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Touch PLS (PLS with Graphical Operator Interface)Instruction & Operation ManualSales and Marketing343 St. Paul Blvd.Carol Stream, IL 60188Tel: (630)668-3900FAX: (630)668-4676Factory Customer Service/Order Entry4140 Utica Ridge Rd.Bettendorf, IA 52722Tel: (319)359-7501(800)711-5109FAX: (319)359-9094Application Hotline1 (800) TEC-ENGR (832-3647)Vist our web site at:MAN-M7251-001REV 00 11/11/98www.avg.net

Touch PLS Instruction and Operation ManualWARNINGIn the application of AVG Automation programmable control devices,you should consider them components. Therefore, provisions otherthan the programmable control device must be taken to protect personnel in the event of a programmable control device malfunction. Programmable control devices should not be used as stand-alone protection in any application. Unless proper safeguards are used, unwantedstart-ups could result in equipment damage or personal injury. If programmable controllers are used with operator interface and like devices, this hazard should be of primary importance. The operator shouldbe made aware of this hazard and appropriate precautions should betaken.In addition, consideration should be given to the use of an emergencystop function that is independent of the programmable controller.The diagrams and examples in this user’s manual are included for illustrative purposes only. The manufacturer cannot assume responsibilityor liability for actual use based on the diagrams and examples.CAUTIONDo not press the Touch PLS touchscreen with any sharpobjects. This practice may damage the unit irreparably. Copyright 1998All rights reservedTouch PLS MANUFACTURING4140 Utica Ridge Rd. Bettendorf, IA 52722-1327CUSTOMER SERVICE / SALES / MARKETING / ADMINISTRATION343 St. Paul Blvd. Carol Stream, IL 60188Application HOTLINE: 1-800-TEC-ENGR (832-3647) Phone: 630-668-3900 Fax: 630-668-46761st printing — 11/98Manual Number MAN-M7251-001

Table of ContentsTouch PLS Instruction ManualWARNING/Caution . inside front coverTable of Contents .iPreface . iiiSection 1 — Overview . 11.1 Touch PLS as Stand-alone Product or as Part of Control System . 31.2 Easy, Economical, Flexible . 41.3 How does the Touch PLS work? . 51.4 Manual Organization . 71.5 What you need to get started . 8Hardware . 8Software . 81.6 Need Help? . 8On-screen HELP . 8Fly-Over HELP . 8Still Need Help? . 8Technical Support . 81.7 Specifications . 9I/O Electrical Specifications . 11Section 2 — Touch PLS Installation . 132.1 Touch PLS Mounting . 145-inch Color Model Outline Dimensions & Mounting Template . 145-inch TFD Color Model Outline Dimensions & Mounting Template . 156-inch Monochrome Model Outline Dimensions & Mounting Template . 1610-inch Color Model Outline Dimensions & Mounting Template . 172.2 Set DIP Switches and Wiring . 185" Color & 6" Monochrome ModelsRear View . 19DIP Switch Settings . 2010" Color ModelRear View . 22DIP Switch Settings . 23Resolver Inputs and Outputs Wiring . 25Resolver Wiring Diagram — Touch PLS with 8 Outputs . 26Resolver Wiring Diagram — Touch PLS with 16 Outputs . 27Computer Interface and Peripheral Device Wiring . 282.3 Communications Setup Mode . 29Adjust Backlight or Contrast . 30Run Mode . 30Comp INT . 30Clock. 31Test. 31Section 3 — PLS Functions . 33Program. 33Groups. 3 3Channels. 333.1 User-Defined Parameters . 34i

