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USER`S MANUAL - Motorsystems Repair

1. CHAPTER 1 SYSTEM DESCRIPTION Lv8ve v 3nssl dud d SISISISISISISISISISISISSISISIS S lt So 8 F seo z o em e ole io 000000 m e es gx p e O LLI o lt 2 Wakaq gt 5 SslsisissssssIssissssis 9 2 190 lt O wi Zo gt O On 858 eS O p 2111918 5122 dp le Oo qw 5 lt LLI De a fs gt lt x gt lt O n I is I Bt OKO 2 z CN CO aw olla 6999 Ere 6 5 i E E ag 4 4 5 4 8 2 LLI D T 8 8 LO H H 8 T 82 I C E fi ES amp 0 TIP TESI TOTOE EERE e tc LLI lt LLI E a O 2 0 A 2 lt gt lt gt LLI oO H lt r MJ O 30551 Lv8ve v Oo 1 16 BDS5 2 STARTED CHAPTER 2 STARTED 2 1 INTRODUCTION information this chapter will enable you to get started with programming the BDS5 Computer requirements and software installation prepare you for Motion Link the Industrial Drives software pa
2. VELOCITY One x4 VXNUM c lt DECODE _ PXDEN _ OPTI position PXNUM GEARI C ANALOG GEARO ty SER 2 BER j PCMD pu MOTION PROFILE GENERATION PROFILE REGULATION C 1 DIGITAL VELOCITY VXDEN _ On ya 10 VXNUM gt c DECODE ND POE 1 POSITION PXNUM 1 C ANALOG REGKHZ 2 MOTION I PROFILE COMMAND GENERATION 7 PCMD ELECTRONIC CAM C 1 DIGITAL VELOCITY VXDEN xb x4 L VXNUM c DECODE _ PXDEN _ OPT position PXNUM GEARI GEARO Y VOFF 2 N zi PCMD x J CAM 7 N pet TABLE Set ratio for X100 BDS5 MASTER SLAVE 360 of Master i23 32768 counts Wim Agggg s TESTING A simple test program was written This test performs the following task 1 Loads X100 X227 with a triangle wave where x100 0 x101 100 x102 200 The mid point of the triangle wave is X164 so that X163 6300 X164 6400 X165 6300 X166 6200 Lines 14 24 2 Enable the BDS5 and enable camming Lines 28 32 3 Use VOFF to move PCMD through the cam cycle VOFF is usually used with the gearboxto add an offset speed It was designed for use with analog input where a customer may need to add an offset speed to adjust out er
3. gt EDITORCHANGE Every prompt is preceded by a lt gt lt 1 gt IL 7 PROGRAM UPLOAD gt s gt t 1 gt gt 1 gt f c gt The 5 will print a prompt to the serial port whenever it is ready to receive a character The BDS5 will echo each character transmitted to it The BDS5 will never print data to the serial port while a prompt or input statement is active This means that if an error occurred the BDS5 would hold the error message if a prompt was present or if an input statement was active error messages respond with the first three characters of ERR The BDS5 can be programmed in the user program to print out data with the PRINT statement and the background BACKGROUNDS routine can be programmed to print out data on an asynchronous interval with the PRINT statement The BDS5 can be programmed to enter an autobaud sequence on power up or can be programmed to a fixed baud rate on power up By setting ABAUD 1 the BDS5 will autobaud on power up After autobauding the variable BAUD will contain the current baud rate The 5 can also be set to automatically power up at a fixed baud rate By setting ABAUD 0 and BAUD 9600 the BDSD5 would power up at 9600 baud The BDS5 can be reset to it s default serial conditions Autobaud by holding the MOTION input off during power up This allows communications to be reestablished it au inco
4. 3 1 223 Re 3 1 3 31 Variable 3 2 3 3 2 Three Types of Variables 3 2 3 3 3 Variable Limits 3 2 9 34 Switches oreet 3 2 3 3 5 Printing Variables sss 3 2 3 3 6 Changing a Variable 3 3 3 3 7 Programming Conditions 3 3 3 3 8 Power up and Control Variables 3 3 3 3 9 Initial Settings of Control and User Variables 3 4 3 3 10 User Variables 3 7 3 3 10 1 Indirect User Variables 3 7 Switches n cete erret 3 8 3 3 12 Special 3 8 34 Math dele 3 8 3 4 1 Hexadecimal u 3 8 3 4 2 Algebraic Functions 3 10 3 4 3 Logical Functions AND OR 3 9 3 5 General Purpose Input Output 3 10 3 5 1 Whole Word I O 3 10 3 6 Fault LO S16 3 11 3 6 1 Firmware Faults Area 1 3 13 3 6 2 Fault Logic Area 2 3 13 3 6 3 Fault Latch Area 3 3 13 3 6 4 Ready L
