion of the Rate Indicator is an important part of its operation. It is used to convert the sampled pulses, which are in pulses per second, to the desired units to be displayed. Appendix B gives a list of several common conversion factors for the prescaler along with an example of how to calculate the conversion factor in case the desired one is not listed. An Application Note at the end of this manual describes how to operate the Rate Indicator. If Preset 3 is assigned to the Rate Indicator, do not set Output 3 for the Follows option. The user may use the Latch option which behaves like the Follows option when the preset is assigned to the Rate Indicator.953-5SB OPERATING MODES (cont.) PRESETS The Model MWB136 has three presets, each programmable from -999999 to +999999. Presets 1 and 2 are dedicated to Counter 1. Preset 3 may be assigned to Counter 1, Counter 2 or the Rate Indicator. Each preset has its own relay and open-collector output. Preset-programming may be disabled through Set-Up Function 18, allowing preset data only to be altered when the back panel remote input (ENB) is connected to D.C. ground. This feature prevents unauthorized access to preset-programming while still allowing data to be viewed at any time. All presets activate their outputs whenever the devices (Counter 1, Counter 2 or the Rate Indicator), assigned to them, pass through their preset value. The delay from when the counter equals a preset to output activation never exceeds 1.5 milliseconds. DECIMAL POINTS ‘The decimal point location for each counter and the Rate Indicator is independently programmed through the front panel. The decimal point may be set to display 000000 to 000000. When the decimal point is programmed for a Counter or the Rate Indicator, any preset that is assigned to it will display the same decimal point location, RELAYS AND OPEN-COLLECTOR OUTPUTS ECCI ‘The Model MWB136 has three relay outputs and 3 open-collector Darlington outputs. Each relay is a Form-C output rated 220 VAC at 10 amps. All contacts are suppressed with a resistor-capacitor network. The open-collector outputs can switch a DC load of up to 150 milliamperes and 30 VDC (referenced to the DC ground of the unit). ‘There are four different operating modes for the outputs: Latch - When the counter equals the preset, the output is latched. It will remain latched until the counter is reset or until remote-unlatch input for the output is closed. Toggle - In this mode, each time the counter equals the preset, the output will toggle and remain in its new state until the counter is reset or until the next preset is equalled. Momentary - ‘The output can be rammed to acti and thee eee OR 10 activate for a set time when the counter equals a preset ‘The hold-in time is programmable from .01 to 99 seconds. Follows - ‘The output is active whenever thi is as selected in SetUp Function Cogent equal to, ess than or greater than the preset In all ir i i .. deenerpacd modes, the output may function as either normally energized or normally953-5B SERIAL COMMUNICATIONS -There are three serial options available for the Micro-Wiz family of counters. These options enable the netters, presets and Rate Indicator to be viewed or changed from a remote location. All information S2ttansmitted to and from the counter over one of the following standard Serial Communications Options: 1, Model MWB-RS422 Se 2, Model MWB-RS232 Serial Option® 3, Model MWB-20MA 20 Milliampere Current Loop Option. {All three options provide the same set of commands that are used for two-way serial communications. ‘These commands are used to address a Micro-Wiz for interrogation (’M’ commands), to display the status of the counters, the Rate Indicator, and presets ('S’ commands), to change a preset ('P’ commands) and to reset the counters (’R’ commands). The Micro-Wiz may be used as a one-way link to interface to a printer. Connecting the control input on the serial option board to D.C ground, forces the unit to ‘dump’ the contents of the counters, presets and Rate Indicator out the serial port. All serial options are set for Half Duplex communications, Odd Parity, 1 Stop Bit and 1 Start Bit. The baud rate is user selectable via a DIP switch on the option board for 150 to 4800 baud. This section will describe the general characteristics of each of the serial options available and the commands that may be sent over the serial link. The manual included with each option contains instructions for interfacing the Micro-Wiz to other devices, and also a more detailed explanation on how to program the option board and wiring of cables. MWB-RS232 Serial Communications Option* RS-232C is the most popular serial communications link used today. Every manufacturer of printers, programmable controllers, and computers offers the ability to communicate using the RS-232C protocol. The Micro-Wiz data may