Table of ContentsTouch PLS Instruction Manual3.2 Program-Specific Parameters . 353.2.1 Speed Compensation . 353.2.2 Modification to Zero (ModZ). 373.2.3 Brake Wear Monitor Time Limits . 383.3 Error Messages . . 39Section 4 — Touch PLS Core Program . 414.1 Introduction . 41Figure 4-1. 5" Color and 6" Monochrome Touch PLS Core Program Screen Map . 41Figure 4-2. 5" Color and 6" Monochrome Touch PLS Core Program Screen Map . 42Figure 4-3. 5" Color and 6" Monochrome Touch PLS Core Program Screen Map . 43Figure 4-4. 5" Color and 6" Monochrome Touch PLS Core Program Screen Map . 44Figure 4-5. 10" Color Touch PLS Core Program Screen Map . 45Figure 4-6. 10" Color Touch PLS Core Program Screen Map . 46Figure 4-7. 10" Color Touch PLS Core Program Screen Map . 47Figure 4-8. 10" Color Touch PLS Core Program Screen Map . 484.2 PLS Programming Screens . 495" Color and 6" Monochrome Programming Screens . 4910" Color Model Programming Screens . 55Section 5 — Modification of Core Program . 615.1 Install uWIN . 615.2 Run uWIN . 615.3 Online or Offline? . 625.4 Open Core Program . 625.5 How do I change my Core Program? . 635.5.1 How to Print Out a Copy of YourTouch PLS Core Program’s Register Map . 645.6 Example. 64Section 6 — How to Order . 676.1 Touch PLS . 676.2 Compatible Transducer/Resolvers . 676.3 Cable. 676.4 Terminal Block Adapter Kits . 676.5 PLC Cable Part Numbers . 68Section 7 — Troubleshooting . 69Section 8 — Replacement Parts & Maintenance . 718.1 Lithium Battery Replacement on the 10" Model . 718.2 Lithium Battery Replacement on the 5" Color and 6" Monochrome Models . 728.3 Fuse Replacement . 728.4 Fluorescent Backlight Bulb Replacement . 728.5 Maintenance of the Touch PLS . 73Index . 75Appendix A Register Mapping and Bit Maps . A-1ii

Touch PLS 1Instruction ManualOverviewTouch PLS byCongratulations on your choice to put the Touch PLS to work for yourcontrol system. AVG Autotech, the company that invented the firstmicroprocessor-based programmable limit switch (PLS) back in 1975,now introduces you to yet another revolutionary concept in PLS technology—a PLS with a Graphical Operator Interface that you can customize to suit your particular needs.The Touch PLS uses a resolver as a position transducer (such as AVGAutotech’s RL100, E7R and E8R Series resolvers). Unlike incrementalencoders, the resolver, along with its noise-immune ratiometric converter, always gives true machine position, even if the machine hasmoved during a power outage. The resolver is constructed to be ruggedand reliable, even in temperature and humidity extremes, and underprolonged exposure to mechanical shock and vibration.MAN-M7251-0011

Touch PLS Instruction ManualThe Touch PLS brings operator-friendly touchscreen control of the PLSto your application, but also offers you the most advanced PLS Features . These features are described below:2 Leading and Trailing Edge Speed CompensationThe Touch PLS features Leading and Trailing Edge SpeedCompensation (Rate Offset) to compensate for speed variations. TheRate Offset, individually programmable for each channel, is used toadvance the PLS settings as a function of the machine speed. Pulse ProgrammingTouch PLS can be fine-tuned while your machine is running. Either orboth of the ON and OFF Setpoints can be incremented or decremented,or a fixed dwell can be incremented or decremented as needed. Angle ON / Time OFFThe Touch PLS can be programmed to have its outputs turned ON at anangle and turned OFF after a programmed time by touching the screen.For example, channel 12 can be turned ON at an angle of 100 and stayON for a period of 2.45 seconds. Programmable Functionality: Brake Wear and ModZThe Touch PLS features a dynamic zeroing or ModZ (Modification Zero)to modify the zero reference point independent of the actual resolverposition. After the PLS receives the ModZ input, the resolver position isreset to zero. The Touch PLS can also perform Brake Wear Monitoringto satisfy the OSHA requirement. This PLS can be field programmed tohave either ModZ or Brake Wear Monitoring functionality. (You mustselect one or the other, the PLS cannot perform both ModZ and BrakeWear functions at the same time.) Flexible Group AssignmentWhen it is desirable to control several different machines linked to thesame drive shaft, the Touch PLS’s Flexible Group Assignment can be apowerful and useful feature. Output channels may be grouped into oneof five independent sections. The Base Group is always PLS, while theother Groups 1-4 may be defined as PLS or ModZ type. Each PLSGroup has its own Group Offset, while each ModZ Group has its ownModZ Inhibit Zone. Built-in Motion Detector and TachThe Touch PLS has a built-in Tachometer and Motion Detector. In theTach Mode, the Touch PLS displays the machine shaft speed in RPM.The Motion Detector energizes a relay when the RPM is between theprogrammed Low and High Limits.MAN-M7251-001