5. 2 1 Software Installation 2 1 R D BASED MOVE MRD Command 3 26 Backing Up the Disk s 2 1 Establishing Communications 2 3 Converter T3 26 p Software Installation sees 2 2 R D Position PRD 3 15 Software Installation 2 2 Ready Latch Area 4 3 13 Install on a Floppy 2 2 RECORD and PLAY 6 6 Install on a Hard Disk 2 2 Reducing ILIM eR UR 6 3 Software Travel Limits PMAX REFRESH R amp RS Commands 4 20 amp PMIN j 3 20 REG amp REGKHZ see 3 35 qe eg NEM AMAN 3 8 3 29 pecial Constants ec Lente Diete eie 1 8 Index vi INDEX BDS5 Specifications and Ratings 1 8 U _ Speeding Up Homing Sequences 3 26 Standard 15 T3 2 STOP S 3 19 22 STOP BREAK with Ta AMPID E E I D Control X 3 19 Dis ooo OSA ieu E 2 Machi
6. 3 14 Idling 4 25 Position 3 38 Main Program Level Task Level 5 4 29 Position Rotary Mode ROTARY amp awanu 4 23 PROTA R Y ss eere 4 37 Multitasking and Autobauding 4 23 Choosing PROTARY PNUM Variable Input Task Level 4 4 27 and PDEN ui eei 4 37 Multi Tasking Debug Prompts T5 3 Rotary Mode and Absolute Moves 4 38 Multi Tasking Overview 2 2222 2 21 T4 24 Post Execution Idle sss 4 26 Multidrop Communications 4 40 Power up and Control Variables 3 3 Bro dcast eee 4 41 Power Up Control Loops 3 39 Multiple JF JT Commands 3 30 Power Up Routine POWER UP3 4 29 Multiple Profile Commands 3 23 Power Up State of Programmable Units T3 4 Multitasking and Autobauding 4 23 PRD Ranges and Resolutions T3 15 Pre Execution Idle sss 4 25 N _ PRINT B aasan aan 4 17 Cursor Addressing sess 4 19 Nesting Commands 2 4 12 e 2 2 Nesting IF commands 2 2222 4 15 Bi a s JUR SU 4 18 NEW
7. 3 32 BDSS Enable Fault Logic Diagram F3 12 and PDEN eee 4 37 BDSS Instruction Screen F2 3 Application Flowchart a 4 3 BDS5 Master Slaving 40041 11 F3 34 Application Specification 4 3 BDS5 Model Number 1 4 Auto Routine AUTO9 9 aa aaa 4 29 BDS5 Model Number 5 1 4 Auto Manual Flowchart F4 31 BDS5 Model Number 5 TI 4 Auto aud mp arces ra 4 38 55 Prompts 4 44 49 T2 10 Autobauding and MOTION 4 38 BDS5 Prompts ene enm T4 41 Baud Rate 4 39 BD55 Resident Editor sss 4 7 Enabling Autobaud with ABAUD 4 38 CHANGE 1C iiie 4 8 Setting the BDS5 to Autobaud 4 38 DELETE DEL eee 4 9 Autobauding and MOTION eee 4 38 Editor Print D 4 7 Avoiding Hlling PC Ute 4 26 FIND 4 8 INSERT D epe ERE 4 8 NEW sassa e URS 4 9 Next Line teet 4 7 Password PASS 4 7 Background Task Level 6 4 30 Size MH 4 9 Restricti
8. 3 9 MCA MCI MCD amp 3 24 JOG J Coitimatid zs coo nnde 3 23 o e enus and Windows 2 4 Jog From JF F3 28 Capture y 2 5 JOG TO JT amp JOG FROM JP 3 28 Hel 2 6 Changing Profiles During Motion A3 30 Options iere rre ed eh 2 5 MUTET 2741 a 2 4 Registration A3 29 Sope 2 5 E 3 29 00 tilities is oen B ed 2 6 POSTS RED OBAMA iiio rst tese 5228 2 4 Metric Conversion 12 bit K R D ORIS T4 35 Molex Assembly Tools 1 7 L Monitor Mode 2 12 Monitor Mode Commands T2 12 Monitoring Current Limits 3 18 Labels E SA COH 4 10 Motion Commands ccccccccccccccccccccccccceccccecece 3 18 Limiting Motion serere nennen nennen 3 19 Basic Motion Commands 3 18 Hardware Travel Limits 3 19 Capturing Position 3 26 Software Travel Limits PMAX GUE ris i it eee ec eee enon PIT CORON 3 27 seen 3 20 CONTINUE 3 37 User Position Trip Points PTRIPI Electro
9. 4 17 Printing Switches a 4 18 ae Printing 3 2 Part Number 1 3 Printing with Alarms 4 27 BDS5 Model Number 1 4 Problems6 6 Compensation Module Model Number 1 5 Compliance 2 6 7 ER External Resistor Kit Model Number 1 7 Low Pass Filters 6 7 Molex Assembly 18 4 2 1 7 Non Linear Mechanics sese 6 7 PSR4 5 Model Number a 1 6 Overloading the Motor sss 6 6 Password PASS 457 Resonance scaena re red 6 7 BDS5 INDEX Processor Modes eoe Rem 2 9 Registration Example sse 3 29 Descriptions of Modes 2 10 Regulation Example esses 3 36 Sena 2 9 Regulation Timer 2 4 44 222 1 5 4 Product Description a 1 1 Relay and STATUS Control Area 6 3 13 Profile Final Position PFNL 3 23 Removing Code eee 5 3 Profile Limits eco 3 22 Resonate 6 7 Profile Regulation eee 3 35 Restrictions of Alarms esee 4 27 Profile Regulation and Counting Restrictions of Background 4 32 Backwar
10. 2 11 3 1 BDS5 Enable Fault Logic Diagram 3 12 32 A Smple Protile 3 20 3 3 S Curve Profile eene 3 21 3 4 Macro Move Example 1 3 25 FIGURE PAGE 3 5 Macro Move Example 2 3 25 3 6 Jog From JF Command 3 28 3 7 Jog To JT Command 3 29 3 8 BDS5 Master Slaving 3 34 3 9 BDS5 Control Modes 3 40 4 1 Sample Flowchart 4 4 4 2 Auto Manual Flowchart 4 31 4 3 Master Slave Block Diagram 4 34 6 1 Critical Damping see 6 2 6 2 Underdamping eee 6 2 6 3 Overdamping sese 6 2 64 Ringing ii neenon r 6 2 LIST OF TABLES BDS5 LIST OF TABLES TABLE PAGE TABLE PAGE 1 1 BDS5 Model Number Scheme 1 4 4 4 Printing BDS5 Status 4 20 1 2 PSRA 5 Model Number Scheme 1 6 4 5 Multi Tasking Overview 4 24 1 3 External Regen Resistor Model 4 6 How to Enable Multi Tasking 4 25 Number Scheme eee 1 7 4 7 How to Disable Multitasking 4 25 1 4 Specifications
