gen_epac-0g010
gen_epac-0g010
This section provides user information, including a disclaimer that AMCI is not liable for damages from the use of the manual or products. It outlines the copyright policy, allowing reproduction for personal use with proper credit.
AMCI offers a one-year warranty on its equipment, covering defects in materials and workmanship under normal use, excluding damages from misuse or improper installation.
All returns require a Return Merchandise Authorization (RMA) number. Customers must prepay shipping, and the risk of loss remains with them until AMCI receives the shipment.
24-hour technical support is available. During business hours, calls are answered directly; after hours, an automated system pages on-call engineers.
AMCI encourages feedback to improve their manuals, with contact details provided for submitting comments.
This manual is intended for engineers responsible for the design and installation of the EASYPack Genesis. It includes navigation tips for both printed and online formats, with hyperlinks for easy access to sections.
This chapter provides an overview of the EASYPack Genesis, detailing its features, operator interface, power input, and compatible components.
Guides users through deciding on functionality, determining parameter values, installing hardware, programming, and verifying system setup.
Describes the equipment needed for system checkout, including optional relays and transducer setup, and provides instructions for applying power and programming limit switches.
Details specifications for transducers, output relays, and programmable parameters, including password settings and transducer setup parameters.
Covers installation background, surge suppression, grounding, wiring, and power supply requirements.
Provides detailed instructions for power supply requirements, panel cutout, grounding, mounting, and wiring.
Explains the use of the display and keyboard, data screens, modes, password access levels, and error messages.
Outlines configuration screens and parameters such as scale factor, machine preset value, and motion detector setpoints.
Describes the LS setpoint screen, limit switch types, and entering multiple setpoints.
Covers programming timed limit switch outputs and ANDing screens.
Discusses monitoring while the machine is running, including main and status screens, and handling error messages.
The EASYPack Genesis is a standalone programmable limit switch controller designed for packaging applications. It features a compact design, making it suitable for machines with limited panel space. The unit supports eight solid-state relay outputs and five opto-isolated DC inputs, and it is compatible with a brushless resolver for position feedback. Typical applications include vertical form, fill & seal, glue gun control, labelers, and shrink wrap machines.
- Two types of limit switch outputs: Position on/position off and Position on/position off OR time off.
- Automatic Advances for compensating fixed delays as line speed changes.
- Motion Detector for speed-based limit switch operation.
- LS Enable input for conditional limit switch activation.
- PLS Group Programming for grouping limit switches with logical functions.
The manual distinguishes between basic features, necessary for basic operation, and advanced features, which include additional functionalities like time off limits, motion and LS Enable ANDing, and group functionality.
- The EASYPack Genesis is mounted using four #8-32 studs and includes a neoprene mounting gasket.
- The operator interface consists of a four-line display and a keypad with bi-level keys for various functions.
- Power input requires +24Vdc, and the unit includes connectors for transducer input and limit switch outputs.
- Compatible with Opto 22’s G4 output relays, available as KD-6 (DC) and KA-3 (AC).
- Compatible with various AMCI single-resolver transducers, with specifications provided for each model.
The EASYPack line includes various products designed to simplify packaging machine automation, with more products available on the AMCI website.
- DuraCoders: These are robust encoders available in absolute, analog, or incremental types, designed to replace fragile optical encoders with industrial resolvers.
- Stepper Motion: This includes motors, drives, and indexers providing cost-effective motion control solutions.
- PLC Plug-in Modules: Compatible with major PLC brands, these modules offer various interfaces and control modules.
- Resolver Transducers: AMCI manufactures its own resolvers for diverse position feedback applications.
- GN3A1-02C-10: A standalone unit with 16 outputs and additional features like velocity-based analog outputs.
- 8511, 8512, 8513, 8523: SLC 500 Modules with varying functionalities and output configurations.
- 8213: A ControlLogix module with similar functionalities to the 8513.
- NX3B1C, NX3A1P, NX3A1E: Modules with different interface options like ControlNet, Profibus, and Ethernet IP.
- Decide on Needed Functionality: Determine passwords, output types, and machine speed reporting preferences.
- Determine Parameter Values: Set up transducer parameters, output types, and advanced features like LS Enable ANDing.
- Install System Hardware: Follow installation guidelines for panel cutouts, grounding, and wiring.
- Program EASYPack Genesis: Use specific keys to configure parameters and limit switch setpoints.
- Verify System Setup: Run the machine to ensure basic operation.
- Fine Tune Programming: Adjust limit switch setpoints and other parameters as needed.