be sent over cables of up to 50 feet using this option. ‘The data signals have a wide hysteresis for noise immunity. One-way communication links used to interface with a printer need only a 3-wire cable. Two-way communications can be performed with as few as 4 wires. -MWB-RS422 Serial Communications Option This option allows the Micro-Wiz counter to be connected to a RS-422 serial port. The RS-422 I link can provide a longer, cleaner and more reliable data transfer than the other two serial tions. The RS-422 protocol provides for each signal to be made up of a differential pair. These signals are then sent down cables of up to 1 kilometer made up of twisted pairs of conductors, providing for very high noise immunity on the data paths. These signals may also be tri-stated, allowing for up to 50 Micro-Wiz units to be connected to the same cable, Each unit on the cable is programmed with its own address, or Machine Number, so that they may be interrogated at random. * The MWB-RS232 Option is not available on the MWB136/12VDC Model. 31 ECCI953-5B SERIAL COMMUNICATIONS (cont.) MWB-20MA Serial Communications Option The 20 Milliampere Current Loop protocol provides a reliable serial link over long distances, Multiple units may be “daisy-chained’ together, requiring only two wires (minimum) to complete the link. This option allows the Micro-Wiz Counters to be interfaced with older existing equipment. SERIAL COMMANDS °M’ Command The 'M’ command is used to address the Micro-Wiz counter. This command is sent along with a two-digit Machine Number. If this number matches the one programmed into the unit through Set-Up Function 19, the Micro-Wiz can be asked one of the three other serial commands. This feature is required by the MWB-RS422 and MWB-20MA options so that only one unit is driving the data path when multiple units are on the same cable, It must also be used with the MWB-RS232 option even though this protocol doesn't allow multiple units on the same cable, After the serial option board has been installed per the instructions included with the board, an 'M’ command is sent to address the unit. If the Micro-Wiz has been programmed with the Machine Number equal to 20, the sending device would send M20 ‘The indicates an ASCII carriage return. In all cases, an ASCII line feed may also be included. When the Micro-Wiz recognizes this Machine Number (20), it will respond .. MACH 20 At this time the Ri i fequest-To-Send (RTS) signal is activated and, for the MWB-RS422 option only, the transmit data lines from the unit are no longer tri-stated. ‘The unit is now waiting for a valid ’S', P’, or ’R’ command. If anything other than one of be broken. The -d and the data lines are again tri-stated. A valid Fe the unit will accept other commands, these valid commands follow the ’M’ command, the link wil Request-To-Send (RTS) signal is deactivate 'M’ command must be retransmitted befor the status of the counters, presets *S', followed by a aber from 1 carriage return. If a character other then one of th is recaived kot the carriage feturn, the data link will be broken and the ’M’ command would have to be ECCI 32953-5B SERIAL COMMUNICATIONS (cont.) ‘The three valid 'S’ commands are: -COMMAND __ PRINTOUT ______DESCRIPTION si CNT 1 = +000,000 ‘Counter 1 CNT2 = +000000. Counter 2 PST1 = +001.234 Preset 1 PST2 == +005.678 Preset 2 PST3 == +004000. Preset 3 TACH = +000000. Rate Indicator sz CNT 1 = +000.000 Counter 1 CNT2 = +000000. Counter 2 TACH = +000000. Rate Indicator 83 PST1 = = +001.234 Preset 1 PST2 == +005.678 Preset 2 PST3 == +004000, Preset 3 For each printout, the Machine Number was printed when the val command was received. When the printout does start, the 'S’ command will be written over by the data that is displ Preset 1 and 2 will always show the same decimal point location as Counter 1. Preset 3 will al show the same decimal point location as Counter 2, even though it may have been assigned to Counter 1 or the Rate Indicator. It should also be noted that the counter information to be printed is latched at the time the 'S’ command is received. If the Micro-Wiz receives more count pulses after this, the counter information displayed on the print out will not reflect it. ’P’ Commands ‘The 'P’ commands are used to reprogram the three presets through the serial port. New Preset data, including the polarity, may be entered at any time. Since the operation of the unit changes when the new preset data is received, the machine should be stopped when using these commands. ‘Two steps are required to change a preset. After receiving a valid "M’ command, the Micro-Wiz will print out the Machine Number. When one of the three valid 'P’ commands is received (Pt, P2, of P3), followed by a carriage return, the Micro-Wiz will respond .... PST 1 = (Assuming ’P1* was entered) ‘This statement is printed over the entered command. No carriage return is sent after the line is printed. ‘This will leave the cursor of a CRT at the point where new data is entered. The Micro-Wiz is now waiting for new preset date. ‘The unit will accept all data and will store it in the preset called for. All numbers, the '+’, -’, and decimal point are accepted and stored. The decimal point is accepted but the location of the decimal point can not be changed through the serial port. The new data is now entered, starting with the polarity, then the most significant decade (MSD), followed by 5 more digits. @Six numbers must be received so leading zeros need to be sent.