® coi ltek Operating Manual CS-5000 and CS-5100 Ultrasonic Controls Coil Technology, Incorporated — Wadsworth, Ohio 44281 Phone: 330-334-1525 Fax: 330-335-4406 Web: www.coiltek.com e-mail: info@coiltek.com This Manual can be downloaded from our website.
COILTEK Operating Manual CS-5000 SeriesUltrasonic Controlsl TABLE OF CONTENTS I INTRODUCTION 3 II DESIGN 4 III HOW THE CONTROL WORKS 5 IV WIRING & INSTALLATION V Mainboard Wiring (Figure 1) 7 Transducer Assembly (Figure 2) 8 PROGRAMING SWITCHES Switch Settings (Figure 3) VI VII PROGRAMMING Page 9-11 9 12-14 Basic Manual Programming 12 Storing Programs 13 Switching between Programs 14 TROUBLESHOOTING Default Settings (Table 1) VIII 6-8 SPECIFICATIONS 14 14 15-16
INTRODUCTION This manual contains information about the normal installation, operation and maintenance of COILTEK CS-5000 Series Ultrasonic Controls as used with SCR (DC) motor controls, variable-frequency AC motor controls, and eddy-current drive controls. The manual tells how the loop control works, and gives basic setup procedures.
DESIGN COILTEK CS-5000 Series controls operate on 120 or 240-volt ac current. Properly enclosed, it will give years of reliable service in normal industrial environments. Both CS-5000 and CS-5100 controls come with a NEMA-12 enclosure. Auto ranging and easy-to-understand switch settings simplify setup. To prevent unauthorized changes, setup controls are on the circuit board inside an enclosure. No external adjustments are available to unauthorized personnel.
HOW THE CONTROL WORKS CS24-Series controls monitor distance between a sensor and a target by echolocation, the same principle that bats and porpoises use to find their way in the dark. The sensor emits a burst of high-frequency sound (50 to 60 kHz.) varying from 15 to 82 times per second. (Rate depends on target distance.) This burst is actually a controlled sequence of four separate frequencies. After each burst the control measures how long it takes until the sensor picks up the echo.
WIRING Figure 1 (Opposite) details the wiring connections to the Main Board. J4 provides optically buffered inputs that duplicate of PreSet Switches #1, & #2 to permit program change from a remote location. Figure 2 (Page 8) shows cable connections to the Range (Sensor) board. INSTALLATION Motor Control Settings Power Connections IMPORTANT: Set the AC Power Switch for 115 or 230 VAC. Use # 16 ga wire to the mains. The control should remain powered at all times during system operation.
WIRING CS-5000 Series Controls 3 X 0 0 B 0 X X C 0 0 X GREEN A Cable to Range Board BROWN 2 YELLOW PURPLE BLACK BLUE WHITE RED ORANGE 1 Optional Setup for Remote Selection of Preset Programs 1 2 3 A B NC C Control Relay L2 L1 AC Power 120 or 240 vac (Set Power Switch) RESET SIGNAL (4-20mA) COMMON SIGNAL (0-10vdc) JOG (0-12vdc) RESET Near Relay Earth Ground Far Relay The above circuit is available as a prepackaged 3CPO Option.
GND Sensitivity Adjustment HV Transformer and Choke DO NOT ATTEMPT ADJUSTMENT! PC Board Locking Clip NOTE: WHEN CONNECTING CABLE , ORIENT CONNECTOR SO THAT LOCKING CLIP ENGAGES RAMP AS SHOWN ABOVE. N Cable to Processor Board CB-5000R Transducer Rangeboard Assembly NOTE: If your unit was purchased on or after May 2007, you may have the RB-2006R Rangeboard Assembly. See next page.
GND HV Transformer and Choke DO NOT ATTEMPT ADJUSTMENT! Sensitivity Adjustment PC Board Locking Clip OW GREEN PURPLE YELLOW NOTE: WHEN CONNECTING CABLE , ORIENT CONNECTOR SO THAT LOCKING CLIP ENGAGES RAMP AS SHOWN ABOVE.