The document outlines the specifications and programmable parameters for the EASYPack Genesis system by Advanced Micro Controls Inc. Key electrical specifications include a minimum load current of 0 mAdc and 20 mAac, a surge current of 5 Adc for 1 second and 80 Apk for 1 cycle, an isolation rating of 4000 Vrms, a leakage current of 1 mA and 5 mArms, and an output voltage drop of 1.6 Vdc max and 1.6 Vac max. The ON and OFF times are specified as 50 microseconds and 1/2 cycle max, respectively.
The EASYPack Genesis is configured through programmable parameters divided into four categories: Password and Display Parameters, Transducer Setup Parameters, Limit Switch Parameters, and Group Setup Parameters.
These parameters include enabling/disabling passwords and setting operator, setup, and master passwords. The default passwords are 1111, 2222, and 1234, respectively. The Rate Value parameter allows the display of machine speed in different units such as RPM, IPM, CPM, and BPM. The Toggle Speed parameter affects the display when machine speed exceeds a certain value.
These parameters include Scale Factor, Machine Preset Value, Count Direction, Rate Multiplier, Divisor, and Decimal Point. The Scale Factor determines the position resolution, while the Machine Preset Value adjusts the position value without rotating the transducer. The Count Direction can be set to clockwise or counter-clockwise. The Rate Multiplier, Divisor, and Decimal Point allow scaling of machine speed.
These parameters are distributed across different screens and include Limit Switch Type, LS ON/OFF Setpoint Pairs, and LS ON/OFF Advances. Limit switches can be configured as Normal or Timed, with setpoints determining when the switch turns on or off. ON/OFF Advances compensate for system delays by adjusting the timing of switch activation based on shaft speed.
This document outlines the specifications and parameters for limit switches and programmable limit switch (PLS) group setups. It includes detailed descriptions of ON/OFF setpoints, LS motion ANDing, and enable ANDing parameters.
The document explains the use of limit switch advances in applications such as glue gun operations. It describes how the glue pattern shifts with varying machine speeds and how ON/OFF advances can be adjusted to maintain the desired glue pattern on boxes.
Motion ANDing parameters allow the output of each limit switch to be logically ANDed with the state of the Motion Detector, ensuring outputs only fire when the machine is running at the correct speed.
This feature allows the output of each limit switch to be logically ANDed with the LS Enable Input, preventing outputs from firing if the material is not present.
The document details the setup parameters for PLS groups, including group mode, group window, and group offset/preset. It explains the different modes (0 to 4) and their functionalities, such as enabling outputs, presetting group positions, and synchronizing outputs with product positions.
- Mode 0: Basic functionality without additional features. Outputs cycle once per transducer rotation.
- Mode 1: Outputs are always enabled to fire, using the Group Input to preset positions.
- Mode 2: Outputs are normally disabled and fire for one cycle when the input transitions.
- Mode 3: Uses the Group Input to enable outputs, cycling once per transducer rotation.
- Mode 4: Outputs are enabled for one cycle when a positive transition on the Group Input occurs during the Group Window dwell.
The document includes several figures and diagrams illustrating the functional diagrams of different modes and examples of applications, such as glue gun operations and sensor integrations.
This section provides guidelines to avoid common installation problems for the EASYPack Genesis. It emphasizes that these guidelines are not a substitute for local and national electrical codes, which must be followed in case of conflicts. Key areas impacting system operation include surge suppression, grounding, wiring, and power supply wattage and filtering.
Inductive devices like motors and relays must have surge suppression devices installed. DC loads typically use a flyback diode, while AC loads use RC networks or varistors. RC networks are preferred for AC loads as they effectively dampen fast transients.
Proper grounding is crucial for safety and noise reduction. All ground connections must be permanent and continuous. The EASYPack Genesis chassis must be connected to chassis ground, and any non-isolated power supply or sensor must share the same ground to avoid loops.
Wiring should separate low power from high power cabling to prevent noise coupling. Transducer and input cabling should be shielded and kept separate from output wiring. Power supply wiring should be routed with output lines if local codes permit.
A properly sized power supply is essential. It should accommodate surge currents and have good output filtering to absorb noise. The EASYPack Genesis requires a DC supply between 18 and 30 Vdc, providing at least ten watts of power.
The EASYPack Genesis requires an external DC power supply. If using a system supply, ensure it does not switch large inductive loads without proper surge suppression. The power supply should be close to the unit if dedicated, and recommendations for specific power supplies are not provided due to the variety of reputable vendors.
The EASYPack Genesis is designed for panel or enclosure door mounting. It requires a panel cutout and a clearance area of 6.00" square to a minimum depth of 4.00". The maximum panel thickness is 0.150 inches. A neoprene gasket is included for installation.