@ The polarity and decimal points are not required. If no polarity is sent, the Micro-Wiz will default to ’+’, The unit will always default to the decimal point location that was programmed via the Set-Up Functions. -33- ECCI953-5B SERIAL COMMUNICATIONS (cont.) After the data has been sent and the Micro-Wiz receives a carriage return, the unit will store the new information and will echo back to the sending device the data it has received. PST 1 = +001.500 Ifa non-numeric character is received, the unit will respond with a7’ in the location(s) with the invalid character. PST 1 = +001.570 ‘The sending device should monitor this data and compare it to what was sent. If a difference exists, the new preset data must be sent again. All data received is stored in the Preset. The Micro-Wiz will store non-numeric information and will use it in trying to count and compare. This will cause the Micro-Wiz to function very erratically. °R’ Commands The three 'R’ commands are used to reset the two counters. A valid ’M’ command must be received before an 'R’ cummand can be used. There is no printout associated with the *R’ commands. To verify that the reset did occur, an °S1’ or 'S2’ command can be used to check the counters. —COMMAND __DESCRIPTION RI Resets Counter 1. R2 Resets Counter 2. R3 Resets both Counters. Counter 1 is reset according to the option selected in the Set-Up Function for Counter 1 operation. Counter 2 is always reset to 0. Print Control Input Pin 15 of the fifteen pin "D’ connector on the Serial Option board can be used to command the Micro-Wiz to print the current status of the counters, presets and Rate Indicator. This input is designed to be used when interfacing the Micro-Wiz counter with a printer. ‘When this input is connected to D.C. id, the Micro-Wiz will begi: inting data in the following format: Broun te MONE WAN eBin Piaing datas ——PRINIOUT______DATA PRINTED __ MACH = 20 Machine Number CNT 1 = +000,000 Counter 1 CNT2 = +000000. Counter 2 PST1 = +001.234 Preset 1 PST2 = +005.678 Preset 2 PST3 = +004000. Preset 3 TACH = +000000. Rate Indicator 34953-5B DIAGNOSTICS AND TROUBLESHOOTING Every Micro-Wiz counter is designed for years of trouble-free operation. Each time the unit is powered up, it tests itself to make sure it is functioning correctly. The non-volatile memory and all RAM memory are tested. If an error is detected, the unit will indicate the failure. A Watch-Dog Timer is also included in every Micro-Wiz counter. This circuit is continuously updated by the computer inside the unit. If the computer stops (due to component failure) or if it gets caught in a software loop (due to the unit receiving an excessive amount of RFI or EMI noise), the Watch-Dog Timer would reset the computer and an error code will be displayed. Three tests are performed on power-up. These tests are: 1. Checksum test on the non-volatile memory. 2. Bit test on the external static RAM. 3. Bit test on the CPU internal RAM. If the Checksum test fails, or if the Watch-Dog Timer trips, the unit will show ‘01’ on the display and the LED lamp on the ’Set-Up’ key will flash. This error is caused by data in the non-volatile memory being lost at power-up. Since this data dictates how the unit operates, the unit ‘locks up’ in the indicated manner preventing the operator from using it until all the information programmed in the unit is checked. ‘This is done by pressing the ‘Enter’ key. The ‘01’ indicates that the data for the Set-Up Function 01 will be displayed when the ‘Enter’ key is pressed. This data can then be compared to the data programmed into the unit that is recorded on the programming form in Appendix A. If the data is incorrect, it may be changed if the back panel input ENB is connected to ground. The next time the ‘Enter’ key is pressed, ‘02’ will be displayed, indicating Set-Up Function 2. Its data may then be checked. This process continues through the 19 functions listed in Figure 6. Three new functions, numbered 20, 21 and 22, are then displayed. These functions are actually Presets 1, 2 and 3. They are repeated in this routine so that the operator is forced to check their value before the unit may be used. The last Set-Up Function, number 23, calls the same diagnostics