Eaton Ambassador Counter Complete Guide

Eaton Durant Ambassador Series Counting Controller: The Intelligent Core of Industrial Counting

Product Overview

The Ambassador series counting controller is a powerful programmable counting device that offers a six bit master counter, a single preset batch counter, an eight bit accumulator, and a 1/Tau rate meter. Users can "assemble" counters into the required tools through programming according to application requirements.

1.1 Model Description

The Ambassador series offers multiple models to meet different power supply and application needs:

Model Power Display Special Features

57600-405 10-15 VDC Green Standard Type

57601-405 115 VAC Green Standard Type

57602-405 230 VAC Green Standard Type

57601-415 115 VAC Green Foot/Inch Control

57601-465 115 VAC Red Foot/Inch Control

All models have the following core functions:

Six digit main counter, configurable up to four preset values

Six digit single preset batch counter

8-bit bidirectional accumulator

1/Tau speedometer

Four users can configure control inputs

Two relay outputs

Two solid-state transistor outputs

RS-485 serial communication

Detailed explanation of core functions

2.1 Main Counter

The main counter is a six bit bidirectional counting register, represented by the letter C on the display screen. Users can assign up to four preset values to the main counter. It is the core of the entire controller, and all count pulses are scaled to increment or decrement the register.

The "preferred counting direction" of the main counter depends on the reset mode: it counts up in the "reset to zero" mode and counts down in the "reset to final preset" mode. This direction affects the counting input function, the counting direction of the accumulator, and the current preset selection. The main counting display screen can be customized to identify the type of unit being counted.

2.2 Accumulator

The accumulator is an eight bit bidirectional counting register that counts in parallel with the main counter. When the main counter counts in the preferred direction, the accumulator increments the count; When the main counter counts in a non preferred direction, the accumulator counts down. The accumulator displays customizable units, but does not have preset or output functions.

2.3 Batch Counter

Batch counters are used to count the number of "batches" in the main counter, increasing once each time the main counter automatically cycles or reaches the final preset. This register is six bits and can only count. The batch counter has a preset value and automatically loops whenever the set point is reached. Batch count displays customizable units.

2.4 Rate meter

The rate meter calculates the rate using the counting pulse frequency of input A. The rate scaler can compensate for the "weight" and time unit of each pulse to display the desired rate, such as revolutions per minute, barrels per hour, etc. The average time and zeroing time of the speedometer are programmable. Two alarm setpoints are assigned to the speedometer. The speed display text can be customized.

2.5 Output

Provide two C-type relay outputs and two collector open NPN transistor outputs. Each output can be individually assigned to either rate or count. The output based on counting can be turned on or off in any combination of eight preset and control events. These outputs can be timed or latched, and each has a programmable conduction delay timer. The rate based output is turned on based on a comparison with one of the two rate alarm setpoints. The rate output is turned off after timeout (pulse), external control signal (latch), or when the rate returns to a non alarm state beyond the set point (follow).

Hardware installation and wiring

3.1 Terminal Description

The Ambassador controller adopts pluggable screw terminals for easy wiring and disassembly. The terminal can accommodate wires ranging from 14 to 22 AWG.

Terminal Function Description

1+12 VDC output (AC model)/10-15 VDC input (DC model) AC model provides 12 VDC (± 25%, 100 mA max) to external devices; DC model connected to the positive pole of the power supply

Negative pole of internal DC power supply for 2,3,4 DC common terminal counter

5,6,7 Relays 2 Contact Type C Contact (NC, COM, NO)

8, 9, 10 relay 1 contact C-type contact (NC, COM, NO)

11,12 AC power input 115 VAC or 230 VAC

13,14 transistors output 2 and 1 NPN collector open circuit output, and when conducting, connect the DC common terminal

15, 16, 17, 18 control inputs 1-4 programmable inputs, require current absorption signal to DC common terminal

19,20 count inputs B and A can accept current absorption or current source signals, rate calculation only uses input A

21,22 RS-485 serial I/O positive (21) and negative (22)

3.2 DIP switch settings

There are four DIP switches at the bottom of the device for configuring counting inputs:

Switch 1: Input A source/absorption. OFF: Requires current to absorb input signal; ON: A current source input signal is required.