11. 3 17 IF ELIF ELSE and ENDIF ia Soins 3 14 2 22 4 13 Velocity ic hehe 3 15 Nesting Commands 4 12 DWELL D 4 22 Nesting IF commands 4 15 Quick IF 4 11 E TIL Command a 4 12 CONTINUE depen 3 37 Continuous Current 3 17 bd ais Sel piers atin nie i INS KR CONTROL I BDS5 Resident Editor 4 7 Position Loop eee 3 38 Motion Link Editor sess 4 6 Power Up Control Loops 3 39 T Editor se a aus E a 2 7 orque Command eee 3 39 Suc 2 8 Velocity Lo0p encoded 3 38 i Edit Seno eie died 2 7 Controlling the Velocity Loop Files asas i sasi 2 7 with PROP annans eean iaa 3 16 i GOTO 7 aint ee a hee 2 8 Critical Damping esee 6 2 5E 2 8 Critical Damping niies et F6 2 Insert Delete Jahn none tunay 2 8 ede eee Reid 3 16 Editor Print P 47 Current Limits IMAX amp 3 16 E E RO EHE eere NE 5 Motor Current ICMD amp IMON
12. LED LATCH ACTIVE SOFTWARE RESET READY SWITCH MEUS EN SOFTWARE COMMAND SWITCH ACTIVE LED DIS COMMAND SYS OK LED T COMMAND HARDWARE __ HALT MICROPROCESSOR WATCHDOG C2 PIN 17 RELAY __ C2 PIN 16 REMOTE INPUT eines saav 1 cu LED eed OPTICAL SWITCH C2 PIN6 ISOLATION 71 __ gt STATUS OUTPUT OPTIONAL oo 8 35 STATMODE SOFTWARE SWITCH Figure 3 1 BDS5 Enable Fault Logic Diagram 3 12 BDS5 3 6 1 Firmware Faults Area 1 Area 1 shows how firmware faults are combined Firmware faults are the most serious errors They include checksums to help verify computer memory watchdogs to help verify that the computer is running properly and the 5 volt logic power supply monitor These circuits are designed to watch the basic operation of the microprocessor They do not generate error messages because the detected fault affects the microprocessor directly Instead they Just blink the Central Processing Unit CPU LED As shown in Figure 3 1 firmware faults set a latch to turn off communications and blink the CPU LED The CPU LED blinks in cycles consisting of 2 to 8 blinks and a pause The number of blinks corresponds to the error number which you can look up in Appendix D The only way to reset these faults is to power down the BDS5 These faults are serious and you should consult the factory if they occur Do no
13. 2 12 Changing Profiles During Motion 3 30 Other Mog6S oi eH 2 13 Choosing PROTARY PNUM Rumi Mode ur 2 12 nie iain 4 37 Single Step Mode 2 12 Clamping 3 27 Trace Mode 2 12 Clamping and Homing 3 27 Desired Operation of Program Clamping and Homing eee 3 27 Example eset Hiei a T4 14 Commented 4 5 Direction Control DIR 3 14 Comments nnne RE E ES Eeri ie 3 1 Displaying Error Messages 5 9 Common User Unit ts esse T4 32 Drive Control sse eoe ies E 3 14 Compensation Model Number Scheme F1 5 Controlling the Velocity Loop Compensation Module Model Number 1 5 With PROP 2 epe RES 3 16 Compliance n nme 6 7 Current 3 16 Computer Requirements eese 2 1 Direction Control DIR 3 14 Conditional Commands 4 11 Enabling the 55 2222 2 2 3 16 anna ne RR RR E 4 14 Enabling the Position Loop with PL 3 16 IF s with GOTO and GOSUB 4 15 Limiting Motor Current
14. eee 4 10 4 4 1 Basic Commands 4 10 Pabelgu 4 10 441 2 RUN 4 10 4413 BREAKAB iine ett 4 10 44 T4 GOTO eise 4 10 4 4 1 5 GOSUB and 4 11 4 4 2 Conditional Commands 4 11 4 4 2 1 Quick IF 4 11 4 4 2 2 Nesting Commands 4 12 TABLE OF CONTENTS 4 4 2 3 TIL 2 2 0 4 12 4 4 2 4 IF ELIF ELSE and ENDIF Commands 4 13 442S BNS p s sti Mie oett 4 14 4 4 2 6 Nesting IF commands 4 15 4 4 2 7 IF s with GOTO and GOSUB 4 15 4 5 Using the General Purpose Inputs 4 15 4 6 Interfacing with the Operator 4 16 T6 T PRINT P itte ett EE 4 17 4 6 1 1 Printing Decimal Numbers 4 17 4 6 1 2 Printing Decimal Points 4 17 4 6 1 3 Printing Hex Numbers 4 17 4 6 1 4 Printing Binary Numbers 4 18 4 6 1 5 Printing Switches 4 18 4 6 1 6 Printing Expressions 4 18 4 6 1 7 Printing ASCII Characters 4 18 4 6 1 8 Printing Control Characters 4 19 4 6 1 9 Cursor Addressing