routine that is used at power-up. If ‘01’ is again displayed, the non-volatile memory has failed and the unit should be returned for service. If the test now passes, the unit will come up with the default display and operation can continue, Set-Up Function 23 may be called at any time when the unit is not controlling the process. It is called using the same key stroke sequence described for programming a Set-Up Function. The two other tests performed by this routine are on the RAM. All bits of this RAM are set to 0. Each bit is then set to 1 and tested, Any defective bit can then be found. If the RAM external to the CPU fails, all the LED status lamps will flash. If the RAM internal to the CPU fails, all the decimal points will flash, In either case, the unit will lock up completely and no operations can be performed. If either of these two results occur, the unit should be returned for service. 35 Eccl953-5B TROUBLESHOOTING (cont.) IN THE CASE OF ANY FAILURE FROM THESE TESTS, THE OUTPUTS WILL BE DE-ENERGIZED. STEPS SHOULD BE TAKEN SO THAT THIS ACTION HAS NO HAZARDOUS EFFECT ON THE PROCESS BEING CONTROLLED. Troubleshooting The diagnostic tests performed by Set-Up Function 23 cover only the RAM and non-volatile data. It is very possible that other failures can occur in areas on the unit's hardware not tested by this function. ‘The following troubleshooting chart, Figure 11, should help in determining other failures. If such a failure is found to be internal to the Micro-Wiz counter, return the unit for service. There are no user serviceable parts inside the unit. Disassembly of the unit may cause additional damage. ‘When a unit Is returned for service, the contents of the non-volatile memory will be altered. ‘The user must record his program and presets in Appendix A so this data can be restored when the unit is sent back. ECCIUnit does not light when power is applied. 1 2 TROUBLESHOOTING (cont.) No or low input power. 1 +5V or -V supplies are 2, shorted, 953-SB Test power inputs. Refer to the specification for the Neither Counter nor the Rate Indicator operates. aeoN s Transducer is wired 1, incorrectly. Unit was programmed for the incorrect transducer. Loose wiring. Input filter set incorrectly. yay oy Unit is set for the wrong input voltage level. Check all back pane! wiring. Check Set-up Function 1, Cheek wiris Check position of back panel DIP switch. Check posi DIP switch. of back panel Counter 1 does not count correctly. we Input prescaler for Counter 1, 1is incorrect. Unit was" programmed 2. incorrectly for the transducer used. Electrical noise is causing 3. extra counts. Loose wiring. 4. Input filter selection set 5. incorrectly. Unit programmed for wrong 6. input voltage level. Check Set-Up Function 6. Check Set-Up Function 1. Shield the cable used for the transducer and route away from possible noise sources. Check Check position of back panel DIP switch. Counter 1 counts in the wrong direction. Inputs are wired incorrectly. 1, Reverse inputs to the counter. Counter 1 works fine but Counter incorrectly, 2 counts Counter 2 is programmed 1. for the incorrect input, Input prescaler for Counter 2. 2 is incorrect. Check Set-UP Function 2, Check Set-Up Function 7. Figure 11: Troubleshooting Chart -37- ECCI953-5B TROUBLESHOOTING (cont.) —EROQBLEM __________POSSIBLE CAUSES __REMEDIES_________ Counter 1 and Counter 2 1. Input prescaler for Rate 1. Check Set-Up Function 8. work fine but the Rate Indicator is incorrect. indicator works incorrectly. A digit is not displayed or 1. LED display is out. 1. Program a preset 10 888888. an incomplete number is A bad LED or a segment will showing while counting or not be lit. programming. Unit displays ’01' and the 1. A diagnostics test failed. ie Refer to the Diagnostics and Set-Up Key LED is flashing. ‘Troubleshooting section of this manual. Figure 11: Troubleshooting Chart ECCI -38-953-SB APPENDIX A Model MWB136 Programming Chart 01 ‘Counter 1 Input Configur a” a Counter 2 Input Configuration and Operating Mode 03, Counter 1 Operating Mode _ 04 Counter 1 Reset Options - 05 Counter 2 Reset Options _ 06 Counter 1 Input Prescaler 7 Counter 2 Input Prescaler 08 Rate Indicator Prescaler Counter 1 Decimal Point 7 10 Counter 2 Decimal Point . uu Rate Indicator Decimal Point 7 12 Preset 3 Device Assignment . 13 Output 1 Options a 4 Output 2 Options —s 15 Output 3 Options 16 Default Display - 7 Power-On-Reset Option 7 18 Preset Programming Disable 7 19 Follows Output Mode . 