THE 1/16 DIN COUNTERS MODEL C48C INSTRUCTION MANUAL
INTRODUCTION The C48 Counters (C48C) are a multi-purpose series of industrial control products that are field-programmable for solving various applications. This series of products is built around the concept that the end user has the capability to program different personalities and functions into the unit in order to adapt to different indication and control requirements.
TABLE OF CONTENTS GENERAL DESCRIPTION.............................................................................................................................................................1 Safety Summary.......................................................................................................................................................................1 Block Diagram .......................................................................................................................
TABLE OF CONTENTS (Cont’d) Auto Scrolling...................................................................................................................................................................15 Saving Program ...............................................................................................................................................................15 USER INTERFACE/PROGRAMMING MODES ...............................................................................................
TABLE OF CONTENTS (Cont’d) Serial Baud Rate and Parity Settings ..............................................................................................................................26 Serial Unit Address (00-99) .............................................................................................................................................26 Serial Abbreviate Mnemonics .......................................................................................................................
parameters can all be utilized to provide multi-level protection against unauthorized changes to data values and unit configuration. The Standard Counter with Dual Presets is available with solid-state or Relay outputs. The Single Preset model has a solid-state and relay output. The Batch Counter has relay outputs for Output 2 and the Batch/Total Output (3), with Output 1 available as solid-state. The Batch Counter is also available with three solid-state outputs.
BLOCK DIAGRAM Figure 1, Block Diagram -2-
INSTALLATION & CONNECTIONS The C48 Counter meets NEMA 4X/IP65 requirements for indoor use to provide a watertight seal in steel panels with a minimum thickness of 0.09 inch, or aluminum panels with a minimum thickness of 0.12 inch. The units are intended to be installed into an enclosed panel. The complete unit assembly (i.e. PC boards and bezel), MUST be in the case when mounting the unit. Multiple Unit Stacking The C48C is designed for close spacing of multiple units.
Mounting Instructions 1. Prepare the panel cutout to the dimensions shown in Figure 3, Multiple Unit Stacking. 2. Remove the panel latch from the unit. Discard the cardboard sleeve. 3. Carefully remove the center section of the panel gasket and discard. Slide the panel gasket over the unit from the rear, seating it against the lip at the front of the case. 4. Insert the unit into the panel cutout.
Output Board The C48C is supplied with an output board installed. The output board is preconfigured for the type of output needed, based upon the Model ordered. See Ordering Information, page 48, for available models. All relay output boards are field replaceable. Replacing Relay Output Board 1. Remove the unit assembly. (See Removing Unit Assembly, page 4). 2. Lift up on the top bezel board latch while gently pulling out on the bezel/display board assembly. Do NOT remove the display board from the bezel.
core several times or use multiple cores on each cable for additional protection. Install line filters on the power input cable to the unit to suppress power line interference. Install them near the power entry point of the enclosure.
POWER WIRING AC Versions (C48CXX0X) DC Versions (C48CXX1X) AC Power Wiring DC power (18 to 36 VDC) or low voltage AC power (24 VAC) is connected to terminals 11 and 12, labeled DC+ (AC) and DC- (AC) respectively. Primary AC power is connected to terminals 11 and 12, labeled AC. To reduce the chance of noise spikes entering the AC line and affecting the counter, an AC feed separate from that of the load should be used to power the counter.
Serial Communications Wiring OUTPUT WIRING It is recommended that shielded (screened) cable be used for serial communications. This unit meets the EMC specifications using Alpha #2404 cable or equivalent. There are higher grades of shielded cable, such as four conductor twisted pair, that offer an even higher degree of noise immunity. Refer to RS-485 Serial Communications, page 30, for wiring and operational procedures.
SW3 - HI BIAS: Sets input trigger levels at mid-range, to accept outputs from 2-wire proximity sensors, resistive photo-cells, and logic pulses with full 0 to +12V swings. Input trigger levels: VIL = 5.5 V max; VIH = 7.5 V min. LO BIAS: Sets input trigger levels to low range, to accept logic pulses with 0 to +5 V swings. Input trigger levels: VIL = 1.5 V max; VIH = 3.75 V min. Note: VIL and VIH levels given are typical values ±10%, when the counter voltage at the DC OUT/IN terminal, is +12 VDC.