Touch PLS Instruction Manual 1.1Password ProtectionThe Touch PLS has a Password Protection feature eight-levels deep. Upto eight different passwords (user programmable from the touchscreen)allow access to different screens in the Touch PLS, providing ultimateprotection and security of machine settings.Touch PLS as Stand-alone Productor as Part of Control SystemUsed as a stand-alone product, the Touch PLS comes with a preloaded“Core Program” in its memory. Simply connect the resolver and power leads,turn it on, and the factory-installed program provides all of the screensessential to setup and monitor your PLS. Each screen consists of displayedtext and graphics, plus pushbuttons, all implemented for quick operatoraccess directly on the configurable touchscreen.If this is all your application demands, follow the instructions to configure yourPLS and you’re ready to run. For secure backup, and as an aid to customizing the Touch PLS to your application, a copy of the Core Program Softwarehas been provided on a 3.5" Floppy Disk.When you need more than a simple stand-alone application, integratingthe Touch PLS with a PLC offers almost limitless possibilities. Touch PLS’sPowerPanel touchscreen operator interface is fully ready to integrate thepower of a PLS and a PLC into a seamless system, bringing the ease oftouchscreen control to your machinery in the simplest manner yet devised.Because the operator interface uses two processors, one for the PLS operation, and the other to manage, display, and communicate with the PLC, theTouch PLS can share PLS information with the PLC, while displaying thedata from both on a single screen. Bar code readers, printers, and a marqueecan also be connected and configured with the Touch PLS.Also included with your unit is a copy of uWIN Programming Software (P/N10F64). You will need it to install uWIN on a PC so you can modify the CoreProgram, as needed.Over 30 models of PLCs can be accommodated by the Touch PLS’s libraryof drivers and new drivers are continually being added. (Contact AVGAutotech if your PLC is not in the following list.)MAN-M7251-0013