20 Machine Number = 2 Preset 2 Prest2 2 Preset 3 Functions 21, 22 and 23 are only called as part of the Checksum Error recovery routine. The value of the preset will probably change frequently, depending upon the application, -39- ECCI953-5B APPENDIX B Rate Indicator Prescaler Values Example 1: Feet per minute Measured units = 0.01" Desired Display = feet per minute Time Units Rate Indicator Conversion Conversion —Pisscaler_ nin. . Taba Pbrry = 9.08000 EE FRR Example 2: RPM Encoder = 60 line count quadrature encoder Unit is set to count at Quad X4 Units Line Count _ Time Rate Indicator Conversion Multiplier = Conversion —Prescaler_ rev —-L 60 sec. re aot: x a % ‘ain. = 0.25000 —ifteiia Commonly Used Prescaler Values hes per second 1.00000 (x K)* inches per minute 0.60000 (x K) inches per minute 0.06000 (x K) or" feet per minute 0.50000 (x K) 0.01" feet per minute 0.05000 (x K) 0.001" feet per minute 0.00500 (x K) ou" lV feet per minute 5.00000 (x K) oor «1 feet per minute (0.50000 (x K) 0.001" «1 feet per minute 0.05000 (x K) In case the measured units are inaccurate (due to a worn measuring wheel, for instance) the Prescaler should be multiplied by a compensation factor to correct the error. This factor is found by the equation: peal Measured Unit ECCI 40.953-5B APPLICATION NOTE Counter Input Prescaler Programming ‘the input prescaler available for all Series MWB100 Counters multpl : THEctor of 0.00001 to 9.99999. This enables the Counter to use | ge arg 4 imering the unit by Sree and convert them into standard engineering units of measure. This permits easy setmsinr aa ace Sod reading of display information. point data entry ‘The three most common uses for prescalers are: Converting pulses from an uncalibrated source into standard engineering units. 1 2. Correcting pulses from a worn measuring wheel back into standard pulses. 3. Converting from one unit of measure to another. Example 1: Converting Uncalibrated Pulse Inputs eine In the above application, it is desired to measure the length of material in 0.1 inch increments. A pulse generator can be conveniently coupled to an existing pinch roll with a diameter of 15.2 inches or a circumference = 47.7522 inches. Since an encoder is not available that will produce 477.522 pulses per revolution (required to produce 10 pulses per inch) a standard encoder with more pulses per revolution was chosen to work with the Series MWB100 Counter. 41 ECCI953-5B APPLICATION (cont.) With 600 pulses per revolution equal to 47.752 inches of material travel, 1 inch = 12.5648 pulses. To correct this to 1 inch = 10 pulses, the input prescaler is set to a correction factor of: red Pulses per_{n Input Prescaler = -"Aetual Pulses per Inc Jo. “4750 | ~«O 79587 Example 2: Correcting Pulses from a Worn Measuring Wheel In this application, a 12.00" measuring wheel has worn down to a 11.89" circumference. For each Fevolution of the encoder, the counter still displays 12.00" but the actual distance moved is only 11.89°. To correct for the wear, the following equation is used: 1M Input Prescaler = -Ast Desired Dimension =~ 1 1b 60" 0.99083 This result is entered at the Set-Up Function for the input prescaler. Example 3: Converting Units of Measure ‘The system in this application is currently measuring in 0.01". It is desired for a particular job to measure in 0.1 centimeters. ‘The following steps are used to calculate the input prescaler: 1.0 inch = 2.54 centimeters +01 inch = 0.0254 centimeters For 0.1 centimeter resolution, the prescaler will be entered as: Input Prescaler = 0.25400 In all situations, it is always best for the prescaler to be less than 1.00000 to eliminate measuring errors. Eccl 42953-5B APPLICATION (cont) Series MWB100 Rate Indicator All Series MWB100 counters include a Rate Indicator. This device it Aloning ander it and ore sa, TAS Sv monitors he eee ofthe included so the read-out may be in any desired engineering units. The Rate Indicator fas its independently programmable decimal point, “ The Rate Indicator may be viewed at any time without loss of count or coincidence on the number ’8' key on all front panels is pressed to display the current line speed. ‘The Rare inten oo vues is updated every 0.5 seconds. The Rate Indicator may also be assigned as the default display of the unit. a ten eae it may also be assigned a preset (Preset 3) to be used as an overspeed oF ‘Theory of Operation ‘The Rate Indicator is continuously sampling the incoming count pulses used by Counters. This sample is taken for 0.5 seconds. At the end of this time, the lated sample is converted to pulses per second and then averaged with the previous samples. This limits the amount of jitter that may eventually show up on the display. ‘The sample is then multiplied by the Rate Indicator's input prescaler. ‘This prescaler is used to: a) convert the sample, measured in pulses per second, into the desired engineering units; and b) compensate for any inaccuracies of the measuring device. The input prescaler for the Rate Indicator is calculated by the equation: Input Prescater = -fuBbecaf aaegude: x Desired tne x k Where: Humber of Seconds . unber of seconds in the tine base of the final desires display. For Desired Time Case example, if the desired display is feet