An external 18 to 30Vdc supply, typically 24Vdc, is required, with a power consumption of 10 watts (0.4A @ 24Vdc). The SOLA SDN 5-24-100 power supply is recommended.
A ground bus is required in each enclosure, directly tied to the grounding electrode system. Bonding wires should be run from the enclosure and each piece of equipment to the ground bus. A bonding strap must be installed from the enclosure door to the ground bus.
The connector labeled “RESOLVER” has eight contacts. The shields of the transducer cable must be grounded at the EASYPack only to avoid ground loops.
The cable type used is CM (Communications, General Purpose cable), and installation falls under Article 800 of the National Electrical Code. The shield should be treated as a signal carrying conductor and not grounded at any junction box or transducer.
AMCI resolver-based transducers require minimal attention but should be installed with flexible couplers to minimize shaft misalignment. The I/O wiring includes group input wiring for sensors, which must be either all sourcing or all sinking.
Options for AC or DC outputs are available when ordering solid-state relays.
Relay specifications are detailed on page 24 under the Single-Turn Transducer Specifications section. Figure 6.9 on page 50 illustrates the I/O Connector Placement, showing relay placement and output connector pinouts. When installing output cabling, adhere to local and national codes, maintain physical separation between output and input wiring, and use separate conduits for inputs and outputs. Inductive loads require surge suppressors, especially with mechanical relays, as detailed in the Surge (EMI) Suppression section on page 39.
The display features four lines of text, each twenty characters long, with line 1 identifying the screen, lines 2 and 3 showing parameters and values, and line 4 displaying unit status or error messages. The keypad has twenty keys, thirteen of which are bi-level, functioning differently based on the Function LED state. The [FUNCTION] key toggles this state. Navigation is done using arrow keys, and parameters are adjusted using [INC] and [DEC] keys. The [ENTER] key saves changes, while the [CLEAR] key clears faults.
This section covers keyboard navigation, switching between View and Edit Modes, programming functions based on password levels, enabling passwords, and managing programs. View Mode allows parameter inspection, while Edit Mode permits programming, restricted by password levels if enabled. Passwords can be set for Master, Set-up, and Operator levels, each granting different access rights.
Table 7.1 lists data screens accessible via specific keys, detailing their functions. The display operates in View Mode by default, switching to Edit Mode upon password entry if enabled. Passwords restrict programming access, with Master level allowing full access, Set-up level restricting transducer setup, and Operator level limiting program selection and setpoint adjustments.
The Program Select Screen allows program selection, creation, copying, and deletion, accessible via the [PRGSEL] key in Edit Mode. Up to 35 programs can be stored, numbered 0 to 99. Error messages during programming are displayed for two seconds, with a table listing potential errors and their causes.
- Group Window ON Error: Setpoint outside 0 to (Scale Factor -1).
- Limit Switch Errors: LS ON/OFF Setpoints outside range or equal to each other.
- Motion Limit Error: Setpoint greater than 2,000.
- Multiplier Error: Rate Multiplier outside 1 to 1,100.
- Scale Factor Error: Value less than 2 or greater than 1,000.
- Configuration 1: Program Scale Factor (2-1,000), Machine Preset Value, Count Direction (CW/CCW), and Rate Value (RPM, IPM, CPM, BPM).
- Configuration 2: Set Motion Detector Low/High Setpoints (0-2,000) and Toggle Speed (0-2,000).
- Configuration 3: Program Rate Multiplier (1-1,100), Divisor (1-63), and Decimal Point (1, 10, 100, 1,000).
- LS Setpoint Screen: Program Limit Switch Type (Normal, Timed), PLS Group Number (1-4), and LS ON/OFF Setpoints (0 to Scale Factor -1).
- LS Advance Screen: Program ON/OFF Advances (0-999 ms).
Catalog excerpts
ADVANCED MICRO CONTROL S INC. Manual #: 940-0G010 Programmable Limit Switch
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GENERAL INFORMATION Important User Information The products and application data described in this manual are useful in a wide variety of different applications. Therefore, the user and others responsible for applying these products described herein are responsible for determining the acceptability for each application. While efforts have been made to provide accurate information within this manual, AMCI assumes no responsibility for the application or the completeness of the information contained herein. UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS, INC. BE RESPONSIBLE OR LIABLE FOR ANY...
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Chapter 3: System Checkout IFC IFC IFC IFC IFC Chapter 1: Introducing The EASYPack Genesis 20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786 Tel: (860) 585-1254 Fax: (860) 584-1973 http://www.amci.com
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TABLE OF CONTENTS Chapter 4: Specifications (continued) Chapter 7: Programming Overview ADVANCED MICRO CONTROLS INC.
