the production rate meter

The Production Rate MeterOwners Manual

2”, 4 Digit, 2 Line, Goal / Actual PRM with 4x3 Matrix KeypadFirmware: PP-2110-552G Hardware: AB-2486-224D

Manual PB-2149-624Revision E

May 6, 2015

American LED-gible® Inc.1776 Lone Eagle St.

Columbus, OH 43228(614) 851-1100 Phone

(614) 851-1121 Fax

www.ledgible.com www

[email protected] e-mail

Table of Contents1.0 Getting Started........................................................................................................................1

1.1 Product Description............................................................................................................11.2 Unpacking the Unit.............................................................................................................21.3 Mounting the PRM Enclosure............................................................................................21.4 Introduction to the PRM Circuit Board...............................................................................3

1.4.1 120VAC Power Connectors........................................................................................51.4.2 Logic Input Connectors...............................................................................................61.4.3 Serial Port Connectors................................................................................................71.4.4 Relay Output Connectors............................................................................................81.4.5 Status Indicator Lamps...............................................................................................91.4.6 Configuration Dip-Switches......................................................................................10

1.5 120VAC Power Installation..............................................................................................111.6 Logic Input Installation.....................................................................................................121.7 Serial Communications Installation..................................................................................141.8 Basic Dip Switch Configuration........................................................................................15

1.8.1 Rate Calculation Time Base Selection.....................................................................151.9 Proper use of the PRM Keypad.......................................................................................16

2.0 Basic Operation....................................................................................................................172.1 Adjusting Option Register Values....................................................................................182.2 Selecting Which Result is Displayed on the Actual Line.................................................202.3 Using the Optional Red / Green Stack Light....................................................................212.4 Basic Operation Examples...............................................................................................22

2.4.1 Using the PRM in a “Smooth” Production Process..................................................232.4.2 Using the PRM in a “Not Smooth” Production Process............................................242.4.3 Using the PRM in an“Extremely Not Smooth” Process............................................25

3.0 Using The PRM Serial Port..................................................................................................263.1 RS-232 Communications.................................................................................................26

3.1.1 RS-232 Communications Switch Settings................................................................273.2 RS-485 Communications.................................................................................................28

3.2.1 RS-485 Command Mode Switch Settings................................................................293.3 PRM Communications Protocol.......................................................................................30

4.0 Installing the Optional PRM Monitor PC Software...............................................................324.1 Configuring a Privileged Operation Password (Optional)................................................344.2 Configuring Schedules (Optional)....................................................................................354.3 Configuring Production Rate Meters (Required)..............................................................384.4 Configuring Slave Totalizer Displays (Optional)..............................................................39

5.0 Using the PRM(s) via the PC Software................................................................................405.1 Adjusting Individual PRM Register Values.......................................................................415.2 Adjusting a Register in All PRMs at the Same Time.......................................................425.3 Viewing Real Time Totalizer Data....................................................................................435.4 Exporting PRM Data.........................................................................................................44

6.0 In Case of Difficulties............................................................................................................456.1 Contacting American LED-gible® Inc..............................................................................45

7.0 Product Specifications..........................................................................................................468.0 Limited Warranty..................................................................................................................479.0 ASCII Chart...........................................................................................................................4810.0 Connection Labels..............................................................................................................50


1.0 Getting StartedThank you for your purchase of an AMERICAN LED-gible® product. Wetake pride in the equipment we build, and we appreciate your support.We will do everything we can to keep you happy with your purchase formany years to come. Please review this manual carefully, and if youhave any questions, call, e-mail, or fax us and we will be glad to help you.American LED-gible support can be reached at:

1.1 Product DescriptionThe Production Rate Meter (PRM) is a special purpose numericmarquee designed to measure the production rate of any manualprocess. Each line of the marquee is a four-digit displayconstructed from 2.3” LED display modules providing visibility fromup to 130 feet away.

The GOAL line of the PRM displays a static, unchanging, goal rate,entered by the system operator via the marquee keypad. TheACTUAL line of the marquee displays a measured actualproduction rate computed from signals presented to the marqueelogic input(s). The PRM computes both a real time rate based onthe time consumed to produce the last few units of production, andan average rate based upon the total work time elapsed, and thetotal number of units produced. Either real time rate or averagerate can be selected for display on the actual line of the marquee.

The PRM elapsed work time timer, and product piece counter maybe reset to zero. A reset logic input is provided for connection to acontrolling device, or the operator may reset the PRM via the frontpanel keypad.

The PRM product piece counter is incremented by one each timeany of the four COUNT logic inputs is pulsed. The three extra countinputs allow the PRM to monitor multi-lane production lines with upto four lanes.

The elapsed work time timer may be paused during breaks. AHOLD input is provided for connection to a controlling device, or the operator may hold the timer via the front panelkeypad.

A 1 Farad Super-Cap backs up the PRM’s memory. The Super-Cap allows the PRM to retain operational valuesfor five days without power. Unlike batteries, Super-Caps do not require special recharge circuitry and have anexpected life span in excess of 10 years.

An RS-232 / RS-485 capable serial port allows the PRM to interface with a central computer system. All of thePRM’s registers can be accessed via the serial interface. When the PRM is being controlled via the serialinterface, the front panel keypad may be disabled to prevent operator modification of PRM registers.

The PRM is enclosed in a NEMA-1 black satin painted 16-gauge steel enclosure with a 1/8” thick, acrylic displaylens. The enclosure is designed to be mounted to a wall by four holes in the back of the enclosure.

Internal screw terminals are provided to connect: 120VAC power; serial communications; HOLD, T-RST, B-RST,and (4) CNT logic inputs.

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(614) 851-1121 Fax



http://www.ledgible.com/

mailto:[email protected]


1.2 Unpacking the UnitEvery PRM is carefully tested, both mechanically and electrically, before shipment. Inspect the marquee fordamage, which may have occurred in transit. If there is evidence of shipping damage, file a claim with the shipperand notify American LED-gible.® Save the shipping materials for inspection.

If there are no signs of shipping damage, carefully remove the PRM from the shipping carton. Then mount, hang,or set the PRM in a location where the unit is readily visible.

1.3 Mounting the PRM EnclosureThe PRM is designed to be mounted to a wall by four screw holes in the back of the enclosure. When choosingthe location to mount the PRM, keep in mind the operator will need access to the keypad on the front of the unit.

The PRM should be moved to its operating position and mounted to the wall using the four holes in the back of theenclosure. A drawing of the box portion of the enclosure is shown below.

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MountingHoles

MountingHoles


1.4 Introduction to the PRM Circuit BoardA convenient way to work on the PRM is to loosen the front panel, flip it over, and then temporarily support the fontpanel by hanging it on two of the box screws as shown in the picture below.

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A diagram of the PRM circuit board is shown below. Take note of the indicated connectors, switches, andindicator lamps. Other sections of this manual will direct the customer to wire to these connectors, set dip switchoptions, and observe indicator lamp behavior. If you are having difficulty locating a referenced connector, switch,or lamp, referring back to this page may help you locate it.

Most of the electrical connections to the PRM are available on both a customer connector, and a factoryconnector. Customer connectors provide simple screw terminal termination for 22 to 16 gauge wires for use bythe customer. Factory connectors provide crimped pin termination for 20 gauge wires. The primary purpose ofthe factory connectors is to provide American LED-gible with an alternate location to terminate factory installedwiring that will not consume customer screw terminals.

Indicator lamps provide real time feedback on the status of the PRM to aid debugging problems. The powerindicator lamp illuminates when power is applied to the PRM. The TXD, RXD, and ENB lights blink during serialcommunications, and the remaining lamps illuminate when the associated logic input is activated.

Dip switch blocks provide a way to configure several PRM options. Most of the switches are used to configure thePRM serial port. One switch is used to select pieces per hour mode vs pieces per minute mode.

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120VAC Relay Outputs Connector

Firmware EPROM in Socket

Configuration Dip Switch Blocks

DC Sink Relay Outputs Connector

Factory 120VAC Power Connector

Customer 120VAC Power Connector

Keypad Connector

Example Dip Switch Settings

Serial Port Status Indicator Lamps

Factory Serial Port Connector

Customer Serial Port Connector

Factory Logic Input Connector

Customer Logic Input Connector

Inputs StatusIndicator Lamps


1.4.1 120VAC Power Connectors

The PRM requires 120VAC at ½ Amp current draw to operate. However, If custom devices are connected to thesilicon relay outputs, the maximum current draw could be as high as 1½ Amps. The PRM can operate from either60Hz or 50Hz power.

If your unit was purchased with the power cord option, the factory will have already installed an industry standardthree prong power cord, and connected it to the factory 120VAC power connector. If this is the case, do notconnect any wires to the customer 120VAC power connector.

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Customer 120VACPower Connector

Factory 120VACPower Connector


1.4.2 Logic Input Connectors

The PRM has seven digital logic inputs. Each input is activatedby connecting the input terminal to the GND terminal with a drycontact or an NPN (current sinking) output.

If your PRM was purchased with the optional logic inputextension cable, the factory will have already installed wiringthat provides the CNT-1 and HOLD inputs on a six footextension cable terminated in a four pin Molex Minifit Jrconnector as diagrammed to the right.