15. esee 6 2 iii BDS5 6 2 3 Overdamping esee 6 2 624 RINGING eo Seen eC eerte 6 2 6 3 as n hee Oe Sea CERE 6 3 6 3 1 If Your System Is Completely Unstable 6 3 6 3 2 Reducing 6 3 6 4 TUNE 6 4 6 5 Tuning the Bds5 Yourself 6 4 6 5 1 Tuning the Velocity Loop 6 4 6 5 2 Tuning the Position 6 5 6 6 RECORD and PLAY 6 6 6 7 Problems ose BA Ae 6 6 6 7 1 Overloading the Motor 6 6 6 72 Compliance o eee ep ee 6 7 6 7 3 Non Linear Mechanics 6 7 6 7 4 6 7 6 7 5 Low Pass 22 202021 6 8 APPENDIX A WARRANTY INFORMATION APPENDIX B ASCII TABLE APPENDIX C SOFTWARE COMMANDS APPENDIX D ERROR CODES APPENDIX E VARIABLE QUICK REFERENCE APPENDIX F COMMAND TIMINGS iv TABLE OF CONTENTS BDS5 LIST OF FIGURES LIST OF FIGURES FIGURE PAGE 1 1 BDS5 Model Number Scheme 1 4 1 2 Compensation Model Number 1 5 1 3 PSRA 5 Model Number Scheme 1 6 1 4 External Regen Resistor Model Number Scheme 1 7 2 1 BDS5 Instruction Screen 2 3 2 2 BDSS State Table
16. 4 19 4 6 1 10 Printing BDS5 Status PS 4 20 4 6 2 REFRESH R amp RS Commands 4 20 46 3 INPUT inihi eet eis 4 20 4 6 3 1 INPUT Limits 4 20 4 6 3 2 INPUT and Decimal Point 4 21 4 6 4 SERIAL Switch 4 21 4 7 Idling Commands sss 4 21 4T Y HOED H neret 4 21 4 7 2 DWELL 4 22 4 7 3 WAIT W 4 22 4 8 5 2 22 222222 4 23 4 8 1 Multitasking and Autobauding 4 23 ASD MULTI eee 4 23 4 8 3 END Command 4 23 4 8 4 Enabling and Disabling Multi tasking 4 23 4 8 5 4 25 4 8 5 1 Pre Execution Hle 4 25 4 8 5 2 Post Execution Idle 4 26 4 8 5 3 Avoiding Idling sss 4 26 4 8 6 Alarms Task Levels 1 3 4 26 4 8 6 1 Restrictions of Alarms 4 27 4 8 6 2 Printing with Alarms 4 27 4 8 7 Variable Input Task Level 4 4 27 4 8 7 1 Using Variable Input with Profiles 4 28 4 8 7 2 Restrictions of Variable Input 4 28 4 8 8 Main Program Level Task Level 5 4 29 4 8 8 1 Power Up Routine
17. 0 TURN OFF OUTPUTS DIS DISABLE DRIVE P MESSAGE NOW PRINT A MESSAGE B Do not print before you turn outputs off or disable the BDS5 Otherwise an INPUT command from another task may idle the alarm indefinitely CHAPTER 4 USER PROGRAMS 4 8 7 Variable Input Task Level 4 The variable input task is the next highest priority Normally the variable input task is used to prompt the operator for input while still allowing the main section of the program to continue For example the operator could be entering a new distance while the main program continues executing the program using the old distance The variable input task is similar to an alarm except that it is fired upon receiving a special character from the terminal or computer which is V control V or ASCII 16H The ATTN button on the DEP 01 Data Entry Panel from Industrial Drives also transmits a V to fire the variable input task The variable input task begins with VARIABLES You can then follow that label with various statements usually printing and input commands For example enter the following program TASK LEVEL 4 VARIABLES P X1 IS X1 INPUT INPUT NEW VALUE OF X2 X2 P X1 IS NOW END EXECUTION TASK LEVEL 5 10 1 0 11 1 1 1 11 Now you can enable multi tasking by typing RUN 10 This program resets X1 then begins to count up Now enter V from your terminal or ATTN from your DEP 01
18. 3 16 ectronic Gearbox s Current Limits IMAX amp ILIM 111121 2 3 16 Gen IO OE RSP ne RO qiie 1 Gearbox Example 1 3 32 Current Units see eerte tren 4 32 Cursor 2 8 Gearbox Example 2 3 33 pu eee nennen Gearbox ACC DEC and Jogs 3 35 Cursor Addressing 4 19 Cursor Control T2 8 C stomer Servite 4 6 Velocity Offset VOFF 3 35 HA ME EN STOP amp LIMITS 3 18 Enabling and Disabling Multi tasking 4 23 u D 5 Enabling Autobaud with ABAUD 4 38 Enabling Capture CAP amp 3 26 Debugging and Multi Tasking 5 2 Enabling Motion with MOTION 3 19 Index ii INDEX BDS5 Enabling the BDSS 22 22 2 242424242 2 2 3 16 Gating Motion with GATE 5 6 Enabling the Position Loop with PL 3 16 Gear Ratio GEARI amp 3 32 Encoder Feedback sess 3 37 Gearbox Example 1 sss 3 32 Encoder Resolution sees T3 37 Gearbox Example 2 sese 3 33 END Commat d 4 23 Gearbox ACC DEC and