per minute, this factor would ~Pesined Uotts_ = The number of count pulses is determined for the unit of measure for a the display. The reciprocal of this is then used in this equation. For example, if feet per minute is desired and each count pulse from the transducer equals 0.01", there would be 1200 count pulses for each foot. k = A-compensation number for inaccuracies in the measuring device or transducer. This factor would normally be the same as the input prescaler of Counter 1. ‘An Appendix earlier in this manual gives a few examples of calculating the Rate Indicator’s input prescaler along with a list of some common factors. Refer to that section if additional information on calculating the input prescaler is desired. 43. ECCI953-SB APPLICATION (cont.) After the sample is multiplied by this input prescaler, itis stored so it may be viewed on the display. Also at this time, the resulting speed is compared to the preset that may be optionally tied to the Rate Indicator in some MWB models. If the Rate Indicator is less than the preset, the output associated with the preset will be set to its normal status. If the speed is greater than the preset, the output will be activated per its option selected in the Set-Up Functions. ‘The decimal point for the Rate Indicator is selectable to display from .000000 to 000000 . SET-UP EXAMPLES The following examples cite a few applications for the Rate Indicator and illustrates how the MWB Counter would be programmed. For all of the examples, it is assumed that there is no compensation needed for the transducer and so the K factor is 1. Example 1: ‘The unit is controlling a cut-to-length I'n¢ that is measuring in 0,01". It is desired to have the Rate Indicator display the line speed in feet per minute. The input prescaler is first calculated. Since each pulse from the transducer increments the Counter by 0.01", there would be 1200 transducer pulses per foot. Input Prescaler = 6} Seconds y Pi feot — . 9.05000 ‘This factor is entered in the Set-Up Function for the input prescaler. Since the display resolution is in feet per minute, the decimal point is set in another Set-Up Function to 1 (for a 000000 display). Example 2: In this example it is desired to indicate the line speed in RPM’s. The encoder used in this application is a 60 line count quadrature encoder. The MWB Counter has been set to count in the X4 mode. In this situation the line count is used in determining the input prescaler. Since the unit has been Programmed to count in the X4 mode, each revolution of the encoder will produce 240 count pulses. ni —1 Revolution Input Prescaler - -S? Seconds. , [Revolution . 9, 25999WARRANTY Electronic Counters & Controls, Inc. warrants all equipment against any defects in workmanship or materials for a period of two years after delivery. Electronic Counters & Controls, Inc. will provide, free of charge, all labor and parts required to reinstate proper operation within this period providing the work is done at the factory. Included is free shipment via land carrier from the factory providing shipment was prepaid to the factory. The customer assumes all responsibility for any air shipment charges to ot from the factory. A written description of the malfunction must accompany all equipment returned for warranty service, Please include name and phone number of person we may contact regarding malfunction. ECCI reserves the right to charge a service fee for troubleshooting equipment that is returned for warranty repair and found to have no defect. This warranty does not apply to any of our products which have been repaired or altered by unauthorized persons in any way so as, in our judgment to injure their ability or reliability or which have been subject to misuse, negligence of accident or which have had the serial number altered, effaced, or removed. Neither does this warranty apply to any of our products which have been connected, installed, or adjusted otherwise than in accordance with the instructions furnished by us. Accessories including batteries not of our manufacture used with this product are not covered by this warranty. Electronic Counters & Controls, Inc. reserves the right to discontinue models at any time, or change specifications, price or design, without notice and without incurring any obligation. Upon acceptance of this material the purchaser agrees to assume all liability for any damages, and bodily injury which may result from the use or misuse of the material by the purchaser, his employees, or others and that Electronic Counters & Controls, Ine. shall incur no liability for direct or consequential damage of any kind. This warranty and conditions of sale are in lieu of all others expressed or implied and no representative or person is authorized to assume for us any other liability in connection with the sale of our products. AS. Eccl