Even if the logic input extension cable is installed, it is stillpermissible to use the customer logic input connector toconnect other devices to the PRM. The CNT-1 wire of theextension cable is connected in parallel with the CNT-1 screwterminal on the customer logic input connector.

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Optional Logic InputExtension Cable Pinout

Customer LogicInput Connector

Factory LogicInput Connector


1.4.3 Serial Port Connectors

The PRM has one serial communications channel that can be configured for RS-232 or RS-485 communications.Separate wiring terminals are provided for RS-232 and RS-485 wiring, on both the customer and the factoryconnectors.

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Customer SerialPort Connector

Factory SerialPort Connector


1.4.4 Relay Output Connectors

The PRM provides two 120VAC silicon relay outputs or two DC Sink (NPN) relay outputs. These connectors arenot intended to be used by the customer. They are used by ALI to control various optional PRM add on features.

Note: Do not connect any wiring to the 120VAC or DC Sink relay output connectors unless directed to doso by American Led-gible Inc.

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Factory 120VACSilicon Relay Outputs

Factory DC SinkNPN Relay Outputs


1.4.5 Status Indicator Lamps

The PRM has several indicator lamps that are quite helpful for debugging wiring problems.

To debug power wiring, apply 120VAC power to the PRM and then make sure the PWR indicator is illuminated. Ifit does not, then the 120VAC power wiring is probably incorrect.

To debug logic input wiring, activate the switch or sensor while observing the LED2 and LED3 indicator blocks.The lamp corresponding to the activated input should illuminate. If it does not, try activating the input with a fewinches of wire. When you connect the input screw terminal to the ground screw terminal, the input should activate,and the indicator lamp should illuminate.

To debug serial communications wiring, observe the ENB, TXD, and RXD lamps while attempting to communicatewith the PRM. The RXD lamp should illuminate if the PRM is receiving commands. The TXD lamp shouldilluminate when the PRM is responding.

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Logic Input StatusIndicator Lamps

Serial Port / PowerStatus Indicator Lamps


1.4.6 Configuration Dip-Switches

The configuration dip switch blocks are used to configure semi-permanent PRM settings such as baud rate,address, and rate time base selection. These are settings that are likely to be decided upon when the PRM is firstinstalled, and then never changed. PRM settings that may change from week to week are set using the keypad onthe front of the unit.

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SW2 ConfigurationSwitch Block

SW1 ConfigurationSwitch Block

Shown with switches1, 7, and 8 ON



1.5 120VAC Power InstallationIf your PRM was ordered with the optional American 120VAC power cord option, you will simply need to provide astandard 120VAC duplex near the PRM. However if your unit does not have the optional power cord, you will needto connect 120VAC power to screw terminals inside the PRM as shown below.

Connect the power wiring to the customer 120VAC power screw terminal connector on the PRM circuit board.Power wires should be American Wire Gauge #16 with a 600 volt insulation rating. The PRM requires 120VACpower at less than ½ Amp of current. However, if custom equipment is connected to the 120VAC output relays,the PRM power draw can be as great as 1 ½ Amps. Both 60Hz and 50Hz line frequencies are acceptable.

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Typical Power Wiring


1.6 Logic Input InstallationIf your PRM was ordered with the optional count push button kit, or the optional photo-eye kit, some / all of thelogic wiring you need may have already been completed by the factory. However you may still wish to review thissection for information on how the PRM logic inputs are operated.

The PRM's logic inputs are designed to be activated by connecting an input screw terminal (HOLD, T-RST,B-RST,or CNT) to a ground screw terminal (GND). Typically this is accomplished with a push button switch, whiskerswitch, or mechanical relay contact. However it can also be done with an NPN or CURRENT SINKING photo-eye,proximity sensor, or solid state relay.

The digital logic inputs are sampled once every 1mS, and then processed by a simple software debouncealgorithm. Transient conditions lasting less than 5mS are rejected as noise. Due to this filtering, the maximumallowed count rate is 10Hz, with a 50% duty cycle waveform (50mS On Time, 50mS Off Time), and the minimumwidth of a reset pulse is 50mS.

If your PRM was purchased with the optional logic input extension cable, the factory will have already installedwiring that provides the CNT-1 and HOLD inputs on a six foot extension cable terminated in a four pin MolexMinifit Jr connector as diagrammed below.

Even if the logic input extension cable is installed, it is still permissible to use the customer logic input connector toconnect other devices to the PRM. The CNT-1 wire of the extension cable is connected in parallel with the CNT-1screw terminal on the customer logic input connector.

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Optional Logic InputExtension Cable Pinout

1K 1K

+12VDC +12VDC

0.1uF 0.1uF

2003 2003INPUT INPUT

GND GND

PRM Logic Input PRM Logic InputCustomer Wiring Customer Wiring

Push ButtonSwitch NPN

Transister


If you are using a 12VDC photo-eye or proximity sensor, the PRM can supply up to ½ amp of power to the sensor.Be careful when connecting the +12VDC output to your sensor. If the sensor draws too much current, the fuse(F1) soldered to the PRM board will blow to protect the PRM power supply.

Example logic input wiring is shown in the diagram below. Keep in mind, that for your application, you may choseto not use some of the logic inputs. The minimum requirement is one switch or sensor that is used to activate oneof the count inputs each time a unit of production is completed. All of the other inputs (HOLD, T-RST, B-RST)functionality can be replicated by pressing buttons on the PRM keypad.

Connecting the HOLD input to GND pauses the elapsed work time timer. Connecting the T-RST or B-RST inputto GND resets the elapsed work time timer and accumulated production piece count counter to zero. Connectingany of the CNT inputs to GND increments the production piece counter by one.

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Example Logic Input WiringOptional Customer Supplied Photo-Eye ShownMaximum Allowed Eye Power Draw is ½ Amp

*

*HO

LDT

-RS

TB

-RS

TC

NT

-1C

NT

-2C

NT

-3C

NT

-4G

ND

GN

D1

2VD

C


1.7 Serial Communications InstallationUse of the PRM’s RS-232 / RS-485 serial port is an optional advanced feature. Some installations will not use theserial port, rendering serial port wiring and configuration unnecessary.

If use of the serial port is desired, it is still advisable to first complete and test a basic installation, and then add useof the serial port later. For this reason, wiring and configuration of the serial port is covered in the manual sectionsthat discuss operation of the PRM serial port instead of the installation sections.

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RS-485

RS-485 RS-485 RS-485

CommunicationsConverter

RS-232or

USB


1.8 Basic Dip Switch ConfigurationFor a basic PRM installation, only the rate calculation time base option selected on dip switch SW2 switch 4 hasany effect. Switch 4 selects between pieces per hour rate calculations, and pieces per minute rate calculations.All of the other dip switch settings can be ignored until the PRM serial port is used because they have no effect onthe basic operation of the PRM. Dip switch settings that effect the serial port are covered in the manual sectionsexplaining how to use the PRM serial port.

1.8.1 Rate Calculation Time Base Selection

By default, the PRM computes both real time rate and average rate in Pieces Per Hour (PPH). However the PRMcan optionally be configured to compute both real time rate and average rate in Pieces Per Minute (PPM).

To configure the PRM to compute rate in Pieces per Minute (PPM), turn dip switch SW2 switch 4 ON (CLOSED).To configure the PRM to compute rate in Pieces Per Hour, turn dip switch SW2 switch 4 OFF (OPEN).

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1.9 Proper use of the PRM KeypadThe PRM keypad is designed for operation by a human finger, and when properly used, each key is rated for over1,000,000 operations. However, if a hard object, such as a pen, pencil, or wood / steel rod is used to operate thekeypad, it will severely decrease its operational lifespan. We have observed keypads failing in as little as threemonths when abused. Keypad failures due to abuse are not covered under the 1 year warranty.

The photo below shows the typical damage cased by using a hard object such as a pencil to depress the [RUN]key. The polycarbonate overlay has warn through exposing the 12oz tri-dome. Additionally the tri-dome hascollapsed, causing the key to “stick on”. When this happens, all of the keys on the keypad become non-functional.To repair the PRM, the keypad must be pealed off of the PRM front panel and replaced.

Replacement keypads may be purchased and shipped to your factory for you to install. Contact American LED-gible and order part number, KB-2659-003 which has a list price of $25 each.

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2.0 Basic OperationPlace the PRM front panel back on the box and apply power to the unit. When the PRM powers up, it first restoresGOAL and other register values from backed up memory. If the PRM's backed up memory has expired then allPRM registers are reset to default values.

Every PRM is operated at the factory for 24 hours before shipping the unit to the customer. Therefore it is verylikely that when the PRM starts up, the register values that were programmed into the PRM when it was packed atthe factory will be restored.

The rightmost decimal point of the GOAL line flashes when the elapsed work time timer is running. The rightmostdecimal point of the ACTUAL line lights when any COUNT input is activated.

Both the [TOP] and [BOT] buttons reset the PRM's elapsed work time timer and piece count counter to zero. The[HOLD] button pauses the elapsed work time timer. The [RUN] button cancels the operator request to pause thetimer.

The [F1], [+], and [F4] buttons are used to adjust option registers, which is covered in the next section.

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The GOAL 1’s digitdecimal point flashes when the ELAPSED

time timer is running.