19. These commands are similar W 0 delays program execution until the last motion command entered has stopped W 1 delays program execution until the last motion command entered has started W 14 waits for segment 14 of the last motion command to begin In the example below the WAIT command is used to delay the calculations of the third move until the second move has begun The use of W 1 here allows the third move to be calculated while the second is being executed Do not type in the following example it is meant to run as a part of the user program MI 10000 100 BEGIN THE FIRST MOVE CALCULATE THE SECOND MOVE WHILE THE FIRST IS IN PROGRESS DELAY PROGRAM MI 10000 200 EXECUTION UNTIL THE SECOND MOVE HAS STARTED MI 10000 300 CALCULATE THE THIRD MOVE AND PREPARE IT FOR EXECUTION The WAIT W command and synchronization will be discussed in more detail later in this chapter BDS5 4 8 MULTI TASKING Multi tasking is an important feature of the BDS5 Multi tasking allows you to write separate tasks that run concurrently which means more than one task executes at the same time For example you can write a program with two separate tasks one to ask the operator questions and another to command motion These two tasks can run independently so that while the operator is answering questions the motion continues Each task has a priority level The BDS5 has 6 different task levels as shown
20. To enable the BDS5 turn on the AC Line and enter the enable command The 5 should turn on To verify that it did turn on print ACTIVE If ACTIVE is 1 then the BDS5 is enabled otherwise it is disabled To disable the BDSS enter the disable command As an alternative you can disable the BDS5 with the one letter kill command by typing K ENABLE DISABLE and KILL are examples of BDS5 commands of the BDS5 commands are listed with their formats and syntax in Appendix C Appendix C is a quick reference for all BDS5 NOTE commands CHAPTER 3 PROGRAMMING LANGUAGE 3 7 8 Limiting Motor Current The following section discusses how the BDS5 limits motor current 3 7 8 1 Continuous Current ICONT The BDS5 limits current in two ways peak current is limited according to the variable ILIM which was discussed earlier in this chapter continuous that is average current is limited according to the variable ICONT The software that limits the time that motor current is allowed to be above ICONT is called foldback since the current is gradually folded back to ICONT ICONT is dependent on the BDS5 rating and on the motor ICONT is set at the factory and it is in current units Most BDS5 systems have about 2 1 peak to continuous rating Generally ILIM is 100 of the maximum current and ICONT is about 5096 The purpose of the foldback software is to allow the output current to go above I
21. Always hardwire safety functions This includes EMERGENCY STOP or ESTOP You should not depend on your program for safety functions because of three potential problems 1 You can easily make 4 1 CHAPTER 4 USER PROGRAMS programming errors software problem 2 A function on the BDS5 may not work in exactly the way you expect it to in every condition firmware problem and 3 A critical component in your system may fail and prevent the function from working hardware problem Remember safety functions are rarely exercised so that if one of these problems does occur it can go undetected indefinitely If personal safety is involved always hardwire the function USE CAUTION WHEN PROGRAMMING EQUIPMENT PROTECTION FUNCTIONS Use caution when programming equipment protection functions CAUTION Programming errors can 4 2 damage your equipment Sometimes you can hardwire equipment protection functions but other times this is impractical and you must program the functions If this is the case be very careful Remember if your program has an error it can result in damage to your equipment For example suppose you want to wire your motor thermostat so that when a fault occurs the present machine cycle continues until complete In this case you must program the function hardwiring the thermostat would result in motion stopping the moment a thermostat fault is encountered Carefully test these functions WR