Touch PLS PLC’s1.2Instruction ManualAllen-Bradley Remote I/OAllen-Bradley Data Highway PlusAllen-Bradley SLC500 AICAllen-Bradley SLC500 DF1Allen-Bradley PLC5 DF1CTC 2200 and 2600 SeriesGE Fanuc Series 90 SNP/SNPXGE Genius I/OIDECKeyenceKlockner-Moeller PS 306/316Klockkner-Moeller PS4-201-MM1Koyo (PLC Direct)MagnetekMitsubishiModicon AEGModicon ModbusModicon Modbus PlusOmron Host LinkProfibusReliance Automate 15/20/30/40Square D SymaxSiemens/TI Series 5x5Siemens/TI Series 100Siemens S7Texas InstrumentsToshibaUTICOR Director 6001Easy, Economical, FlexibleMore than just a touchscreen-based replacement for hard-wired switches,pilot lights, LEDs, etc., the Touch PLS can accommodate changing production requirements, often in minutes, with its advanced graphical operatorinterface—and you can make these changes online, offline, or even remotely(with a modem connection you can access and change your Touch PLSprogram at any time, from just about anywhere!)The OI part of the Touch PLS offers you functionality that is not possible withdiscrete operator panels. It’s not only an economical replacement for commonhard-wired panel components, such as pushbuttons, pilot lights, and selectorswitches, it also provides complete flexibility—with the Touch PLS, your panelis never obsolete! Additionally, panels based on Touch PLS can be made farless cluttered by displaying only the necessary controls, thereby reducingpossible operator confusion.The PowerPanel touchscreen used in the Touch PLS has been designed tointerchange and display graphical data from a programmable limit switch(PLS) by merely touching the screen.The Touch PLS is available in four display types designed to suit any application and budget. Any of these display types may be ordered with eight or 16outputs and N-Type or P-Type output polarity. All other features remain thesame, except for the size and availability of colors on the screen. The fourdisplay types are listed below:4 5" Color The 5-inch TFD color model offers 16 bright colors, highcontrast with 320 x 240 pixel resolution, and an 8 x 6 touch-cell grid. 5" Color The 5-inch passive color model offers 16 colors with 320 x240 pixel resolution, and an 8 x 6 touch-cell grid. 6" Monochrome The 6-inch monochrome model provides 320 x 240resolution with 3 shades of grayscale and an 8 x 6 touch-cell grid. 10" Color The 10-inch color model comes with a bright 640 x 480resolution, 16 color display and a 16 x 12 touch-cell grid.MAN-M7251-001

Touch PLS 1.3Instruction ManualHow does the Touch PLS work?Principle of OperationThe Touch PLS, as shown in the block diagram below, uses two processors,one for the PLS and the other to manage, display and communicate to thePLC, if used. The PLS processor reads its position signals from the resolvermounted on the machine shaft. It controls position-based outputs independent of the interface processor, providing fast repeatable outputs. There are2,048 registers available for mapping the PLS. The PLS processor and theinterface processor share information using a 1,024 register-shared memory.The dynamic information, such as position, RPM, and output status, isavailable to the interface processor for display through registers.The interface processor also shares data with the connected PLC through thefirst set of 1,024 registers. (Registers 1,025 through 2,048 may only be usedas internal registers or mapped to the PLS). This arrangement makes it easyto display data from both the PLS and the PLC on one screen. 32 registers(16 in each direction) are used to exchange time-critical information betweenthe PLC and PLS through the interface processor. These registers can beused to send position, RPM, and output status information to the PLC.Inside theTouch PLSMAN-M7251-0015

Touch PLS Instruction ManualTouch PLS Total IntegrationUntil the advent of the Touch PLS, the only way you communicated yourmachine position, speed, or PLS status to a PLC network, was through hardwired discrete outputs. As far as the PLS program settings were concerned,they were simply not available to the PLC. The Touch PLS can communicateto more than 30 different PLCs and their networks through a serial connection such as A-B DH , A-B Remote I/O, Modbus Plus, or Profibus. The entirePLS program can either be uploaded or downloaded to the PLC through thisserial bus connection. PLS status can also be fed to the PLC through thesame bus connection. Hard PLS outputs are available to activate machinesolenoids directly.6MAN-M7251-001