The ACTUAL 1’s digitdecimal point illuminateswhen any COUNT input

is activated.

When adjusting PRMoption registers, the [+]

buttons adjust theregister value.

Both [TOP] and [BOT] reset the PRM internal

timer and counter to zero

Each press of [F1]selects the next

option register foradjustment.

The left [+] key adjuststhe left digit of the register.

The right [+] key adjuststhe right digit of the register.

[HOLD] pauses therun time timer.

[RUN] cancels theoperator hold request.

[F4] writes theadjusted optionregister value to

PRM memory.


2.1 Adjusting Option Register ValuesThe following option registers can be accessed and adjusted from the PRM operator keypad by pressing the [F1]key on the PRM keypad.

Register Name Register Function

GOAL

(GOAL)

The GOAL register holds the static, unchanging number that is displayed on the GOALline of the PRM.

GOAL can be set to any value ranging from 0000 to 9999.

REAL TIME RATELOW SAMPLE TIME

(rLOt)

The REAL TIME RATE LOW SAMPLE TIME (rLOt) and the REAL TIME RATE HIGHSAMPLE TIME (rHIt) registers control how long the PRM monitors the COUNT inputsbefore rendering a real time rate calculation.

The low sample time sets the minimum amount of time the PRM must collect databefore rendering a real time rate result. Setting this register to lower values allows thePRM real time rate result to be updated faster, but may result in the PRM being “too”responsive to variations in the real time production rate.

Setting the low sample time to longer time values forces the PRM to collect data for alonger period of time, which effectively forces the PRM to compute an “average” rate forthe specified sample time. The default low sample time is 5.0 seconds, but may be setto any value from 1.0 seconds to 999.9 seconds.

NOTE: For proper operation of the PRM, it is important that the low sample timesetting is less than the high sample time setting.

REAL TIME RATEHIGH SAMPLE TIME

(rHIt)

The REAL TIME RATE LOW SAMPLE TIME (rLOt) and the REAL TIME RATE HIGHSAMPLE TIME (rHIt) registers control how long the PRM monitors the COUNT inputsbefore rendering a real time rate calculation.

The high sample time sets the maximum amount of time the PRM is allowed to collectdata before rendering a real time rate result. Additionally this register also effectively setsthe minimum real time rate the PRM can measure.

Setting this register to higher values allows the PRM to measure lower rates, but it alsohas the effect of lengthening the time interval between real time rate result updates. Thedefault high sample time is 10.0 seconds, which corresponds with a minimummeasurable rate of 360 pieces per hour, or 6 pieces per minute. High sample time maybe set to any value from 1.0 seconds to 999.9 seconds.

NOTE: For proper operation of the PRM, it's is important that the low sample timesetting is less than the high sample time setting.

AVERAGE RATEHIGH SAMPLE TIME

(AHIt)

The AVERAGE RATE HIGH SAMPLE TIME (AHIt) register sets an upper limit on howlong the PRM waits before recomputing average rate from elapsed work time andaccumulated piece count.

If the average rate high sample time register is set to 0.0 seconds, then the limit isdisabled, and the average rate is only recomputed when a count pules occurs.

The default average rate high sample time is 0.0 seconds, but can be setup up to 999.9seconds.

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VERY HIGHEFFICIENCY TRIP

POINT

(HIHI)

The HIGH-HIGH (HIHI) register holds the very high efficiency trip percentage. Thisregister only has an effect if your PRM has the optional red / green stack light installed.

The HIGH-HIGH (HIHI) can be set to any value ranging from 000.0% to 999.9%

If production efficiency exceeds the HIGH-HIGH (HIHI) trip percentage, the PRM willflash the red stack light. The HIGH-HIGH (HIHI) trip point can be disabled by settingthe register to 000.0%.

HIGH EFFICIENCYTRIP POINT

(HI)

The HIGH (HI) register holds the high efficiency trip percentage. This register only hasan effect if your PRM has the optional red / green stack light installed.

HIGH (HI) can be set to any value ranging from 000.0% to 999.9%

If production efficiency exceeds the HIGH (HI) trip percentage, the PRM will illuminatethe red stack light. The HIGH (HI) trip point can be disabled by setting the register to000.0%.

LOW EFFICIENCYTRIP POINT

(LO)

The LOW (LO) register holds the low efficiency trip percentage. This register only has aneffect if your PRM has the optional red / green stack light installed.

LOW (LO) can be set to any value ranging from 000.0% to 999.9%

If production efficiency drops below the LOW (LO) trip percentage, the PRM willilluminate the red stack light. The LOW (LO) trip point can be disabled by setting theregister to 000.0%.

VERY LOWEFFICIENCY TRIP

POINT

(LOLO)

The LOW-LOW (LOLO) register holds the very low efficiency trip percentage. Thisregister only has an effect if your PRM has the optional red / green stack light installed.

LOW-LOW (LOLO) can be set to any value ranging from 000.0% to 999.9%

If production efficiency drops below the LOW-LOW (LOLO) trip percentage, the PRM willflash the red stack light. The LOW-LOW (LOLO) trip point can be disabled by setting theregister to 000.0%.

To adjust any option register, first use the [F1] key to select the desired register. Each press of the [F1] keyselects the next option register for adjustment until finally rotating back to normal operating mode.

After selecting a PRM option register, use the [+] keys to adjust the digits. The leftmost [+] key adjusts theleftmost digit of the register value. The rightmost [+] key adjusts the rightmost digit of the register value.

Once the desired new register value is displayed on the PRM, press the [F4] key to save the adjustment andreturn the PRM to normal operating mode. If the [F4] key is not pressed, the adjustment will not take effect.

There is a timeout on adjusting PRM registers, if no keys are pressed for 10 seconds, the PRM will automaticallycancel the adjustment, return to normal operating mode, and the register will remain unchanged.

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2.2 Selecting Which Result is Displayed on the Actual LineThe PRM has several result registers that can be viewed by pressing the [F2] key on the operator keypad.


REAL TIME RATE

(rAtE)

The result of the most recent REAL TIME RATE calculation. The result is in Pieces PerHour if SW2.4 is OFF (OPEN), or Pieces per Minute if SW2.4 is ON (CLOSED). Realtime rate is computed from the time consumed to produce the last few pieces ofproduction.

AVERAGE RATE

(ArtE)

The result of the most recent AVERAGE RATE calculation. The result is in Pieces PerHour if SW2.4 is OFF (OPEN), or Pieces per Minute if SW2.4 is ON (CLOSED).Average rate is computed from the accumulated piece count, and the elapsed worktime.

AVERAGE CYCLE

(ACyL)

The result of the most recent AVERAGE CYCLE time calculation. The result is inseconds per piece.

Average cycle time is computed from the accumulated piece count, and the elapsedwork time.

ACCUMILATEDPIECE COUNT

(Cnt)

The current value of the internal piece counter. The counter is incremented by all fourCOUNT inputs, and reset back to zero by both RESET inputs, and both reset buttons onthe keypad.

ELAPSED WORKTIME

(ELAP)

The elapsed work time in xxx.x minutes. The elapsed work time timer is paused byactivating the HOLD input, and can also be paused by pressing the hold button on thekeypad. To cancel a keypad hold, press the run button.

AVERAGE COUNTACTIVATION TIME

(ACAt)

The average amount of time a count input was activated for each completed piece inseconds.

Average count activation time is computed from the cumulative count activation time,and the piece count.

CUM. COUNTACTIVATION TIME

(CCAt)

The cumulative amount of time any count input has been activated in xxx.x minutes.

After selecting a PRM result register via the [F2] key, press the [F4] key to select that result register for display onthe ACTUAL line of the PRM during normal operating mode. If no keys are pressed for 10 seconds, the PRM willautomatically return to normal operating mode, and the result register selected for display on the ACTUAL line willnot be changed.

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2.3 Using the Optional Red / Green Stack LightThe PRM computes a real time percent efficiency from the displayed goal and actual values. Efficiency valuesless than 100% mean that actual is less than goal. Efficiency values greater than 100% mean that actual isgreater than goal.

LOW-LOW, LOW, HIGH, and HIGH-HIGH efficiency trip points can be set to make the optional red / green stacklight turn on / off when trip points are exceeded. If your PRM does not have the optional stack light installed, thenyou can skip this manual section and ignore the HIGH-HIGH, HIGH, LOW, and LWO-LOW register settings.

Normally the green light is turned on, and the red light is turned off. If the LOW or HIGH efficiency trip point isexceeded then the green light turns off, and the red light turns on. If the LOW-LOW or HIGH-HIGH efficiency trippoint is exceeded, then the green light turns off, and the red light is flashed. A diagram of the trip points andresulting light conditions is shown below.

Any efficiency trip point can be disabled by setting it to 0.0%. This allows the system operator to program the PRMto activate the green and red lights in several different patterns, some of which are shown below.