22. TASK LEVEL 5 MAIN PROGRAM MI 10000 10 FIRST MOVE P FIRST MOVE PROCESSED MI 10000 10 SECOND MOVE P SECOND MOVE PROCESSED MI 10000 10 THIRD MOVE P THIRD MOVE PROCESSED TASK LEVEL 6 BACKGROUND P UPPER TASK IDLED DWELL 0 25 Apply DC bus power to your BDS5 and type RUN 1 The result should be FIRST MOVE PROCESSED SECOND MOVE PROCESSED UPPER TASK IDLED UPPER TASK IDLED UPPER TASK IDLED UPPER TASK IDLED THIRD MOVE PROCESSED The first and second moves are processed immediately Then task level 5 is idled while the first move finishes While task level 5 is idle the background task executes over and over printing the simple message on the screen 4 25 CHAPTER 4 USER PROGRAMS 4 8 5 2 Post Execution Idle A task also can be idled by waiting for a condition after executing a command This is called a post execution idle because the task is idled after executing the command that causes the idle Commands that cause post execution idling are called idling commands There are four idling commands Table 4 8 Four Idling Commands Wait W Dwell D Hold H Input INPUT For example you can modify the above program to make one move then run the background routine until motion has stopped Use the BDS5 Editor to enter this program TASK LEVEL 5 MAIN PROGRAM MI 10000 10 START MOVE P MOVE PROCESSED W 0 WAIT FOR MOVE P ALL MOTION STOPPED TASK LEVEL 6 BA
23. esc lt cr gt lt lf gt lt gt ENTER MONITOR PUSH TO EXIT lt cr gt lt lf gt gt NOW AN ERROR OCCURS BUT A PROMPT IS PRESENT SO THE ERROR WILL NOT PRINT OUT TYPE IN A COMMAND AND lt gt gt P PFB lt cr gt lt cr gt lt lf gt ERROR MSG WAITING COMMAND IGNORED lt cr gt lt lf gt lt er gt lt lf gt lt lf gt lt bell gt ERR 17 FEEDBACK LOSS lt cr gt lt lf gt gt 25 UPLOADING amp DOWNLOADING PROGRAMS The BDS5 has two commands to allow the up loading and down loading of the BDS5 program memory lt BDS will print to the serial port each line of the program memory Each program line is terminated with a lt cr gt lt lf gt This command terminates with a lt cr gt lt lf gt gt prompt gt lt BDS lt cr gt lt BDS lt cr gt lt lf gt Program Line 1 gt lt cr gt lt lf gt Last Program Line gt lt gt lt 1 gt gt BDS will place the BDS5 into the program upload mode On getting the first cr terminated line the program memory will be erased Each cr terminated line will respond with a lt cr gt lt lf gt l gt prompt Sending an esc tot BDS5 will end the program upload mode Upon completing a program upload the host may request a special BDS5 checksum of the data stored in memory After receiving this special checksum the host may in future uploads use this value to verify the BDS5 p
24. Any time you store your programs variable sets or captured communication onto your computer disk Motion Link will automatically determine the proper file extension 2 4 4 Using IBM PC Compatibles If you are using an IBM PC Compatible make sure it has been booted with the optional serial parallel adapter plugged in Also make sure it has been configured to allow the operation of the serial parallel adapter on batteries This configuration may be accomplished through the IBM supplied program SYSPROF COM To run this program type SYSPROF lt cr gt This program may also be reached through the APP SELECTOR DISK but this is a remain resident program that will not leave enough memory to load Motion Link after running So a three key computer reboot Ctrl Alt Del must be done to remove this program from memory before loading Motion Link Because of this it is easier to simply run SYSPROF in order to configure the IBM CONVERTIBLE 2 5 MOTION LINK SETUP PROGRAM The Motion Link Setup Program is accessed through the Utilities Menu Setup provides the following test capabilities Communicate with the BDS5 Resolver Zeroing Test Tune Drive Drive Test Drive Feedback CHAPTER 2 GETTING STARTED Input Test Output Test Machine Setup Units Machine Setup Limits Motor Setup BDS5 Modes Communications Other Send Variables Reset Variables This test program provides the operator with user friendly methods for
25. CHAPTER 5 DEBUGGING sections of your program a few lines at a time Of course save the original program on your computer for later use Remove lines that you do not think are involved in the problem Removing lines that you suspect are causing the problem can provide false leads for example the problem may be interaction between a section you removed which was operating properly and another unsuspected section of your program that was the actual source of the problem Your false suspicions can be incorrectly confirmed The best situation is when you can make a short lt 20 line program demonstrate the problem After this it is usually easy to determine the problem If you get to the point where you cannot figure out your problem call INDUSTRIAL DRIVES for help we will be happy to help you However in order to make efficient use of your time and ours you must trim down your program to a few lines that are not working It is very difficult for even a skilled person to help debug a large program over the telephone 5 3 CHAPTER 5 DEBUGGING 5 5 SYNCHRONIZING YOUR PROGRAM This section describes the functions and variables that allow you to synchronize the program to events both external and internal 5 5 1 Using the Timers TMR1 4 The general purpose timers TMR1 TMR2 TMR3 and TMR4 are provided for situations where the required timing is too complex for the Dwell command The timers are set in milliseco