Various Sensor Output Connections COUNT SWITCH OR ISOLATED TRANSISTOR OUTPUTS CURRENT SOURCE CONNECTED (COUNT ON OPENING) OLDER STYLE SENSORS WITH E-F OUTPUT - CURRENT SOURCE CONNECTED (COUNT ON FALLING EDGE) CURRENT SINK CONNECTED (COUNT ON CLOSING) 2 WIRE PROXIMITY SENSORS - CURRENT SOURCE CONNECTED (COUNT ON CURRENT FALL) SENSORS WITH CURRENT SOURCE OUTPUT (PNP O.C.) (COUNT ON TURN-OFF) INTERFACING WITH TTL SENSORS WITH CURRENT SINK OUTPUT (NPN O.C.
FRONT PANEL DESCRIPTION The front panel bezel material is flame and scratch resistant, textured plastic with clear viewing window that meets NEMA 4X/IP65 requirements, when properly installed. Continuous exposure to direct sunlight might accelerate the aging process of the plastic material used in the bezel. The bezel should be cleaned only with a soft cloth and neutral soap product. Do NOT use solvents. The display is a dual line, 6 digit LCD.
Normal Operating Mode BASIC OPERATION In the normal operating mode, the count or batch/total value is shown on the main display. By successively pressing the A key, the accessible presets, prescaler, output time values, or batch/total count can be viewed in the secondary display. With the exception of the batch/total count, each of the values can be independently programmed to be viewable only, viewable and changeable, or locked (not viewable) in the normal operating mode.
Protected Value Menu The Protected Value Menu allows access to selected presets, prescaler, and output time values without having them viewable or changeable from the main display. To enter the protected menu, the A key is pressed and held, and a code value is entered. The Protected Value Menu and the Programming Menu are not available at the same time. See Front Panel Accessible Functions With Program Disable, page 14, for available options.
Front Panel Accessible Functions With Program Disable There are several ways to limit the programming of parameters from the front panel keypad. The Accessible Value parameters are used with the Program Disable DIP switch and an external programmable User Input selected for Pro.dis to limit programming. To enter the programming mode, a code number PGM.DIS. SWITCH USER INPUT TERMINAL may need to be entered, depending on the Program Disable Setting.
PROGRAMMING GENERAL DESCRIPTION Programming of the C48 Counter is done through the front panel keypad. English language prompts, flashing parameter values, and the front panel keypad aid the operator during programming. Although the unit has been programmed at the factory, the parameters generally have to be changed to suit the desired application. In order to access the Programming Menu, the Program Disable DIP switch and/or any User Input programmed for Pro.dIS may need to be turned off or deactivated.
USER INTERFACE/PROGRAMMING MODES The operating modes of the C48 Counter are programmed using the front panel keypad. Accessibility to the Programming Menu depends on the Program Disable Function setting (See Front Panel Accessible Functions With Program Disable, page 14, for available settings). Ac PSc -L Note: Before attempting to program the C48C, read the section Programming General Description, page 15, for detailed information on using the front panel keypad to navigate through the Programming Menu.
dEc Pt ------ Cnt In C1-Ud Decimal Point Position Count Modes Programmable for display of 0 to 5 digits right of decimal point. Input A signal is used for the count input. Input B is used in combination with Input A for Count Direction Control, Quadrature counting, Anticoincidence Add/Subtract, or Anti-coincidence Add/Add counting applications. MODE DESCRIPTION ----------.----.----.----.----.
QUAD 1 - Quadrature counting modes are primarily used in positioning and anti-jitter applications. This mode works due to the manner in which the two incoming pulses are positioned relative to each other. The pulse signal on Input B is shifted 90° away from the pulse signal at Input A. These two signals are processed by the C48C as follows: Input A serves as the count input, while Input B serves as the quadrature input.
SINGLE PRESET OPERATING MODES Use either of the two charts below for more information on specific operating modes. DUAL PRESET/ BATCH COUNTER 1 OPERATING MODES Use either of the two charts below for more information on specific operating modes.