LOW-LOW = 80.0 LOW = 90.0 HIGH = 0.0 HIGH-HIGH = 120.0




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100%Efficiency

Green RedRed Flashing RedFlashing Red

LOWTrip %

LOW-LOWTrip %

HIGHTrip %

HIGH-HIGHTrip %

100%90%80% 120%

GreenRed Flashing RedFlashing Red

100%90% 110%

Green Flashing RedFlashing Red

100%90% 110%

Green RedFlashing Red

100%90%80%

GreenRedFlashing Red


2.4 Basic Operation ExamplesTo properly operate the PRM, the sample time settings need to be set to values that are appropriate for yourproduction process. The choice of sample time settings involves balancing the responsiveness of the meteragainst averaging out short term time variations in the production process. Unfortunately, for a given productionprocess, a single “correct” choice of sample time does not exist, but there are choices that will not produce usefulresults. If after reading the following description of how to choose sample times, you are still having difficulty,please contact American LED-gible technical support, and we will be happy to help you.

The primary factor impacting the choice of sample time settings is how “smooth” the production process is. In a“smooth” production process, the amount of time that elapses between each unit of production is consistent andpredictable.

Imagine a machine that automatically produces widgets. The widget machine can be sped up, or slowed down,but if it is running normally, and no one changes it's settings, the widget machine will repetitively produce a newwidget in a predicable amount of time, over and over again. The widget machine is an example of a “smooth”production process. In a “smooth” production process, the production rate can accurately be measured by simplymeasuring how much time elapses between each item produced and then doing a little bit of math. For example,if exactly 4.0 seconds elapses between each widget, then the widget machine is producing exactly 900 widgets perhour.

To contrast, instead of an automatic widget producing machine, imagine that the widgets are being manuallyassembled by 4 employees in parallel. Imagine that it takes 16.0 seconds for each employee to assemble onewidget. Like the widget machine, on average one widget will be completed every 4.0 seconds, but unlike thewidget machine, this production process is “not smooth”. If the 4 employees are perfectly synchronized with eachother, then 4 widgets are completed at the same time, and then 16.0 seconds later another 4 widgets arecompleted at the same time. However, If the 4 employees are perfectly sequenced, then Employee #1 finishes awidget, 4.0 seconds later Employee #2 finishes a widget, 4.0 seconds later Employee #3 finishes a widget, 4.0seconds later Employee #4 finishes a widget, so forth and so on. In reality, due to the variability of manualprocesses, the actual widget output will drift between these two extremes throughout the day.

When a production process is “not smooth”, the production rate can not accurately be measured by simplymeasuring how much time elapses between one item and the next. Consider the synchronized manual widgetproduction process described above. The time interval between the 1st and 2nd widgets is essentially 0.0 secondswhich correlates with a production rate of infinity widgets per hour, which is obviously incorrect. On the other hand,the time interval between the 4th and 5th widgets is 16.0 seconds which correlates with a production rate of 225widgets per hour, which is also incorrect.

In a widget production process that is “not smooth”, we must measure the amount of time it takes to produceseveral widgets to arrive at a reasonably good rate measurement. But there is a tradeoff that exists in our choiceof how many widgets to measure over. If we choose to measure how long it takes to produce a very large numberof widgets, the resulting rate measurement is very accurate, but it also takes a very long time to produce. Forexample, if we choose to measure the amount of time it takes to produce 100 widgets, the resulting ratemeasurement will be very accurate, but it will take about 400 seconds (over 6½ minutes) to take themeasurement. Alternatively if we choose to measure how long it takes to produce a relatively small number ofwidgets, the resulting rate measurement is much less accurate, but takes far less time to produce. For example, ifwe choose to measure the amount of time it takes to produce 12 widgets, the resulting rate measurement will beless accurate and more “noisy”, but it will only take about 48 seconds (slightly over ¾ of a minute) to take themeasurement.

In extreme cases, a production process can be so variable that real time rate measurements become useless. Inthese cases it's best to abandon the real time rate result of the PRM, and fall back to using the average rate resultwhich is computed from total pieces produced and total elapsed work time instead.

The following three manual sections provide examples of setting up the PRM for “smooth”, “not smooth”, and“extremely not smooth” production processes.

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2.4.1 Using the PRM in a “Smooth” Production Process

Widget Co. the worlds leading manufacturer of widgets, is connecting an American LED-gible PRM to anautomatic widget producing machine. A whisker switch is installed on the output of the widget machine to detectcompleted widgets and connected to one of the PRM COUNT inputs. Widget Co is not interested in using theaverage rate, piece counter, or elapsed work time features of the PRM, so they do not connect anything to thePRM HOLD or RESET inputs.

The automatic widget machine is scheduled to run for 8 hours per day, and must complete 7200 widgets in thatamount of time. From this, we can compute the PRM GOAL setting...

GOAL = 7200 Widgets per Day / 8 Hours Running per Day = 900 Widgets per Hour

From the goal rate of 900 widget per hour, we can compute the average takt time to produce each widget.

TAKT = 3600 Seconds per Hour / 900 Widgets per Hour = 4.0 Seconds per Widget

Next we need to choose a REAL TIME RATE LOW SAMPLE TIME, and a REAL TIME RATE HIGH SAMPLETIME. Since the production process is smooth, we can use very short sample times. A low sample time of TAKT* 1.5 = 6.0 seconds and a high sample time of TAKT * 5.5 = 22.0 seconds would probably be a good choice forthis production process.

With these settings, when production is running at near the expected rate, the PRM will update the real time ratemeasurement about every second widget (about 8.0 seconds), but If no widgets are produced for 22.0 seconds,the real time rate measurement will drop to zero.

It's important to note that a high sample time of 22.0 seconds also limits the slowest real time rate the PRM canmeasure, to one widget every 22.0 seconds, or 164 widgets per hour. Changing the high sample time to 36.0seconds would extend the PRM real time rate measurement to rates as low as 100 widgets per hour.

Next we need to choose an AVERAGE RATE HIGH SAMPLE TIME. Since Widget Co has decided not to use theaverage rate feature, the AVERAAGE RATE HIGH SAMPLE TIME should be set to the factory default of 0.0seconds.

To set the GOAL option register to 900 widgets per hour, press the [F1] key once to select the GOAL register.Then use the [+] keys to dial in the number “0900”. Then press the [F4] key to save the setting.

To set the REAL TIME RATE LOW SAMPLE TIME option register to 6.0 seconds, press the [F1] key twice toselect the REAL TIME RATE LOW SAMPLE TIME register. Then use the [+] keys to dial in the number “006.0”.Then press the [F4] key to save the setting.

To set the REAL TIME RATE HIGH SAMPLE TIME option register to 22.0 seconds, press the [F1] key three timesto select the REAL TIME RATE HIGH SAMPLE TIME register. Then use the [+] keys to dial in the number“022.0”. Then press the [F4] key to save the setting.

To set the AVERAGE RATE HIGH SAMPLE TIME option register to 0.0 seconds, press the [F1] key four times toselect the AVERAGE RATE HIGH SAMPLE TIME register. Then use the [+] keys to dial in the number “000.0”.Then press the [F4] key to save the setting.

To make the PRM display the REAL TIME RATE result on the ACTUAL line of the PRM, press the [F2] key onceto select the REAL TIME RATE result register, and the press the [F4] key to save the selection.

At this point the PRM is ready to measure the rate of the widget production process. As widgets are produced, thewhisker switch will send pulses to the PRM count input. Every few pulses, the PRM will compute and display themeasured real time rate.

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2.4.2 Using the PRM in a “Not Smooth” Production Process

Widget Co. the worlds leading manufacturer of widgets, is using an American LED-gible PRM to measure the rateat which 4 employees are manually assembling widgets. A push button is installed at each assembly station andwired to one of the PRM count inputs. The employees are instructed to push the button once each time theycomplete a widget. Widget Co. management also wants to record the accumulated widget count, the elapsedwork time, and the average rate measurement at the end of the shift. The shop supervisor will be responsible forresetting the PRM at the start of the shift, and holding the PRM during breaks.

The employees assemble widgets 8 hours per day, and must complete 7200 widgets in that amount of time. Fromthis, we can compute the PRM GOAL setting...

GOAL = 7200 Widgets per Day / 8 Hours Worked per Day = 900 Widgets per Hour

From the goal rate of 900 widget per hour, we can compute the average takt time to produce each widget.

TAKT = 3600 Seconds per Hour / 900 Widgets per Hour = 4.0 Seconds per Widget

Next we need to choose a REAL TIME RATE LOW SAMPLE TIME, and a REAL TIME RATE HIGH SAMPLETIME. Since the production process is not smooth, we must use longer sample times. A low sample time ofTAKT * 10.5 = 42.0 Seconds and a high sample time of TAKT * 15.5 = 62.0 will probably produce acceptableresults.

With these settings, when production is running at near the expected rate, the PRM will update the real time ratemeasurement about every eleventh widget (about 44.0 seconds), and if no widgets are produced for 62.0seconds, the real time rate measurement will drop to zero.

Next we need to choose an AVERAGE RATE HIGH SAMPLE TIME. By default, the PRM only recomputesaverage rate when a count pulse is detected. To force the PRM to update the average rate calculation whileproduction is down, set the AVEREAGE RATE HIGH SAMPLE TIME anything other than 0.0. A setting of 30.0seconds will force the PRM to recompute average rate at least once every 30.0 seconds.



To set the REAL TIME RATE HIGH SAMPLE TIME option register to 62.0 seconds, press the [F1] key three timesto select the REAL TIME RATE HIGH SAMPLE TIME register. Then use the [+] keys to dial in the number“062.0”. Then press the [F4] key to save the setting.