26. P SPEED VFB 5 3 KRPM Assuming VFB was 1962 this command would produce SPEED 1 962 KRPM The 3 which follows the 5 in the format causes the BDS5 to insert a decimal point three places from the right of the number To the operator this is more convenient though the programmer still must work in integer units You also have the option of printing fewer than all the digits which follow the decimal point This also can be specified in the format For example suppose you only wanted to print one digit after the decimal point The print command from above would be changed to limit the number of digits to be printed P SPEED VFB 5 3 1 KRPM This command would produce SPEED 1 9 KRPM So the general format for decimal format is OVERALL WIDTH DECIMAL POSITION PRINTABLE DIGITS For the example above 5 3 1 the overall width was 5 the decimal position was 3 and the number of printable digits after the decimal was 1 You can leave off any of these three specifications The overall width defaults to 12 the decimal position to Zero and the printable digits to the value of the decimal position 4 6 1 3 Printing Hex Numbers To print a variable in hexadecimal follow the variable name with an H enclosed in square brackets H The variable will be printed in a field 9 characters wide including an appended H indicating hex The default field width of 9 can be changed by following the H with the
27. 2 c E un d z et In this example Find command has a default FIND WHAT string The default is the find string from the last Find command If you enter an empty line the next line with EDITOR will be found If you do not want to use the default string from the last Find command type in the word or words you want to find this time Pressing the escape key will abort the F command If the Editor cannot find the specified word it will respond with NOT FOUND and return to the edit mode NOT FOUND gt print line you typed from the previous discussion of the Insert command Type v and the BDS5 should respond 1 TEST LINE FOR LEARNING ABOUT THE EDITOR Now use the C command to change EDITOR to BDS5 EDITOR Type and the BDS5 will respond with CHANGE WHAT EDITOR gt Again EDITOR from the Find command is the default input Press the return key to accept the default and the 5 will respond with BDS5 CHANGE TO WHAT gt Now type BDS5 EDITOR The BDS5 will change the line to read 1 TEST LINE FOR LEARNING ABOUT THE BDS5 EDITOR C has defaults for both the CHANGE WHAT and the CHANGE TO WHAT This allows you to step through memory changing each occurrence of one string to another string with minimal keystrokes Like F pressing the escape key will abort the process and return to the Edit mode 4 3 2 7 Delete
28. 4 1 0 1 10000 5 X1 X1 1 lt instruction gt TMRI GT 0 GOTO 5 B time that Output 1 is ON while running the program with the instruction and subtract from this amount of time the Output 41 is ON while running the program without the instruction The result is the amount of time it takes to execute the instruction 5 PLIM 0 EN O1 ON instruction BDS5 SERIAL COMMUNICATIONS 3 DOC BDS5COM3 DOC Rev 5 JANUARY 31 1995 ENHANCED COMMUNICATIONS PROTOCOL Firmware version 3 1 0 There is a need for a more robust ASCII communications protocol for tight computer based communications Beginning with BDS5 firmware version 3 1 0 an enhanced serial communications format will be available The new protocol adds a serial 8 bit checksum to the end of each BDS5 command The BDS5 will process this checksum by comparing it to the actual checksum of the command string If the two checksums match then the BDS5 will echo lt ack gt 06h character to the serial port and then process the command If the two checksums do not match then the 5 will echo an lt nak gt 15h to the serial port and the command will not be processed The Serial Checksum mode is enabled by turning on the user flag SCKSUM The following format will be enabled when the Serial Checksum mode is enabled SCKSUM 1 lt command string gt lt checksum gt lt cr gt where command string is a valid BDS5 ASCII command lt check