CONTROL RANGE SW1 SW2 ON 1 2 3 4 5 6 7 8 OFF OFFSET SETTINGS Open RS-232 Port 5 6 7 8 5 6 7 8 5 inches 5 6 7 8 15 inches 5 6 7 8 5 6 7 8 25 inches 10inches 1 2 3 20 inches 1 2 3 30 inches 5 6 7 8 5 6 7 8 35 inches 1 2 3 40 inches 5 6 7 8 5 6 7 8 45 inches 1 2 3 50 inches 5 6 7 8 5 6 7 8 55 inches 1 2 3 60 inches 5 6 7 8 5 6 7 8 65 inches 1 2 3 70 inches 5 6 7 8 5 6 7 8 1 2 3 Switch 1 is OFF Switch 2 is ON NOTE 1 2 3 1 2 Figure 3 Page 10 Offset #1 Offset #2 Offset #3 Pr
PROGRAMING SWITCHES CS-5000 Series Controls use two blocks of DIP switches for setup. Each block has eight switches. Blocks carry the labels SW1 and SW2. Figure 3 (Page9) shows the position, label and function of each switch. IMPORTANT NOTE! With the exception of the CAL/RUN switch,the processor only recognizes switch changes after it is RESET. Cycle power momentarily, or briefly connect the RESET and COMMON output terminals. This is like pressing the Enter key on your computer.
Computer Connection: To open the RS-232 port for computer programming, set all four Range switches OFF and RESET POWER. The port is now open for serial communication with any IBM compatible personal computer loaded with Coiltek CSWIN32 Control Software. The CSWIN32 Software can be downloaded from our website. www.coiltek.com NOTE. Unless a computer is connected, at least one range switch should remain ON to close the port and protect the unit from noise.
PROGRAMMING CAUTION! When connecting the Coiltek Control to a motor control for the first time, DISABLE THE MOTOR! Switch the drive to STANDBY, disconnect power to the motor control, or disconnect the signal input wire from the Coiltek control. Unless ordered with a special preset program, CS-5000 Series controls are shipped with default values loaded into preset programs #0 through #7. Default values are listed in Table I.
ERROR INDICATION. If the ALIGNMENT light flashes rhythmically from red to green, there is a program error. The BASE DISTANCE (the top of the control range) must be greater than 13 inches from the sensor. Recheck the Range Setting. Return to Step 5 and alter the Control Range. Step 8. Check Settings. Remove the target. The alignment light will turn red. Run your hand up and down under the sensor.
SWITCHING BETWEEN PROGRAMS When changing from one preset program to another remember — Reset the Processor Cycle power or jump RESET terminal to COMMON. The processor now recognizes the program switch change. TROUBLESHOOTING RELOADING DEFAULT CONDITIONS If a system that includes a CS-5000 Series control suddenly acts up, the first task is to isolating the fault. Is it a: Processor or Program glitch, Motor Control failure, Ground fault, or failed Coiltek Control.
SPECIFICATIONS 13 inches to 360 inches. Angle of Vision The sensor views a conical area with a beam angle of 17.3° (8.6° from center line. The diameter of the cone (d) as a function of distance from the sensor (y) is d ≈ 0.3·y. Sampling and Averaging 15 to 82 samples per second depending on distance between transducer and target. In default mode, the control computes a running average of 8 samples and recognizes an out-of-range condition after 10 “misses.
Status Outputs: Three Form-C relay outputs provide ON/OFF control functions. Near Output The near relay is normally ON. It trips OFF when a target is closer than the Base Distance. Far Output The far relay is normally ON. It trips OFF when no target is present within the control range. Control Output This output is normally inactive. A computer, outfitted with Coiltek CSWIN32 control software, can program the CONTROL OUTPUT to trip ON at one target distance and OFF at another.