To set the AVERAGE RATE HIGH SAMPLE TIME option register to 30.0 seconds, press the [F1] key four timesto select the AVERAGE RATE HIGH SAMPLE TIME register. Then use the [+] keys to dial in the number “030.0”.Then press the [F4] key to save the setting.

To make the PRM display the REAL TIME RATE result on the ACTUAL line of the PRM, press the [F2] key onceto select the REAL TIME RATE result register, and the press the [F4] key to save the selection.

At the start of the shift, the shop supervisor must press the [TOP] reset key to reset the PRM's internal piececounter and elapsed work time timer to zero. Next the shop supervisor must press the [RUN] key to allow theelapsed time timer to accumulate time. As widgets are produced, the employees must press their count buttons,and the PRM will periodically recompute the real time rate. At the start of lunch break, the shop supervisor mustpress the [HOLD] key to pause the elapsed work time timer. Once lunch is over, the shop supervisor must pressthe [RUN] key to allow the timer to continue timing up. At the end of the shift, the shop supervisor must press the[HOLD] key to pause the elapsed work time timer, and then press the [F2] key several times to observe the end ofshift average rate, and then the piece count, and then the elapsed run time in minutes.

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2.4.3 Using the PRM in an“Extremely Not Smooth” Process

Widget Co. the worlds leading manufacturer of widgets, is using an American LED-gible PRM to measure theaverage rate of widget production. A whisker switch is installed at the bottom of a shoot that caries finishedwidgets to the packing area. The shop supervisor will be responsible for resetting the PRM at the start of the shift,and holding the PRM during breaks.

Production produces widgets 8 hours per day, and must complete 7200 widgets in that amount of time. From this,we can compute the PRM GOAL setting...

GOAL = 7200 Widgets per Day / 8 Hours Worked per Day = 900 Widgets per Hour

Since the PRM's real time rate measurement will be ignored, the REAL TIME RATE LOW SAMPLE TIME shouldbe set to the factory default of 5.0 seconds, and the REAL TIME RATE HIGH SAMPLE TIME should be set to thefactory default of 10.0 seconds.

Next we need to choose an AVERAGE RATE HIGH SAMPLE TIME. By default, the PRM only recomputesaverage rate when a count pulse is detected. To force the PRM to update the average rate result while productionis down, set the AVEREAGE RATE HIGH SAMPLE TIME to anything other than 0.0. A setting of 15.0 secondswill force the PRM to recompute average rate at least once every 15.0 seconds.



To set the REAL TIME RATE HIGH SAMPLE TIME option register to 10.0 seconds, press the [F1] key three timesto select the REAL TIME RATE HIGH SAMPLE TIME register. Then use the [+] keys to dial in the number“010.0”. Then use the [F4] key to save the setting.

To set the AVERAGE RATE HIGH SAMPLE TIME option register to 15.0 seconds, press the [F1] key four timesto select the AVERAGE RATE HIGH SAMPLE TIME register. Then use the [+] keys to dial in the number “030.0”.Then press the [F4] key to save the setting.

To make the PRM display the AVERGAE RATE result on the ACTUAL line of the PRM, press the [F2] key twice toselect the AVERAGE RATE result register, and the press the [F4] key to save the selection.

At the start of the shift, the shop supervisor must press the [TOP] reset key to reset the PRM's internal piececounter and elapsed work time timer to zero. Next the shop supervisor must press the [RUN] key to allow theelapsed work time timer to accumulate time. As widgets are produced, the PRM will recompute the average ratefrom the accumulated piece count and the elapsed work time.

At the start of lunch break, the shop supervisor must press the [HOLD] key to pause the elapsed work time timer.Once lunch is over, the shop supervisor must press the [RUN] key to allow the timer to continue timing up.

At the end of the shift, the shop supervisor must press the [HOLD] key to pause the elapsed work time timer, andthen press the [F2] key several times to observe the end of shift average rate, and then the piece count, and thenthe elapsed run time in minutes.

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3.0 Using The PRM Serial PortThe PRM serial port can accept commands from a central computersystem via RS-232 or RS-485 communications.

Depending on the distances involved, quantity of PRMs, and thecapabilities of your PC or other smart device, you may need acommunications converter. In most cases, American LED-gible Inc.suggests using converters manufactured by B&B Electronics. We useB&B converters to test our products before shipping them to you. Thismeans that our technical support staff is familiar with and comfortableusing B&B converters, allowing us to give you the best support possiblewhen you choose B&B converters. B&B Electronics can be reached at(815) 433-5100, www.bb-elec.com.

Most of our customers use the B&B Electronics USOPTL4 converter,which adapts any PC USB port to RS-485, is powered by the PC's USBport, and provides up to 2000 Volts of optical isolation, protecting the PCfrom over voltage conditions on the RS-485 wiring.

3.1 RS-232 CommunicationsIf a single PRM is being managed by a PC, and the cable between thePRM and the PC will be no longer than 50 feet long, RS-232communication may be used instead of RS-485 communications.

When using RS-232, a three-conductor cable designed for serialcommunications will be needed. American LED-gible suggests usingBelden 9463 “Blue Hose” cable.

Typical wiring between an IBM PC compatible DB9 serial port and the PRMis illustrated to the right.

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5 GND3 TXD2RXD


3.1.1 RS-232 Communications Switch Settings

Several switch settings need to be completed to communicate with the PRM via RS-232 communications.

Switch Setting ReasonSW1 switches 1 through 7ASCII AddressSW1 switch 1 is the LSBSW1 witch 7 is the MSBON = Logic 1OFF = Logic 0

These switches set the PRM's address. The PRM's address canbe any printable character between space (20h) and “~” (7Eh).The address is selected by setting the binary number representingthe ASCII character. Selecting an invalid address results in thePRM address being set to “A” (41h). An example address settingtable is printed on the PRM circuit board.

SW1 switch 8ON

For RS-232 communications, the RS-232 echo must be enabled.

SW2 switches 1 through 3OFF

Turning SW2 switches 1 through 3 OFF selects 19200bps baud.If a different baud rate is required, consult the baud rate tableprinted on the PRM circuit board.

SW2 switch 4OFF = PPHON = PPM

This switch has no effect on serial communications. Set it to OFFto select Pieces per Hour mode. Set it to ON to select Pieces perMinute mode.


With revision B firmware, SW2 switches 5 through 8 have noeffect on the operation of the PRM. Please set these switches toOFF.

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3.2 RS-485 CommunicationsWith RS-485 communications, up to 64 PRMs can be connected to the PC, and the cable connecting the PRMs tothe PC can be up to 4000 feet long.

When using RS-485 communications, a three-conductor cable designed for serial communications will be needed.American LED-gible suggests using Belden 9463 “Blue Hose” cable. Additionally since most PCs do not have anRS-485 capable serial port, a communications converter is typically required.

If you are using an USOPTL4 converter as shown in the diagram above, there are 4 switches on the back side ofthe converter. Turn switch 1 ON to select RS-485 mode, switch 2 OFF to select echo on mode, and switches 3and 4 ON to select 2 wire mode.

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PRM A (41h) PRM B (42h) PRM C (43h)

A TDA(-)

B TDB(+)

C RDA(-)

A RDB(+)

E GND

USOPTL4USB


3.2.1 RS-485 Command Mode Switch Settings

Several switch settings need to be completed to communicate with the PRM via RS-485 communications.

Switch Setting ReasonSW1 switches 1 through 7ASCII AddressSW1 switch 1 is the LSBSW1 witch 7 is the MSBON = Logic 1OFF = Logic 0

These switches set the PRM's address. The PRM's address canbe any printable character between space (20h) and “~” (7Eh).The address is selected by setting the binary number representingthe ASCII character. Selecting an invalid address results in thePRM address being set to “A” (41h). An example address settingtable is printed on the PRM circuit board.

SW1 switch 8OFF

For RS-485 communications, the RS-232 echo must be disabled.


Turning SW2 switches 1 through 3 OFF selects 19200bps baud.If a different baud rate is required, consult the baud rate tableprinted on the PRM circuit board.

SW2 switch 4OFF = PPHON = PPM

This switch has no effect on serial communications. Set to OFF toselect Pieces per Hour mode. Set to ON to select Pieces perMinute mode.


With revision B firmware, SW2 switches 5 through 8 have noeffect on the operation of the PRM. Please set these switches toOFF.

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3.3 PRM Communications ProtocolThe PRM has many registers that can be accessed in real time via the serial port. The option registers supportboth read and write access. The result registers support read only access.

Each PRM has a single character (byte) address ranging from space (20h) to “~” (7Eh) which is set on dip-switchSW1. Each unit’s address in a communications network must be unique or collisions will occur on the network.There is an ASCII chart detailing the correspondence between characters and the hexadecimal ASCII codenumbers for that character at the back of this manual.

All commands begin with a CTRL-B character followed by the address of the PRM the command is directed too.All commands end with a CTRL-C character. The PRM uses the CTRL-B and CTRL-C characters to find thebeginning and the end of command packets within the serial data stream.