Switch 2: Input B source/absorption. OFF: Requires current to absorb input signal; ON: A current source input signal is required.

Switch 3: Input A threshold level. OFF: High threshold level (for DC sensors); ON: Low threshold level (used for magnetic sensors, switch 1 needs to be turned on at the same time).

Switch 4: Input B threshold level. OFF: High threshold level (for DC sensors); ON: Low threshold level (used for magnetic sensors, switch 2 needs to be turned on at the same time).

3.3 General wiring specifications

Power off operation: All power sources must be disconnected before wiring.

Use shielded cables: for counting signals, controlling inputs, and communication signals. Connect the shielding layer to the common terminal of the counter (terminals 2, 3, or 4).

The signal line should be as short as possible.

Separate laying: Do not bundle signal lines with power lines or machine control lines in the same cable tray. Use a separate catheter.

Provide a "clean" power supply: Use a power filter or separate power supply if necessary, and do not share the same power supply with the load.

AC power cord: Use 18 AWG (minimum) to 14 AWG (maximum), 600V wire.

3.4 Panel Installation

The panel installation kit includes: 1 mounting washer, 2 mounting clips, and 4 screws. The installation steps are as follows:

Place the counter display screen facing downwards.

Remove the center block of the gasket along the scratch line and keep the outer paper back.

Slide the gasket to the back of the front frame of the device, with the paper back facing upwards.

Pry open the paper back and washer with the tip of the knife, while holding down the washer and tearing off the paper back.

Push the device into the panel opening until the gasket firmly adheres to the panel.

Install the clamps and screws, do not tighten them too tightly to avoid squeezing the washers.

Panel opening size: 2.68 "x 2.68" (68mm x 68mm). NEMA 4 protection level requires the use of the provided gasket.

Programming mode

4.1 Programming Mode Navigation

All programming is completed through the front panel keyboard. After entering programming mode, the display screen shows the main menu item PROGRAMM SCALERS. Use the up/down arrow keys to scroll through the main menu, and use the SELECT and EXIT keys to enter or exit submenus and editing layers.

Attention: Entering programming mode will cause all outputs to shut down. It is necessary to stop the process before entering programming mode.

4.2 Main menu structure

The programming menu of Ambassador is divided into the following main parts:

PROGRAMM SCALERS: Scaling Factor Settings

Program COUNT IN: Count Input Configuration

Program INPUTS: Control input function allocation

Program OUT MODE: Output Mode Configuration

Program Display: Screen Selection for Running Mode Display

Program Text: Customize Display Text

Program SER PORT: Serial Port Configuration

Program SER OUT: Serial Output Content Selection

Program Options: Other options (reset key function, print key function, load default values, etc.)

4.3 Key Programming Options

4.3.1 Scalers

Counting scaling factor (C SCALER): determines the count value of each input pulse. The range is 0.00001 to 9.99999, with a default of 1.00000. Calculation formula: CS=DPF/PPI, where DPF is the decimal factor (depending on the decimal place) and PPI is the number of pulses per term.

Counting decimal point (C DEC PT): Set the decimal point for the main counter and accumulator.

Rate scaling factor (R SCALER): used to adjust the reading of the rate meter. Range 0.00001 to 99999, default 1.0000. Calculation formula: RS=(SEC x DPF)/PPI, where SEC is the number of seconds corresponding to the rate time unit (e.g. 60 per minute).

Rate decimal point (R DEC PT): Set the decimal point for rate display.

ZERO TIME: If there are no pulses within this time, the speedometer is forced to zero.

Rate Average Time (R AVG TIME): Set the minimum rate update time.

4.3.2 Counting input mode

Program item 10 selects counting mode, with a total of 11 options available, such as:

CNT&TOT A-B: Input A to increment the main counter and accumulator, input B to decrement them.

CNT&TOT A+B: Both inputs A and B cause the main counter and accumulator to count up.