Counter 2 Assignment (Batch Model only) DUAL PRESET/ BATCH COUNTER 1 OPERATING MODES MODE# RESET TYPE RESET √ √ √ √ 4 √ √ √ √ 5 √ √ 6 √ √ 7 √ √ √ 8 √ √ √ 9 √ √ √ 10 √ √ √ √ 12 √ √ 13 √ √ 14 √ √ 15 √ √ √ 16 √ √ √ 17 √ √ √ 18 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ -20- Reset to P2 RESULTANT COUNTER 2 COUNT DIRECTION FOR C2 OPERATING MODE Reset to 0 Reset to P3 NOTES Count Reset Modes Normal Count Up Dn Up Dn Direction Reversed Dn Up Dn Up Co
The chart below shows operating modes for Counter 2 of the Batch Counter Model. Counter 2 Operating Mode (Batch Model only) OPEr 2 1 Reset Type: Auto - unit automatically resets when count reaches Output 3 or timed output 3 end. Manual - Counter can only be manually reset by a User Input or by Serial Communications command.
Single Preset Model Ac PrS PRS -Y -ORDual Preset Model Access Preset Values MODE DESCRIPTION -L Locked; Preset is not viewable at main display or in Protected Value Menu. The Preset can only be viewed or changed in the Programming Menu. -P Protected Value; Preset value is viewable and changeable in Protected Value Menu only. It is not viewable at Main Display. No; Preset value is viewable only and not changeable from main display when Programming is Disabled.
Ac Out -L-L-L Access Output Time Values OutPut This parameter configures the type of access given to each Output Time Value when in normal operating mode with Programming disabled (See Front Panel Accessible Functions With Program Disable, page 14, for more details). The accessibility of each Output Time Value can be individually configured. MODE DESCRIPTION -L Locked; Output Time Value is not viewable at main display or in Protected Value Menu.
Programming Keys: User Inputs C - Selects Output being configured as indicated by the Up to three external User Inputs plus the front panel function key are available on the C48 Counter/Batch Counter. The parameter list below shows all available user input functions. The Input Pull-Up / Pull-down resistor and Active logic level for all the User Inputs (except User Input B) are configured with the Snk/Src jumper (See page 8).
MODE DESCRIPTION rSt.2-E Reset Counter 2 (Edge Triggered) [Batch model Only]; When the user input is activated, the Counter 2 value and outputs will be momentarily reset and then continue to count and activate while input is held active. rS.AL-L Reset All (Level Active) [Batch model Only]; When the user input is activated, the Counter 1 and Counter 2 values and outputs will reset and be held reset until user input is released. rS.
ScroLL no Scroll Display SErAdr This parameter determines whether or not the secondary display will scroll or sequence automatically to the next available value. MODE DESCRIPTION no YES Disables or turns off display scrolling 0 no Note: The next five parameters pertain to serial communications, and are only available on Dual Preset and Batch Models with the RS485 serial option installed.
Print Options PrnOPt 3 Print and Reset Count The Print Options parameter determines which values are printed in response to a Print Request command or user input print request. MODE NUMBER PRINT Dual Batch Model Preset Model Preset Counter (1) Prescaler Counter 2 Values Value Value Value PrnrSt no √ 01 01 02 02 √ 03 03 √ 04 04 05 05 06 06 √ 07 07 √ √ PScOAt √ √ 1 √ dig √ √ √ 11 √ √ √ 14 √ 15 √ Do not reset count after Print.
FAcSEt no Factory Settings MODE DESCRIPTION no YES Do not reset parameters to Factory Settings. Reset all programming parameters to their Factory Settings. Ac Out OutrES OutPut OutPut OutPut rEVOut rEVAnu OutP.uP FACTORY SETTINGS CHART * EntrY NUMERIC VALUE ENTRY METHOD 3 OUTPUTS This parameter is used to reset all parameters to their factory defaults. The Factory Settings Chart below shows the settings for each programming parameter.
* Settings on the previous page are shown for Dual Preset and Batch models. Changes to Factory Settings for Single Preset Model are as follows: OPEr PrESEt COUNTER OPERATING MODE 5 PRESET 1 VALUE 20 Ac Out OutrES OutPut OutPut OutPut rEVOut rEVAnu OutP.
RS-485 SERIAL COMMUNICATIONS DATA FORMAT - 10 BIT FRAME (Parity = none) RS-485 communications allows for transmitting and receiving of data over a single pair of wires. This feature can be used for monitoring various values, changing values, and resetting output(s), from a remote location. Typical devices that are connected to a C48C unit are a printer, a terminal, a PLC, an HMI, or a host computer. PC software (SFC48) allows for easy configuration of unit parameters.