Each PRM has the following serial port accessible registers:

RegisterName

RegisterCode

R / W Register Description

GOAL GO R / W 4 Digit GOAL Value, 0000 to 9999rLOt RL R / W 4 Digit Real Time Rate Low Sample Time, 0010 to 9999rHIt RH R / W 4 Digit Real Time Rate High Sample Time, 0010 to 9999AHIt AH R / W 4 Digit Average Rate High Sample Time, 0000 to 9999rAtE RR R / - 4 Digit Real Time Rate Result, 0000 to 9999ArtE AR R / - 4 Digit Average Rate Result, 0000 to 9999AcyL AC R / - 4 Digit Average Cycle Time Result, 0000 to 999Cnt CT R / W 4 Digit Piece Count, 0000 to 9999ELAP EL R / W 4 Digit Elapsed Time, 0000 to 9999ACAt AA R / - 4 Digit Average Count Activation Time, 0000 to 9999CCAT CA R / - 4 Digit Cumulative Count Activation Time, 0000 to 9999KHOLD KH R / W 1 Digit Keyboard Hold Flag, 0 to 1 (1 = HOLD)LHOLD LH R / - 1 Digit Logic Hold Flag, 0 to 1 (1 = HOLD)KDISABLE KD R / W 1 Digit Keyboard Disable Flag, 0 to 1 (1 = Disabled)

The above registers can be read or written, in real time. The operation (Read or Write) and the register selected isspecified by a 3-character opcode.

The first character in an opcode is an “R” character for a READ operation or a “W” character for a WRITEoperation. The second and third characters of the opcode specify a PRM register. See the “Register Code”column in the table above for the two character codes that specify PRM registers.

Write opcodes are followed by numeric data as appropriate for the command. The numeric data must be fixedwidth, and cannot contain spaces or decimal points.

For example, to write 1.0 seconds to the REAL TIME RATE LOW SAMPLE TIME register, the data section of thecommand must be “0010”.

For example, to write “1234” to the GOAL register of PRM “A”, use the opcode “WGO” (Write GOAL) with data“1234” as shown below.

STX ADDR OPCODE DATA ETXCTRL

B A W G O 1 2 3 4CTRL

C02h 41h 57h 47h 4Fh 31h 32h 33h 34h 03h

If the command is accepted, the PRM will respond with a single ACK character (CTRL-F, 06h).

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To read the GOAL register of PRM “B” use the opcode “RGO” (Read GOAL) as shown below:

STX ADDR OPCODE ETXCTRL

B B R G OCTRL

C02h 42h 52h 47h 4Fh 03h

If the command is accepted, the PRM will respond with the requested data followed by an ACK character.

DATA ACK

1 2 3 4CTRL

F31h 32h 33h 34h 06h

If the PRM cannot interpret the command, it will respond with a NAK character (CTRL-U, 15h).

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4.0 Installing the Optional PRM Monitor PC SoftwareThe PRM Monitor PC software is written in Visual Basic 6.0, and designed to run on any Windows 95, Windows98, Windows 2000, Windows XP, or Windows 7 computer. Minimum system requirements are Windows 95, a1GHz processor, with 1GB RAM, and a 100GB Hard drive.

However, even though the minimum system requirements are quite meager, the PRM Monitor software isdesigned to gather PRM data as fast as possible. In most installations it's best to dedicate a PC to running thePRM Monitor software.

To install the PRM monitor software, place the PD-2116-143V2.1 CD in your CD drive, and run the SETUP program on theroot of the CD. Then click on OK to begin the installation.

The setup program will ask you where to install thePRM Monitor program on your PC. In most cases thedefault directory is the best choice. Click on the iconof the PC to continue.

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Next the setup program will ask you to choose a program group.Again the default is generally the best choice. Click on the continuebutton to continue.

The setup program will now install the PRM Monitor program on yourPC.

To start the PRM Monitor software, click on[Start] → [All Programs] → [PRM Monitor] →[PRM Monitor] as shown in the picture to theright.

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4.1 Configuring a Privileged Operation Password (Optional)The first time the PRM Monitor software runs, it will look something like this.

An optional password may be set to prevent unauthorizedmodification of settings. Once a password has been set, theoperator will be required to supply the password when adjustingany PRM registers, or making any configuration changes to thesystem.

If you want to enable password protection, or change the password,click on [File] → [Change Password...] to summon the changepassword dialog shown to the right.

If you have already assigned a password, type it into the Old Passwordbox, otherwise leave this box blank. Enter the desired new passwordinto both of the New Password boxes, then click [Change Password]to apply the change. The software will tell you if the attempt to changethe password was successful or not.

If you want to disable password protection, enter the old password inthe Old Password box, leave both New Password boxes blank, andthen click [Change Password]. The software will tell you if theattempt to change the password was successful or not.

Note: Passwords are case sensitive. Banana, BANANA, and banana are three different passwords.

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4.2 Configuring Schedules (Optional)Schedules allow the PRM Monitoring Software to: resetPRMs at the start of each shift; hold PRMs during eachbreak; and export the end of shift data to CSV file.

Click on [File] → [Configure Schedules...] to summonthe configure weekly schedules dialog shown to the right.

The software supports up to 64 schedules (#1 to #64).Each schedule has a name that you can change toanything that makes sense to you. Each schedule canhave up to 8 shifts per week, and up to 4 breaks per shift.The start of shift reset is optional. The end of shift exportis optional as well, and can optionally be set to happen afew minutes after the end of the shift (to allow forstragglers).

The schedules are very flexible, which also makes themsomewhat complex. The best way to explain how to useschedules is by example.

The first example, is the basic one shift, Monday throughFriday, 8:00AM to 5:00PM work schedule with a lunchbreak from 12:00PM to 1:00PM.

First, use the Schedule drop list to select one of the sixtyfour schedule slots (#1 to #64).

Next change the schedule name to any descriptive namethat makes sense to you. The example shown to the rightis named “Simple Schedule Example”.

On the 1st Shift Tab, check the reset box to enableresetting the PRM(s) to zero at the start of 1st Shift.

Check the Export box to enable exporting the end of shiftdata to a CSV file at the end of 1st Shift.

Check the Monday, Tuesday, Wednesday, Thursday, andFriday check boxes to enable this shift on Mondaythrough Friday, and not on Saturday and Sunday.

Enter a 1st Shift start time of 8:00:00 AM, end time of 5:00:00PM, and an export time of 5:15:00 PM.

Check the Monday, Tuesday, Wednesday, Thursday, and Friday check boxes to enable 1st Break on weekdays,then enter a 1st Break start time of 12:00:00PM and an end time of 1:00:00PM.

Click the [Apply] button or the [OK] button to save the “Simple Schedule Example” settings to disk.

With this schedule, at 8:00AM on weekdays, the PRM(s) will be reset to zero and then released from hold. At12:00:00PM on weekdays, the PRM(s) will be held for lunch break. At 1:00:00PM on weekdays the PRM(s) will bereleased from hold. At 5:00:00PM on weekdays the PRM(s) will be held for end of shift. (Note: The piece countcan still be incremented by stragglers) At 5:15:00PM on weekdays, the final end of shift data will be exported toCSV file.

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The second example, is a more complex twoshifts per weekday schedule named “Two ShiftsExample”

The 1st Shift configuration shown to the rightschedules 1st Shift to start at 6:00AM and end at2:00PM on weekdays. The PRM(s) are reset tozero at the start of 1st Shift, and 1st Shift data isexported to CSV at 2:05PM

There are three breaks during 1st Shift. The firstbreak is from 8:00AM to 8:15AM. The secondbreak is from 10:00AM to 10:30AM. The thirdbreak is from 12:00PM to 12:15PM.

Click the 2nd shift tab to view or change the 2nd

Shift configuration as shown to the right.

2nd shift starts at 3:00PM and ends at 11:00PM onweekdays. The PRM(s) are reset to zero at thestart of 2nd Shift, and 2nd Shift data is exported toCSV at 11:15PM

There are three breaks during 2nd Shift. The firstbreak is from 5:00PM to 5:15PM. The secondbreak is from 7:00PM to 7:30PM. The third breakis from 9:00PM to 9:15PM.

After setting the check boxes and entering the times, click the [Apply] or [OK] button to save the “Two ShiftsExample” schedule to disk.

NOTE: By un-checking the 1st Shift Export check box, and un-checking the 2nd Shift Reset check box. ThePRM(s) would reset at the beginning of the day (beginning of 1st shift), hold between shifts, but not resetat the start of 2nd Shift, and then export data at the end of the day (end of 2nd shift). With this adjustment,the exported data would be daily totals instead of shift totals despite their being two shifts worked.

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The third example schedule is even more complex.

The “Complex Schedule” shown above defines four shifts. 1st Shift, 2nd Shift, and 3rd Shift are worked onweekdays. 4th Shift is a special Saturday overflow shift.