CNT&TOT QUAD X1/X2/X4: Orthogonal encoder counting mode, counting 1, 2, or 4 times per cycle.

TOT A CNT B: Input A counts the accumulator, input B counts the main counter.

The response speed of inputs A and B can be set to solid-state (high speed) or contact (≤ 40 Hz), respectively.

4.3.3 Control input function

The four control inputs can be assigned the following functions (taking input 1 as an example, inputs 2-4 are the same):

Disabled: Disabled

BYP P1: When input 1 is turned on, the counter ignores the preset 1

OUT CTL1/2: When input 1 is turned on, trigger output control 1/2 event

RS C EDG/LVL: edge/level triggered main counter reset

RS B EDG: Edge triggered batch counter reset

RS T EDG: Edge triggered accumulator reset

RS A EDG: Edge triggered reset of all counters

STOP CNT: Level triggered stop counting

PRIMT: Edge triggered serial output list transmission

LOCK PGM: Level triggering prohibits program editing

LOCK ALL: Level triggering prohibits all programming and preset editing

UNL ALMS: Level triggered shutdown of all rate outputs

4.3.4 Output Configuration

Each output (relay 1, relay 2, transistor 1, transistor 2) can be individually configured:

Choose based on count or rate:

Count output: Acting at preset values and/or specific events (such as reset count, output control input).

Rate output: Act when the rate reaches the set point A1 or A2.

Output operation mode:

NORMAL: Connected when receiving a pick up signal, disconnected when receiving a release signal.

REVERSE: opposite to NORMAL.

LATCHED: When receiving a pick up signal, turn on and hold until receiving a release signal.

PULSED: It is turned on when receiving a pick up signal and automatically disconnected after the programmed pulse time.

Conduction delay time: A delay of 0.00 to 99.99 seconds can be set.

Preset event actions: For count outputs, no action (NA), pick up (PU), or release (DO) can be selected for each preset (P1-P4), batch preset (PB), output control event (OCTL1/2), and reset count event (RS C).

Rate alarm action: For rate output, A1 HI, A1 LO, A2 HI, A2 LO can be selected, as well as output continuous mode (Disabled, FOLLOW, LATCHED, PULSED).

4.3.5 Display Screen Selection

There are a total of 16 operating modes to display the screen, each screen can be set to show (SHOW) or hide (HIDE). If all screens are set to hidden, CNT&TXT screens will automatically display. The available screens include:

CNT&TXT (Main Count+Text)

RATE&TXT (Rate+Text)

BCH&TXT (Batch Count+Text)

TOT&TXT (accumulator+text)

CNT&Pc (main count+current preset)

CNT&P1/P2/P3/P4 (main count+preset 1/2/3/4)

BCH&Pb (Batch Count+Batch Preset)

CNT&RATE (Main Count+Rate)

RATE&A1/A2 (Rate+Alarm Setpoint 1/2)

C SCALER (Counting scaling factor)

C DEC PT (counting decimal points)

4.3.6 Custom Text

Customizable display text of up to 8 characters for main count, rate, batch count, and accumulator, with options including letters A-Z, numbers 0-9, spaces, commas, dashes, decimal points, or slashes.

4.3.7 Serial Communication Configuration

ID Number: Assign a unique two digit ID (00-99) to each counter.

Baud rate: selectable from 300, 1200, 2400, 4800, 9600, or 19200.

Parity check: None, Odd check, Even check.

Transmission delay: 2 ms or 100 ms.

Host/printer mode: Select HOST PORT (respond to host commands) or PRINTER PORT (transfer when printing input).

4.3.8 Serial Output List

You can choose which data to send when printing input or host commands: count, batch count, accumulator, rate, etc P1-P4、PB、A1、A2、C SCALER、C DEC PT。

4.3.9 Other Options

Reset button function: It can be disabled or set to edge/level reset main counter, batch counter, accumulator, display counter, or all counters.

Printing key function: enabled or disabled.

Load default values: You can load default programs separately (restoring all program items to factory settings) and default running data (resetting all counters and presets to zero).