VALUE IDENTIFIERS In a multiple unit configuration, an asterisk (2AH) must be sent to clear the input buffer of all units on the line after a transmit value or print request command is sent to a specific unit on the line. The C48C will require a maximum of 50 msec to process the asterisk (*). The command string is constructed in a specific logical sequence. The C48C will not accept command strings that do not follow this sequence. Only one operation can be performed per command string.
It is recommended that a “Transmit Value” command follow a “Change Value” Command. If this is done, the reception of the data can provide a timing reference for sending another command and will ensure that the change has occurred. When a “Change Value or Reset Value” command is sent to the C48, there is time required for the unit to process the command string. The diagrams show the timing considerations that need to be made. The first two digits transmitted are the unit address followed by one blank space.
90 IF INP(LSR) TXEMPTY THEN 90: REM “WAIT UNTIL DONE TRANSMITTING” 100 TIMER ON 110 IF LOC(1) = 0 THEN 110 120 B$ = INPUT$(1, #1) 130 IF B$ = CHR$(10) THEN 160” REM “TO PREVENT DOUBLE SPACING ON PRINT” 140 PRINT B$; 160 IF NOT B$ = “ “ THEN GOTO 90 170 TIMER OFF 200 GOTO 40 300 TIMER OFF: RETURN 40 1000 D = INP(MCR) OR 2: OUT MCR, D: REM “SET FOR TRANSMIT MODE” 1010 PRINT #1, A$; : PRINT A$; : REM “PRINT KEYSTROKE” 1020 IF A$ = “*” THEN PRINT 1030 IF A$ = “*” THEN IF INP(LSR) TXEMPTY THEN 1030 ELSE GOTO 60
CONNECTING TO A HOST TERMINAL different address and all are programmed for the same baud rate and parity as the computer (ex. 9600 baud, parity even). An application program is written to send and receive data from the units using the proper commands. Six C48C units are used to monitor and control parts packaging machines in a plant. C48C units are located at each machine in the production area of the building. A communication line is run to an Industrial computer located in the production office.
Troubleshooting Serial Communications If problems are encountered when interfacing the C48C(s) and host device or printer, the following check list can be used to help find a solution. 1. Check all wiring. Refer to the previous application example and use it as a guide to check your serial communication wiring. Proper polarity of all C48C(s) and other peripherals must be observed. 2.
For PRESCALER OUTPUT OPTION The prescaler output is useful for providing a lower frequency scaled pulse train to a PLC or another external totalizing counter. The prescaler output provides programming parameters to determine when to turn the output on (PScOAt)[display dependent] and when to turn the output off (PScLEn) [input pulse dependent].
APPENDIX “A” - APPLICATION EXAMPLE Slow Down & Cut to Length with Total Yardage To improve production efficiency, a wallpaper manufacturing plant is installing cut to length counters on the roll form machines. Currently, electromechanical counters are used for length measurements. The operator slows the machine down upon arriving at the desired length, stops and then cuts. The addition of the C48CB batch counters eliminates the operator’s manual observation and control.
APPLICATION PROGRAMMING EntrY Ac PSc PScALr dEc Pt Cnt In OPEr 1 C2 ASn OPEr 2 Ac PrS PrESEt PrESEt PrESEt P1trAc Ac Out OutrES OutPut OutPut OutPut rEVOut rEVAnu OutP.uP USrIn1 USr F1 CodE ScroLL SErSEt SErAdr SErAbr PrnOPt PrnrSt FAcSEt 1t 2t 3t AutoSc -L (locked) 0.34907 ----.-qUAd 1 12 totAL 02 -L-y-L PRS1 10.75 (value 0.25 less than PRS2 for slow down) PRS2 11.00 (cut length) PRS3 9000.00 (set high so output does not activate) yES -L-L-L 0.01SEC 0.10 1.00 0.10 -n-n-n -n-n-n -F-F-F rSt.2-E rSt.
APPENDIX “B” - SPECIFICATIONS AND DIMENSIONS 1. DISPLAY: 2 Line by 6 digit LCD display. Positive image reflective or negative image transmissive with red (top line) and green (bottom line) backlighting Main Display: 0.3” (7.62 mm) high digits Secondary Display: 0.2” (5.08 mm) high digits Annunciators: Value: PRS, 1, 2, and 3 Output: 01, 02, and 03. 2. POWER REQUIREMENTS: AC Versions (C48CXX0X): AC Power: 85 to 250 VAC, 50/60 Hz, 9 VA max. DC Power: 11 to 14 VDC @ 150 mA max.