1st Shift starts at 6:00AM and ends at 2:00PM on Weekdays. The PRM(s) are reset at the beginning of the shiftand data is exported at the end of the shift. On Mondays, Wednesdays, and Fridays, 1st Shift takes a break from10:00AM to 11:00AM. On Tuesdays and Thursdays, the break is moved to 11:00AM to 12:00PM

2nd Shift starts at 2:00PM and ends at 10:00PM on Weekdays. The PRM(s) are reset at the beginning of the shiftand data is exported at the end of the shift. On Mondays, Wednesdays, and Fridays, 2nd Shift takes a break from5:00PM to 6:00PM On Tuesdays and Thursdays, the break is moved to 6:00PM to 7:00PM

3rd Shift starts at 10:00PM and ends at 6:00AM on Weekdays. The PRM(s) are reset at the beginning of the shiftand data is exported at the end of the shift. Note that the 3 rd Shift break is on Tuesday through Saturday. This isbecause 3rd Shift begins work at 10:00PM Monday Night and then takes break at 2:00AM Tuesday Morning.

4th Shift is only worked on Saturdays, and runs from 12:00PM to 4:00PM. The PRM(s) are reset at the start of theshift, and data is exported 15 minutes after the end of the shift. A single 15 minute break is taken from 2:00PM to2:15PM.

NOTE: If after reviewing these examples, you still have questions about how to enter your work scheduleinto the PRM Monitoring Software, please call American LED-gible Technical Support, and we will behappy to help you.

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4.3 Configuring Production Rate Meters (Required)To monitor PRMs, the PRM Monitoring Software must be told howto communicate with each PRM. The software can monitor up tosixty four PRMs (#1 to #64) connected to the PC via serial port(COM1: to COM15:) or optionally TCP/IP communications (if thePRM has the optional TCP/IP bridge installed).

Click on [File] → [Configure PRMs...] to summon the configurePRMs dialog shown to the right.

To configure the software to monitor your first PRM, select PRM#1 from the PRM drop list. Then change the PRM's name toanything that makes sense to you. PRMs are typically named forthe machine or processes they are monitoring (Welding, Lube,Paint, etc).

After naming the PRM, specify which port is used to communicatewith that PRM. If a serial port is selected, you will also have tospecify the serial address of the PRM (Set on dip switches insidethe PRM).

Finally you can choose which (if any) schedule is associated with this PRM. In the example show above, the PRMis named “My First PRM”, is connected to the PC via serial port COM4, has a serial address of A (41h), and willoperate on the “Simple Schedule Example” from section 4.2 of this manual.

After configuring how the software will monitor the PRM, click [Apply] or [OK] to save the configuration to disk.

A second example shown to the right, configures the software tomonitor a PRM named “Another PRM”. This PRM is connected tothe PC via TCP/IP (Ethernet) and has an IP address of“192.168.168.62”. This PRM will not run a schedule, so it must bemanually reset at the start of shift, manually held for breaks, anddata will not be exported at the end of shift.

A third example shown to the right, configures the software tomonitor a PRM named “Third PRM”. This PRM is connected tothe PC via serial port COM4, has a serial address of B (42h), andwill operate on the “Two Shifts Example” schedule from section4.2 of this manual.

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4.4 Configuring Slave Totalizer Displays (Optional)Unlike PRMs, Totalizers do not generate information which isthen sent to the PC, instead they receive information from thePC and display it.

The PRM Monitoring Software can compute Total Goal, TotalReal Time Rate, Total Average Rate, Total Piece Count, andTotal Elapsed Time for any subset of PRMs, and then send thatdata to the Totalizer display.

Click on [File] → [Configure Totalizers...] to summon theconfigure totalizer dialog shown to the right.

To configure the software to send data to a Totalizer display,select one of the Totalizer Display slots (#1 to #64). Thenchange the Totalizer's name to anything that makes sense toyou.

After naming the Totalizer, specify which port is used tocommunicate with that Totalizer. If TCP/IP is chosen, you willalso have to specify the host name or IP address of the Totalizerdisplay.

Next specify the serial addresses of each display field. Theexample to the right shows a typical configuration for a threefield Totalizer display. Total Goal data is sent to the display fieldwith a serial address of 1 (31h). Total real time rate data is sentto the display field with a serial address of 2 (32h). Totalaverage rate data is sent to the display field with a serial addressof 3 (33h). Total piece count data is not displayed. Totalelapsed time data is not displayed.

Finally check off which PRM's should be included in the totalcalculations. The example to the right configures the Totalizerdisplay to show totals computed over three PRMs (My First PRM, Another PRM, and Third PRM).

After configuring the Totalizer, click [Apply] or [OK] to save the configuration to disk.

NOTE: The Totalizer feature can be used to copy data from one PRM to a Totalizer Display. To do this,only check one PRM in the Totalizer for box.

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5.0 Using the PRM(s) via the PC SoftwareThe main PRM Monitor screen summarizes the condition of all the PRMs in a spreadsheet like grid. The grid issetup with one row per PRM, and one column per register / data item.

Columns are provided for the following register and data items:

Register / Data Item Description

PRM Name The operator assigned name for this PRM.

Goal The operator assigned goal value to display on this PRM.

Realtime Rate The result of the most recent real time rate calculation.

Average Rate The result of the most recent average rate calculation.

Average Cycle The result of the most recent average cycle time calculation.

Piece Count The quantity of completed production units.

Elapsed Time The quantity of elapsed working time, in minutes.

Average Cnt. Act. Time The average amount of time the count inputs are activated for each item inseconds.

Cumulative Cnt. Act. Time The cumulative amount of time the count inputs have been activated in minutes.

Realtime Min Sample The minimum real time rate sample period, in seconds.

Realtime Max Sample The maximum real time rate sample period, in seconds.

Average Max Sample The maximum time allowed between updates to the average rate result, inseconds.

Keypad Hold Is the PRM held for break because the HOLD key on the keypad was activated.

Logic Hold Is the PRM held for break because the PRM's HOLD logic input is activated.

PRM Keypad Is the PRM keypad enabled or disabled.

Status The status of the last attempt to communicate with this PRM.

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5.1 Adjusting Individual PRM Register Values

To adjust PRM settings, first click on any data value to bring upthe detailed view, shown to the right, and then click on thechange button of the register you wish to adjust. Next type thenew register value into the change dialog and then click on OK toapply the change.

The image to the right shows the detailed view for the “My FirstPRM” PRM. To change the goal value, click the [Change]button to the right of goal value.

This will bring up the change goal dialog shown to the right. Enter the newgoal value, and then click [OK]. At the first opportunity the software willexecute a write to the goal register in the PRM to change the goal value asdirected.

If the attempt to change the goal value fails for any reason, an errordialog will be displayed as shown to the right.

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5.2 Adjusting a Register in All PRMs at the Same Time

To adjust a register in all of the PRMs at the same time, click on the register name. For example, to set theKeypad Run/Hold state of all PRMs at the same time, click on the Keypad Hold column heading.

This will summon the Change All Keyapd Run/Hold Registers dialogshown to the right. Clicking on [Set to Hold] button will set all PRMs tohold mode at the same time.

To set the Average Max Sample setting of all PRMs at the same time, click on the Average Max Sample columnheading.

This will summon the Change All Max Sample Time Registers dialog shownto the right. Enter a new maximum sample time, and then click on [OK] toapply the change.

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5.3 Viewing Real Time Totalizer Data

Click on [File] → [View Totalizers....] to bring up the Totalizer summary screen as shown below.

From this screen you can see the result of all Totalizer calculations, and can also see the current communicationsstate for each Totalizer.

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(614) 851-1121 Fax




5.4 Exporting PRM DataThe Data Export feature can automatically be triggered by a Schedule, or the operator may manually export thecurrent PRM states to a CSV (Comma Separated Values) file. When data is automatically exported, the systemautomatically generates a file name based on the system clock, in the format yyyy_mm_dd.csv where yyyy is thefour digit year, mm is the two digit month, and dd is the two digit day. When data is manually exported, thesoftware opens a standard “Save As” dialog, allowing the operator to specify a file name.

Note: The data exported is always appended to the file. Pre-existing files are never deleted or overwritten.

To execute a manual export, click on the [File] menu andthen select [Export PRM Data to CSV File...]. Thesystem “Save As” dialog box will come up. Select thelocation and file name you would like the report file to bewritten to, and then click [Save].

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6.0 In Case of DifficultiesBefore contacting ALI for technical support, please review the manual sections covering installation and operation.

If the PRM does not power up, check the power indicator lamp on LED1. This indicator. is connected directly tothe PRM 5VDC power supply. If it does not light the 120VAC power wiring is probably incorrect.

If the PRM does not respond to the logic inputs, please observe the input indicator lamps on LED2 and LED3 whileattempting to operate the PRM. When an input is activated, the corresponding lamp will light. The T-RST and B-RST inputs are asynchronous and will prevent the piece counter and elapsed work time timer from accumulatingdata for as long as either is activated. Activating the HOLD input prevents the elapsed work time timer fromrunning for as long as the input is activated, even if the [RUN] button is pressed on the front panel.

If the PRM basic configuration operates, but the PRM serial port is not working, first check all serial port wiring anddip-switch settings. There are several indicator lamps on the PRM circuit board to help troubleshoot serialcommunications problems.

LED1 - ENB Lights when the RS-485 transmitter is active.LED1 - TXD Lights when the PRM is transmitting serial data.LED1 - RXD Lights when the PRM is receiving serial data.

The above LED’s should “flash” during serial communications because they only light during the transmission orreception of a character. When the serial data line is idle, all three LED’s should remain off.