Foot/inch control special function

Models 57601-415 (green display) and 57601-465 (red display) are designed specifically for foot/inch applications and have the following features:

5.1 Main counter display

The main counter displays six digits: the first four digits show feet, the last two digits show inches, and the middle is separated by a fixed decimal point. Internal counting is measured in inches and converted to display in feet and inches. The counter overflows to zero at 120000 counts and overflows to 119999 at 0.

5.2 Counting Presets

The preset values are also entered in feet and inches, with a range of 0000-9999 feet and 00-11 inches. Programmable presets include P1, P2, P3, and warning alerts (Pw). There is a fixed zero preset used to reset to the preset number mode and reset to the overload value of zero mode, which cannot be changed.

The warning value must not exceed the final preset (Pf). The final preset can be P1, P2, or P3. The preset values do not need to be arranged in numerical order, and different presets can be set to the same value.

5.3 Rate meter

The foot/inch model does not have a speedometer function, so there is no speed alarm.

5.4 Counting scaling factor

The scaling factor value must be the number of inches represented by each pulse. For example, when using a 300 PPR encoder and a 12 inch circumference measuring wheel, the scaling factor is 12/300=0.0400.

5.5 Pre warning Tracking

The warning value will automatically track the final preset value. When a new final preset is entered, the warning value will change at the same interval. For example, if the warning is set to 10.00 and the final preset is set to 250.00, the warning will occur at 240.00. If the final preset is changed to 300.00, the warning will automatically change to occur at 290.00.

5.6 Error messages

When the warning value is greater than the final preset value, an error message "ERROR Pw>Pf" will be displayed.

Operation mode

6.1 Operation Mode Navigation

In operation mode, the operator can use the up/down arrow keys to scroll through all screens set to "display". Press the SELECT key to edit the preset value currently displayed (if allowed). When editing presets, use the SELECT key to move the flashing digits, use the up/down arrow keys to change the values, and press the ENTER key to save.

6.2 Reset Counter

According to the setting of program option 80, the operator can reset the counter using the RST/CLR keys. Note: The availability of the reset function depends on the programming configuration.

6.3 Printing Data Transmission

If the print key is enabled (program item 81), the operator can press the PRIMT key to trigger the transmission of the serial output list.

Fault diagnosis and self inspection

7.1 Self checking program

Every time the power is turned on, the counter will perform a series of self checks. If a problem is detected, it will display 'ERROR X', where X is the test number. All outputs will remain closed. The serial command will return 'N' followed by the failed test number.

Test instructions:

0-ROM test: Check the read-only memory that stores operating programs.

1- Internal RAM Test: Check the read-write memory inside the microprocessor.

2- Non volatile RAM Test # 1: Check NOVRAM for storing non running/non program data.

3- Non volatile RAM Test # 2: Check the NOVRAM (counting and preset values) that stores operational data.

4- Non volatile RAM Test # 3: Check the NOVRAM storing user programs.

5- External RAM Test: Check the external read-write memory used for normal operation and communication.

7.2 Fault Handling Methods

Immediately stop the machine or process controlled by the counter and record the error number.

If ERROR 0, 1, 2, or 5 is displayed, disconnect and reconnect the power, and run the self-test again.

If ERROR 3 is displayed, press the reset button on the front panel. This sets all counters and preset values to zero and re runs all tests.

If ERROR 4 is displayed, press the reset button on the front panel. This will reset all user programmable options to factory default settings and rerun all tests.

If the same error occurs again, the counter is internally faulty and needs to be returned to the factory for repair.

After recovering from ERROR 3, all preset values must be reprogrammed.

After recovering from ERROR 4, all program options must be reprogrammed.

7.3 Common Troubleshooting

I. Display screen blank:

Check if the power wiring is correct and measure the power input terminal with a voltmeter.

Disconnect and reconnect the power supply. If it returns to normal, check the cause: electrical noise spikes generated by external electromagnetic coils (installing R-C suppressors) or electrical noise in the power supply (using power filters).

II. Counter does not count:

Check if the counting scaling factor is correct, it can be temporarily set to 1.00000 for testing.

Test using manual counting source:

Disconnect all wires from terminals 19 and 20.