7. MAX. COUNT RATE: Model dependent. All listed values are in KHz. Single Preset Model C48CS C1-Usr C1-Ud C2-Usr C2-Ud * Ad-Sub Ad-Ad 0.00001-0.99999 8.4 4.1 9.4 5.1 4.5 2.1 1.00000 12 5.9 12.4 5.8 6 3 PRESCALER VALUE Batch Model C48CB: With Counter 2 configured as a Batch Counter (C2 QUAD X1 X2 X4 ASn = bAtch) C1-Usr C1-Ud C2-Usr C2-Ud * Ad-Sub Ad-Ad X1 X2 X4 0.00001-0.99999 8.3 4.1 8.4 3.35 3.6 2.2 1.00000 11.4 5.5 11.8 3.87 4.2 3 6.5 3.2 6.6 3.2 3 1.6 1.
8. OUTPUTS: (Output type and quantity, model dependent) Solid-State: NPN Open Collector: ISNK = 100 mA max. @ VOL = 1.1 VDC max.; VOH = 30 VDC max. PNP Open Collector: ISRC = 100 mA max.(See note); VOH = 12 VDC ±15% (using internal supply); VOH = 13 to 30 VDC (using external supply). Note: The internal supply of the C48C can provide a total of 100 mA for the combination of sensor current and PNP output sourcing current.
11. ELECTRICAL CONNECTIONS: Wire clamping screw terminals. 12. CONSTRUCTION: Black plastic case with collar style panel latch. The panel latch can be installed for horizontal or vertical stacking. Black plastic textured bezel with clear display viewing window. Unit assembly with circuit boards can be removed from the case without removing the case from the panel or disconnecting the wiring. This unit is rated for NEMA 4X/IP65 indoor use. Installation Category II, Pollution Degree 2. 13.
APPENDIX “C” - TROUBLESHOOTING The majority of problems can be traced to improper connections or incorrect set-up parameters. Be sure all connections are clean and tight, that the correct output board is fitted, and that the set-up parameters are correct. Also, be sure the DIP switch settings and the User Input Plug Jumper position are correct for the particular application. For further technical assistance, contact technical support at the numbers listed on the back cover of this instruction manual.
APPENDIX “C” - TROUBLESHOOTING (Cont’d) PROBLEMS CAN NOT ENTER INTO PROGRAMMING PROCESS, BATCH, OR TOTAL VALUES WILL NOT RESET WHEN A MANUAL RESET IS PERFORMED POSSIBLE CAUSE REMEDIES 1. Front panel disabled. 1. Check “Front Panel Accessible Functions With Program Disable” section of the manual. 1. User input not properly programmed. 2. User Input Snk/Src jumper configured improperly. 1. Verify programming of User Input parameter. 2. Configure Snk/Src jumper. PRESCALER, PRESETS, OR 1.
APPENDIX “D” - CALCULATING THE PRESCALER The C48C is factory set to provide one count on the display for each pulse that is input to the unit. In many applications, there will not be a one to one correspondence between input pulses and desired display units. In these applications, it will be necessary for the C48C to scale or multiply the input pulses by a prescaler to achieve the proper display units desired (feet, meters, gallons, etc.).
APPENDIX “E” - TERMINAL CONFIGURATIONS FOR C48 COUNTERS C48CXX0X VERSIONS (85 to 250 VAC POWERED) CAUTION: Observe proper polarity when connecting DC voltages. Damage to the unit will occur if polarity is reversed.
TERMINAL CONFIGURATIONS FOR C48 COUNTERS (Cont’d) C48CXX1X VERSIONS (18 to 36 VDC/24 VAC POWERED) CAUTION: Observe proper polarity when connecting DC voltages. Damage to the unit will occur if polarity is reversed.
APPENDIX “F” - ORDERING INFORMATION SINGLE AND DUAL PRESET COUNTERS MODEL NO. C48CS C48CD C48CP DESCRIPTION RELAY NPN O.C.
THREE PRESET BATCH COUNTERS MODEL NO. RELAY NPN O.C.
LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to one year from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option.
C48C/IM - F 7/04 DRAWING NO.