If RS-232 echo is on (SW1 switch 8) then LED1 - ENB should never light because the RS-485 transmitter isdisabled.

If RS-485 communications are being used, and LED1 - RXD remains on even though the serial data line is idle,the 485+ and 485- wires are probably reversed.

TJ1, the self-test jumper can be installed to check the numeric LED display and erase the PRM memory. Whenthe PRM starts, if TJ1 is installed, additional startup code is executed. This code first performs a LAMP TEST,then the baud rate and address are displayed, and finally the PRM memory is erased which has the side effect ofresetting all PRM registers to default values.

6.1 Contacting American LED-gible® Inc.If you need technical assistance, contact us by phone or fax and please have the model number, serial number,and a description of the problem available.

The serial number and model number of the marquee can be located on the right side of the unit imprinted on aSILVER ID TAG.

AMERICAN LED-GIBLE(614) 851-1100

Model # SO-11758-101Serial # SO-11758-101

WWW.LEDGIBLE.COMMARCH 2012

American LED-gible® technical support may be reached at:

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7.0 Product SpecificationsGENERAL:

Line Voltage 120VAC 60Hz or 50HzPower Consumption ½ Amp typical, 1 ½ Amp MaximumOperating Temperature 0° F to 135° F (-17° C to +50° C)Operating Humidity 35% to 80%Dimensions 11” Wide, 15” Tall, 3.5” DeepWeight 15 PoundsEnclosure NEMA-1 Satin Black Painted 16 Gage Steel BoxMounting Wall Mount Holes in Back of Box

L.E.D. DISPLAY:Digit Type 2.3” Tall 7-segment L.E.D. Modules in Red and Green L.E.D.Digit Brightness 36mcd standard brightnessLamp Life 100,000 Hours (11.4Years)Viewing Distance 115 Feet

KEYPAD:Type 4x3 Matrix Keypad, Constructed from Die Cut Velvet PolycarbonateKey Durameter 12 Oz Tri-Domes Standard

OPERATION:Min / Max Count 0000 to 9999 UnitsMax Count Rate 10Hz with a 50% Duty Cycle Pulse Train

LOGIC INPUTS:Quantity 7, HOLD, T-RST, B-RST, and (4) COUNTLogic Level 12VDC, Activated by Dry Contact or NPN OutputMaximum Input Current 30mA per InputLeakage Current Tolerance 3mA MaximumMinimum Detectable Pulse 0.050 Seconds Minimum On Time, 0.050 Seconds Minimum Off Time.

COMMUNICATIONS:Signaling Full Duplex RS-232, or Half Duplex RS-485Baud Rate 19200, 9600, 2400, 1200 switch selectableCharacter Format Eight Data Bits, No Parity, One Stop Bit

BACKUP MEMORY:Memory Size 512 BytesMinimum Retention 5 Days Without PowerCharge Time Backup Cap Charges to 96% within 60 Seconds of Applying Power

RELAY OUTPUTS:Quantity (2) 120VAC Silicon Relays, (2) DC NPN Transistor OutputsAC Relay Rating 120VAC at ½ Amp Resistive LoadDC Contact Rating 24VDC at ½ Amp Resistive Load

Page 46


8.0 Limited WarrantyWe warrant to you that your AMERICAN LED-gible® BRAND MARQUEE, when purchased by you, will be freefrom defects in material and workmanship, under normal use, for one year from date of delivery. If your LED-GIBLE® BRAND MARQUEE should prove to be defective within the warranty period, we will repair it (or, if we thinknecessary, replace it) without charge to you.

To obtain service, please call our Customer Service Department at 1-614-851-1100 or write to:

AMERICAN LED-gible® Inc.1776 LONE EAGLE STREETCOLUMBUS, OHIO 43228

We will furnish you with shipping instructions. This warranty covers merchandise returned to American LED-gible®

(shipped prepaid) for repair, not in plant repairs. Should you need an in plant repair at your facility, American LED-gible® will schedule a trip. Rates are per diem, plus travel expenses.

ALI shall have the right of final determination as to the existence and cause of the defect. This warranty expresslyexcludes any defects or damages caused by accessories, replacement parts, or repair service, other than thosewhich have been authorized by ALI. This warranty does not cover any damage caused by accident, misuse,shipment, or other than ordinary use.

This warranty excludes all incidental or consequential damages. Some states do not allow the exclusion of, orlimitation of, incidental or consequential damages, so the foregoing exclusion may not apply to you. This warrantygives you specific legal rights, and you may also have other rights, which vary from state to state. This warranty isin lieu of any other warranty, express, written, implied, or statutory, and no agreement extending or modifying it willbe binding upon ALI, unless in writing and signed by duly authorized officer.

If your AMERICAN LED-gible® MARQUEE is outside the warranty period, please call our Customer ServiceDepartment as above. After you return the unit to American LED-gible®, we will estimate the repair charges, andcontact you so a purchase order can be issued. Again, should you require in-house repair of your marquees, ALIrates are per diem, plus travel expenses. Please make sure to call, so a trip can be scheduled if this option ispreferred.

LIMITATION OF LIABILITY:

If this product is not in good working order as warranted above, your sole remedy shall be repair or replacementas provided above. In no event will ALI be liable for special, indirect, or consequential damages, or any damageswhatsoever resulting from loss of use, data, or profits arising out of, or in connection with this contract or the useor performance of ALI products, whether in an action of contract or tort, including negligence. ALI's liability fordamage to property shall be limited to the cost of the product sold to the buyer.

Page 47


9.0 ASCII ChartASCII

CHARACTERHexadecimal

CodeDecimal

CodeASCII

CHARACTERHexadecimal

CodeDecimal Code

CTRL-A 01h 1 ! 21h 33

CTRL-B 02h 2 “ 22h 34

CTRL-C 03h 3 # 23h 35

CTRL-D 04h 4 $ 24h 36

CTRL-E 05h 5 % 25h 37

CTRL-F 06h 6 & 26h 38

CTRL-G 07h 7 ' 27h 39

CTRL-H 08h 8 ( 28h 40

CTRL-I 09h 9 ) 29h 41

CTRL-J 0Ah 10 * 2Ah 42

CTRL-K 0Bh 11 + 2Bh 43

CTRL-L 0Ch 12 , 2Ch 44

CTRL-M 0Dh 13 - 2Dh 45

CTRL-N 0Eh 14 . 2Eh 46

CTRL-O 0Fh 15 / 2Fh 47

CTRL-P 10h 16 0 30h 48

CTRL-Q 11h 17 1 31h 49

CTRL-R 12h 18 2 32h 50

CTRL-S 13h 19 3 33h 51

CTRL-T 14h 20 4 34h 52

CTRL-U 15h 21 5 35h 53

CTRL-V 16h 22 6 36h 54

CTRL-W 17h 23 7 37h 55

CTRL-X 18h 24 8 38h 56

CTRL-Y 19h 25 9 39h 57

CTRL-Z 1Ah 26 : 3Ah 58

CTRL-[ 1Bh 27 ; 3Bh 59

CTRL-\ 1Ch 28 < 3Ch 60

CTRL-] 1Dh 29 = 3Dh 61

CTRL-^ 1Eh 30 > 3Eh 62

CTRL-_ 1Fh 31 ? 3Fh 63

SPACE 20h 32 @ 40h 64

Page 48


ASCIICHARACTER

HexadecimalCode

DecimalCode

ASCIICHARACTER

HexadecimalCode

Decimal Code

A 41h 65 a 61h 97

B 42h 66 b 62h 98

C 43h 67 c 63h 99

D 44h 68 d 64h 100

E 45h 69 e 65h 101

F 46h 70 f 66h 102

G 47h 71 g 67h 103

H 48h 72 h 68h 104

I 49h 73 i 69h 105

J 4Ah 74 j 6Ah 106

K 4Bh 75 k 6Bh 107

L 4Ch 76 l 6Ch 108

M 4Dh 77 m 6Dh 109

N 4Eh 78 n 6Eh 110

O 4Fh 79 o 6Fh 111

P 50h 80 p 70h 112

Q 51h 81 q 71h 113

R 52h 82 r 72h 114

S 53h 83 s 73h 115

T 54h 84 t 74h 116

U 55h 85 u 75h 117

V 56h 86 v 76h 118

W 57h 87 w 77h 119

X 58h 88 x 78h 120

Y 59h 89 y 79h 121

Z 5Ah 90 z 7Ah 122

[ 5Bh 91 { 7Bh 123

\ 5Ch 92 | 7Ch 124

] 5Dh 93 } 7Dh 125

^ 5Eh 94 ~ 7Eh 126

_ 5Fh 95 DELETE 7Fh 127

' 60h 96

Page 49


10.0 Connection Labels

Page 50

Typi

cal P

ower

Wiri

ng

Example Logic Input WiringOptional Customer Supplied Photo-Eye ShownMaximum Allowed Eye Power Draw is ½ Amp

*

*2 R

XD

3 T

XD

5 G

ND

Example PC WiringConnection to PCDB9 RS-232 PortIllustrated

HO

LDT-

RS

TB

-RS

TC

NT-

1C

NT-

2C

NT-

3C

NT-

4G

ND

GN

D12

VD

C

the production rate meter

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