Set all DIP switches to OFF.

Reset all program parameters to factory default settings.

Use jumper wires to connect and disconnect between terminals 4 and 20. The main counter and accumulator should count each time they are turned on.

Use jumper wires to connect and disconnect between terminals 4 and 19. The main counter and accumulator should count down each time they are turned on.

If the manual counting is normal, reconnect the sensor and set the correct DIP switch.

III. Other questions:

Most other issues are caused by programming and/or wiring errors. Suggest following these steps to troubleshoot:

Accurately define the problem and its occurrence conditions.

Use block diagrams and programming menu diagrams to identify relevant program options or parameters and check their settings.

Identify the relevant I/O circuits and check their operation on the terminal block using a voltmeter.

Technical specifications

8.1 General specifications

Parameter specifications

Power supply AC model: 115 VAC (± 15%) or 230 VAC (± 15%), 50-60 Hz, 7W; DC model: 10-15 VDC, 300 mA

DC power output 12 VDC (± 25%), 100 mA max

Working temperature 60 Hz power supply: 0 to 55 ° C; 50 Hz power supply: 0 to 50 ° C

Storage temperature -20 to 70 ° C

Working humidity 85% relative humidity, no condensation

Protection level NEMA 4 (when installed with the provided gasket)

Shell size 67mm W × 67mm H × 142mm D

Panel opening 68mm × 68mm

Display 2 lines x 8 characters, 0.30 "high, green backlit LCD or reflective red LCD

8.2 Input specifications

Counting input:

Absorption mode: impedance 4.6k Ω connected to+5V, high level 3.5-34.0V, low level 0.0-1.9V

Source mode (high): impedance 2.3k Ω connected to the common terminal, high level 3.5-17.0V, low level 0.0-1.9V

Source mode (low): Impedance 2.3k Ω connected to the common terminal, high level 0.6-17.0V, low level -17.0 to -0.6V

AC voltage: maximum 17 VAC (48V peak to peak)

Control input:

Impedance: 4.7k Ω connected to+5V

Voltage: High level+3.7 to+24V, low level 0.0 to 0.9V

Response time: minimum low level 15 ms, minimum high level 15 ms

8.3 Output specifications

Relay outputs (2):

Type: SPDT contact

UL rating: 250 VAC, 360 VA pilot duty

Transistor output (2):

Type: NPN collector open circuit, with transient protection

Maximum voltage (off state): 30 VDC

Maximum current (conducting state): 200 mA @ 1.3 VDC

8.4 Communication specifications

Type: RS-485

Format: 1 start bit, 7 data bits, 1 parity bit, 1 stop bit

Protocol: Opto-22 compatible

Speed: 300, 1200, 2400, 4800, 9600, 19200 baud

Parity check: odd, even, none

8.5 Speed Meter Specifications (Non Foot/Inch Models)

Type: 1/Tau

Number of digits displayed: 6

Preset: 2

Scale factor range: 0.00001 to 99999

Decimal point: 5 positions programmable

Accuracy: ± 0.015% of reading

Update time: 0.1 to 99.9 seconds

Zeroing time: 0.1 to 999.9 seconds

Accessories and Accessories

The Ambassador series offers a wide range of accessories to meet various application needs:

Installation accessories:

Panel installation washers, installation clips, screws

Desktop installation kit (48183-401)

Communication attachments:

RS-485 to RS-232 converter (58801-460/461)

RS-485 Interconnection Kit (38145-400)

RS-485 cable (38146 xxxx)

ProFile configuration software (57624-450)

Signal conditioning accessories:

Input signal conditioner (48160-400)

Timer module (48160-440)

Analog to frequency converter (48160-45x)

Simultaneous input processor (49990-4xx)

RC Surge Suppressor (38091-400)

Solid state I/O module (36059-45x)

Sensors and encoders:

Medium/heavy-duty shaft encoder (38150/38151/48370/48371)

Rotating contact point (ES9513-RS)

Zero speed blade sensor (39400-400)

Magnetic Sensor (47004-400)

30 tooth gear (28433-400)