M4500 Product Line

M4500 High Performance Controller

The M4500 product line is a modular design consisting of a high performance Programmable Logic Controller (PLC) chassis, designed for high speed industrial process controls to enhance the performance of machine control applications. The architecture can be configured to handle critical control requirements for a wide variety of small to medium range high speed production applications. It's small form factor and rugged construction makes it a cost effective and reliable solution for system upgrades as well as for OEMs on new and rebuilt equipment.

The M4500 requires a minimum of control cabinet space and versions are available for either door or back-panel mounting in NEMA 12 class cabinets. Modular packaging utilizing removable field wiring arms provides for convenient initial installation, reconfiguration of I/O, as well as easy field maintenance.

Common Features of the M4500:
  • High performance Programmable Logic Controller (PLC).
  • Modular form factor allows user configurable I/O with 16 and 32 point DC inputs, 16 point DC outputs, Analog I/O, communication, and motion control boards.
  • Optional display/keypad with 2 line X 40 character back-lit LCD display and 24 key keypad or touchscreen HMI for operator interface.
  • 32K bytes battery-backed CMOS RAM user program memory and 8K bytes data memory.
  • High performance: 0.25 msec per 1K typical scan time with throughputs as low as 80 microseconds. Resolver PLS tracking rates up to 6,000 RPM.
  • Programmed with SYSdev Program Development software which allows programming in ladder, high-level ("C"), and assembly.
  • RS-232 serial communication for program upload/download, on-line monitoring and PLS timing channel set-point programming.
  • Two additional 10-30VDC differential digital interrupt inputs.
  • Two 0-5 volt 10-bit analog inputs and two 0-10 volt 8-bit analog outputs.
  • Optional integrated Programmable Limit Switch (PLS) with interface to machine mounted resolver.
  • The PLS section incorporates:
    • 8, 16, 32, or 64 timing channels
    • Programmable scale factor (2 to 4096)
    • Up to 8 PLS programs (dependant on number of timing channels)
    • Speed compensation on timing channels CH00 to CH07
For more information, download: The M4500 Data Sheet

Flexible System Architecture

The M4500 is a high performance Programmable Logic Controller (PLC) with an optional built-in high performance Programmable Limit Switch (PLS) with advanced features that interfaces with a rugged machine mounted resolver. Discrete DC input and output boards, Analog I/O boards, plus communication and motion control boards allow the user to configure the system to the I/O requirements of the machine. A display/keypad is available to allow monitoring of production data as well as adjusting set-up parameters. The specific control algorithm is accomplished through the use of SYSdev, a unique program development software. This flexibility allows the user to tailor a high performance critical function controller without having to resort to a black box solution.

Efficient CPU and Program Structure

The M4500 is a compiler based system utilizing advanced Intel MCS-96 microcontrollers. These CPUs provide fast logic solve times to provide sub-millisecond throughputs. SYSdev is an integrated software tool which is used to program the PLC, PLS, display/keypad, communication, and motion control processors. The SYSdev programming language allows PLC program files to be written in blocks of ladder, high-level (subset of "C";), and assembly.

The program structure of the M4500 provides a user adjustable timed interrupt to implement critical function control as well as user functions (subroutines) to implement complex tasks. A library containing a wide variety of pre-written user functions is available which enables enhanced features of the M4500. Drivers are available to implement MODBUS and Allen-Bradley DF1 communication protocols. Comprehensive fault detection and hardware confidence test routines are embedded as well.

General System Features

The M4500 requires a minimum of control cabinet space and versions are available for either door or back-panel mounting in NEMA 12 class cabinets. Modular packaging utilizing removable field wiring arms provides for convenient initial installation, reconfiguration of I/O, as well as easy field maintenance.

Common Features:

  • High performance Programmable Logic Controller (PLC)
    • 32K battery backed CMOS RAM
      (user program memory)
    • 8K data memory
    • 0.25 msec per 1K (typical scan time)
    • Throughputs as low as 80 microseconds
    • Resolver PLS tracking rates up to 6000 RPM
    • Two 10-30VDC digital interrupt inputs
    • Two 0-5 volt 10-bit analog inputs
    • Two 0-10 volt 8-bit analog outputs
    • Interface though RS-232 serial COM port

  • Integrated Programmable Limit Switch (PLS)
    • Configurable 6, 16, 32 or 64 timing channels
      (speed compensation for CH00 - CH08)
    • Programmable scale factor (2 to 4096)
    • 8 PLS programs available

  • Modular form factor user configurable I/O:
    • 16 and 32 point DC inputs
    • 16 point DC outputs
    • Analog I/O
    • Communication
    • Motion Control

  • Operator Interface
    • 2 line X 40 character back-lit LCD display with 24 key keypad
    • HMI touchscreen display

  • Programmed with SYSdev Program Development Software
    (DOS or Windows 32-bit operating systems)
    PLS configuration and timing channel setpoint
    Programmed in a combination of:
    • Ladder
    • High-level (subset of 'C')
    • Assembly

System Configurations

The M4500 can be configured for a specific application as either a PLC, PLS, PLC /PLS, or PLC/PLS/Motion Controller. The basic configuration consists of a PLC CPU mounted in either a 3, 4, 8, or 12 slot chassis together with an integrated or separate power supply. Using 32-point inputs and 16-point outputs, this allows local control of up to 320 I/O points. Using the optional communications board, up to 32 M4500 modules can be networked together.

The CPU contains built-in I/O including two digital interrupt inputs, two analog inputs, two analog outputs and a parallel interface for the optional display/keypad. The PLS section, which is fully integrated into the CPU, can be set for either 8, 16, 32 or 64 timing channels with a scale factor up to 4096. The motion control features allow multiple axis servo motion control using either resolver or encoder feedback. Versions for either door mounting or back-panel mounting are available.

Beyond the common features, different versions of the M4500 have various configurations of I/O slots, optional integrated Programmable Limit Switch (PLS), display/keypad, power supply and mounting methods. Ten versions are available:

  • M4500: 4-I/O slot PLC/PLS
  • M4501: 4-I/O slot PLC
  • M4502: 3-I/O slot PLC w/ Integrated Keypad/Display
  • M4503: 3-I/O slot PLC/PLS w/ Integrated Keypad/Display
  • M4508: 8-I/O slot PLC/PLS
  • M4509: 8-I/O slot PLC
  • M4510: 8-I/O slot PLC/PLS/Motion Controller
  • M4512: 12-I/O slot PLC/PLS/Motion Controller
  • M4513: 12-I/O slot PLC
  • M4530: 8-I/O slot PLC/PLS/PMT Interface