Touch PLS 1.4Instruction ManualManual OrganizationAll of the information that you will need to use the Touch PLS is in thismanual. This manual will take you through the steps necessary to get yourTouch PLS up and running in the shortest possible time. Although yourfamiliarity with programmable graphic operator interface devices will determine how quickly you move through the steps—we provide you with simple,easy-to-follow instructions and examples throughout this manual. Theremaining Sections of this manual are listed below and show you where theinformation you need is to be found!Section 2Provides you with the instructions you need to install the Touch PLS.Included are:nMounting DimensionsnWiring Requirements and DIP Switch SettingsnSetup InstructionsSection 3Remember that theTouch PLS is shipped toyou with pre-programmedscreens for PLS operation—we’ll show you howeasy it is to setup andmonitor your PLS with theTouch PLS.Once you have the Touch PLS installed you are ready to operate the software. Included in this Section are instructions for:nPLS FunctionsnUser-Defined ParametersnSpeed CompensationnModification to Zero (ModZ)nBrake Wear Monitor Time LimitnError MessagesSection 4Section 4 describes the Core Program that is factory installed in yourTouch PLS. The Core Program is unique to the particular Touch PLS Modelyou have received (e.g., 8 output vs 16 output models). Because the displayis larger in the 10" Color Touch PLS, some of the screens that appear in the5" and 6" display size units have been combined. Core Program ScreenMaps are provided for the 10" model, and the 5"/6" models, along with manyactual screen shots for both, with a brief description of their function. Allsignificant differences in the screens between model types are shown.Section 5Please note that you canstart designing yourscreen offline immediately after installinguWIN—you don’t need tohave the hardwareinstalled!You will refer to section 5 when modifying the Core Program. We’ll show youhow to:ninstall and access uWIN Programming Software.nuse uWIN to modify or “customize” screens for theTouch PLS series of operator interfaces.MAN-M7251-0017

Touch PLS 1.5Instruction ManualWhat you need to get started:Hardware Touch PLS RS-232C or RS-422A/485A interface cable Power Lead An IBM or compatible PC with Mouse Separate Serial Port VGA display 4 Mbytes RAM (8 Mbytes recommended) Windows 3.x or higherSoftware 1.6uWIN Programming Software (P/N 10F64) (if modifying or customizing the core program to fit your particular application)Need HELP?Touch screenhere (on HELPpushbutton for Help)On-screen HELPHelp screens are available in the Core Program. Just PRESS the HELPpushbutton to access applicable Help screens. If you are modifying your coreprogram using uWIN, extensive online Help is available. CLICK on the wordHelp on the Main Menu Bar. Also, one of the most important features of theuWIN programming software is the availability of context sensitive, on-screenHelp. To access the Help windows, simply press the F1 function key while onthe topic where you need help. For example, if you need Help while workingwith base screens, hit the F1 function key while in that area and a pop-upwindow will be displayed.Fly-Over HELPWhen in uWIN, and the mouse cursor comes to rest over any toolbar ortoolbox button for a short while, a small window will appear containing a briefdescription of the function of that particular button. The window will disappearas soon as the cursor is moved.Still Need HELP?Technical SupportAlthough most questions can be answered with the Core Program Helpscreens, uWIN HELP, or the manuals, if you are still having difficulty with aparticular aspect of installation or operation, technical support is available atour Application HOTLINE 1-800-TEC-ENGR (832-3647) or FAX us at 1630-668-4676. Visit us at our website www.AVG.net.8MAN-M7251-001

Touch PLS 1.7Instruction ManualSpecificationsPosition Resolution: 1 part in 1,000Update Time: 1.5 msecProgrammable Parameters:Scale FactorPosition OffsetOn / Off SetpointsSetupsSpeed CompensationMotion Limits : High & Lo (RPM)Brake-Wear Monitor Limits: Caution &Danger (9.99 sec. max.)Scale factor:Programmable from 16 to 999, common to allPLS setupPosition Offset:Programmable to full -scale factor value, common to all PLS setupNumber of PLS On / Off Set points:112 per PLS setup (56 per group of eightoutputs)Number of PLS Setups: eightSpeed Compensation:Programmable in scale factor units per 100RPM, up to full-scale factor value. Each PLSoutput (channel) has its own leading and trailingedge speed compensationDiscrete (hard-wired) Outputs/InputsOperation(On Logic True, Off Logic False)Caution OutputOn if stopping time exceeds the caution limitOff if stopping time is within the cautionlimitDanger Output (fail safe)On if stopping time is within the danger limitOff if stopping time exceeds the danger limitPLS OutputsOn if current position is within the dwell (on/offsetpoint)Off if current position is outside the dwell (on/offsetpoint)PE (Program Enable) InputOn Programming EnabledOff Programming DisabledBrake InputOn Run ModeOff Brake ModeNote:The timer for the Stopping Time monitoringwill start when the Brake input goes from theOn (Run Mode) to Off (Brake Mode) state.Motion Detector:Low and High motion limits, common to all PLSsetups, programmable from 0 to 999 RPMBrake-wear Monitor:Caution and Danger Limit, 9.99 sec. max.Number of PLS outputs: 16 totalDynamic Zero or ModZ Input or Brake Input:Modification Zero on the fly with an external input(edge triggered) or brake inputSerial Communication: via RS-485A portBroken Resolver Wire Detection:Indication for broken wire in I/O StatusMAN-M7251-0019