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20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786 Tel: (860) 585-1254 Fax: (860) 584-1973 http://www.amci.com
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TABLE OF CONTENTS Notes ADVANCED MICRO CONTROLS INC.
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ABOUT THIS MANUAL Read this chapter to learn how to navigate through the manual and familiarize yourself with the conventions used in it. The last section of this chapter highlights the manual’s remaining chapters and their targeted audience. Audience This manual explains the operation, installation, and programming of AMCI’s EASYPack Genesis standalone programmable limit switch (PLS), model number GN3B1-01B-10. It is written for the engineer responsible for incorporating the EASYPack Genesis into a design, as well as the engineer or technician responsible for its actual installation. Navigating...
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ABOUT THIS MANUAL Trademark Notices “EASYPack”, and the AMCI logo are trademarks, and “AMCI” is a registered trademark of Advanced Micro Controls Inc. “Adobe” and Acrobat are registered trademarks of Adobe Systems Incorporated. All other trademarks contained herein are the property of their respective holders. Revision Record This manual, 940-0G010, is the first revision of the manual. It was initially released December 21st, 2001. Revision History 940-0G010: 12/31/2001. Initial Release. Where To Go From Here This manual contains information that is of interest to everyone from engineers to operators....
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CHAPTER 1 INTRODUCING THE EASYPACK GENESIS This chapter is written for anyone that wants to familiarize themselves with the features of the EASYPack Genesis, the type of applications it was designed for, and other products available from AMCI you’ll need to complete your system. Overview The EASYPack Genesis, part number is GN3B1-01B-10, is AMCI’s latest addition to our growing line of standalone programmable limit switch controllers for packaging applications. It’s a self contained unit that accepts a brushless resolver for position feedback, and provides eight solid state relay outputs and...
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Basic/Advanced Features AMCI knows that many of you will use the EASYPack Genesis as a basic programmable limit switch. In order to keep this manual simple for those that are using the unit in this way, but still explain all of the features of the unit in an orderly fashion, we decided to break down the features of the EASYPack Genesis into two areas. Basic Features are features needed to get the EASYPack Genesis operating as a position on / position off programmable limit switch with Automatic Advances. Advanced Features are features that add the position on / position off OR time off limits,...
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INTRODUCTION Unit Description (continued) Operator Interface (Display and Keyboard) The operator display provides four lines of text that are twenty characters long. Figure 1.3 shows a typical Genesis display. Line 1: Identifies the screen being displayed Lines 2 and 3: Shows parameters and their values Line 4: Displays the unit’s status. CONFIGURE 1 OF 4 SF: 1000 PRESET 0 DIR CW RATE RPM VIEW 1 P: 90 RPM 0 Figure 1.3 Sample Display Usually, line 4 displays the current mode, (View or Edit), the number of the current program, and the machine’s current position and speed. This information is replaced...
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Unit Description (continued) Group Inputs Group Inputs are only used if you are using the PLS Group Programming advanced feature. If you are not using this feature, then don’t wire anything to the inputs. There are a total of four Group Inputs, with one input assigned to each of the PLS Groups available on the EASYPack Genesis. The exact function of the input depends on the Mode the Group is running. LS Enable Input The LS Enable Input can be ANDed to any limit switch output, which prevents the output from firing unless input is active. If you are not using this feature, then do not wire anything...
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INTRODUCTION Compatible Transducers Table 1.2 lists the AMCI single-resolver transducers that are compatible with the EASYPack Genesis unit. Model Turns Comments Servo Servo Front/Side Front/Side Front/Side Front/Side Flange 0.375" Flange 0.375" Flange 0.375" Servo/Front 0.375" Servo/Front 0.375" Servo/Front NEMA 1, size 11 resolver. Leads only, no connector. NEMA 1, size 11 resolver. Leads only, no connector. NEMA 13 R11X-J12/7 transducer NEMA 4 heavy duty transducer HT-20 with side connector NEMA 4X stainless steel HT-20 w/ Viton® shaft seal, and 0.5" NPT thread for conduit connection. Internal...
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Other EASYPack Family Members “EASYPack” is AMCI’s trademarked name for the line of products we designed to ease the task of packaging machine automation. The following table lists some of the other products in the EASYPack family, but the line is constantly growing, so the list may be incomplete. For the latest information on all of our products, browse through our website www.amci.com. Model Number Interface Type 16 output EASYPack Genesis. Nearly identical to the 8 output EASYPack Genesis described in this manual, the 16 output version also includes 2 velocity based analog outputs and a 256...
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