Touch PLS Instruction ManualSpecifications (continued)Model5" Passive Color5" Active Color10" Color6" Monochrome LCD, 3levels grayscale10" Color - 16 Colors4.7 x 3.5" (119.4 x 88.9 mm)8.3 x 6.2" (210.8 x 157.5 mm)Display Type5" Passive (STN)ColorDisplay Size4.04 x 3.03" (102.6 x 77.0 mm)Screen Pixels320 x 240640 x 480Touchscreen48 resistive touch cells (8 x 6)192 resistive touch cells (16 x12)Service Power21.6 - 32 VDC Input21.6 - 32 VDC Input115/230 VAC/DC InputPower Consumption24 VDC18 W115/230 VAC/DC5" Active (TFD)Color6" Monochrome12 W1.25 A 40 VA------ 40 VAFuse1.5 A @ 24 VDC3/4 A @ 24 VDC2 A @ 24 VDC1 A @ 115/230 VAC/DCEnclosureNEMA 4OperatingTemperature32 to 122 F(0 to 50 C)32 to 131 F(0 to 55 C)32 to 104 F(0 to 40 C)StorageTemperature-40 to 149 F(-40 to 65 C)-40 to 167 F(-40 to 75 C)32 to 133 F(-20 to 60 C)Humidity10 to 95% R. H., noncondensingElectricalNoiseToleranceNEMA ICS 2-230 showering arc, ANSI C37.90a-1974 SWC, ANSI C37.90a- 1974 SWC Level C ChatteringRelay TestBurn-InAll AVG UTICOR products are temperature cycled 96 hours and then are fully, functionally testedUser Memory256 Kbytes256 Kbytes or 512K RAM orFlashReal-Time Clock 1, -2 min. per month error maximum 30, -60 sec. per month errormaximumPLC InterfaceDirect Register Access (program port or remote I/O)Serial InterfaceCOM Port 1RS-232C, RS-422ARS-232CRS-232C, RS-422A/485AExtra PrinterRS-232C, RS-422ARS-232C,RS-422A/485ARS-232C, RS-422A/485APLC PortRS-232C, RS-422ARS-232C,RS-422A/485A, Current LoopRS-232C, RS-422A/485ACOM Port 2RS-422ARS-422ARS-422A/485ANEMA 4X32 to 113 F(0 to 45 C)NOTE: When the unit is in RS-422A or RS-485A mode, the RD (receive data) lines may be terminated by 150 Ohms through theuser accessible switch selection.10MAN-M7251-001

Touch PLS Instruction ManualI/O Electrical SpecificationsI/O Power Input: 24 VDC Nominal (2

CTC 2200 and 2600 Series Profibus GE Fanuc Series 90 SNP/SNPX Reliance Automate 15/20/30/40 GE Genius I/O Square D Symax IDEC Siemens/TI Series 5x5 Keyence Siemens/TI Series 100 Klockner-Moeller PS 306/316 Siemens S7 Klockkner-Moeller PS4-201-MM1 Texas Instruments Koyo (PLC Direct) Toshiba Magnetek UTICOR Director 6001 1.2 Easy,

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