29. Send download a program from the BDS5 Program Memory to the terminal Allowed from the interactive mode and the user program Format BDS Receive upload a program from the terminal and store it in BDS5 program memory This command destroys the old program memory A password may be specified If the editor password has been set and the password is incorrect or not specified then an error will result and the original program memory will remain Allowed from the interactive mode and the user program Format gt BDS PASS where PASS is the password as set in the editor Example gt BDS SECRET UPLOAD PASSWORD SECRET gt BDS UPLOAD NO PASSWORD 15 BDS5 APPENDIX D ERROR CODES ERROR CODES D 1 INTRODUCTION The BDS5 s response to an error depends on the error s severity There are four levels of severity listed below in increasing order Table D 1 Error Severity Levels and Actions Errors which cause warnings Errors which cause a program break and stop motion in addition to Level 1 Actions Errors which cause the system to disable and set the FAULT Hardware Output in addition to Level 2 Actions Errors which disable almost all BDS5 functions including communications and flash the CPU LED to indicate the error number These are called firmware errors See Chapter 5 for more information about error severity The following is a complete list of errors generated by the BDSS
30. W 2 WAIT FOR SEG 2 OF THE SECOND MOVE If TIL SEG EQ 2 were used in place of W 2 then execution would delay until segment 2 of the first move Since you normally want to wait for the specified segment of the last move calculated the WAIT command always applies to the last move The WAIT command never waits when motion has stopped For example if you entered this program MI 50000 1000 TIL SEG EQ 4 BUG DELAYS Y the TIL command would delay execution indefinitely because SEG would never equal 4 However MI 50000 1000 W 4 BUG DELAYS UNTIL MOTION STOPS only delays until motion stops because the WAIT command does not delay program execution when 5 5 CHAPTER 5 DEBUGGING motion has stopped Normally you should use the WAIT command when you are synchronizing motion to program execution It is an idling command and thus allows lower level tasks to execute also it takes less space waits for the last motion program and it does not delay execution when motion has stopped Use the TIL command when you need a special function such as printing during the wait or if you specifically want to stop lower level tasks from executing Another example of the WAIT W command is seen when using multiple JOG TO JOG FROM commands Normally you should place a WAIT W command between these commands This is because the initial traverse of a JOG FROM JOG TO command begins as soon a
31. move incremental 4096 counts 1000 rpm with 2 checksum of 6A echo acknowledge turn off serial checksum echo acknowledge and echo off RS 485 back to standard configuration turn on prompts RS 232 prompt turn on echo prompt print feedback position echo 12 position number leading spaces prompt Additionally maximum through put of data can be achieved by turning off the user flags ECHO and PROMPT These two flags will suppress serial port character echoing and the BDS5 prompt string The Echo flag when set to 0 will suppress echoing of all characters received by the 5 this includes the lt cr gt lt lf gt termination sequence Prompt flag when set to 0 will suppress the BDS5 three character prompt when it is set to 0 Please note that the BDS5 uses the prompt gt gt etc to indicate to the user that it is ready for another command This means that until the prompt is transmitted BDS5 is not listening to the serial port When the BDS5 prompt is suppressed it may be necessary to wait a few milli seconds after each command before transmitting the next command With both ECHO 0 and PROMPT 0 the reply string for command string gt lt checksum gt lt cr gt would be lt ack gt or nak Example with MultiDrop enabled PROMPT 0 and ECHO 0 PROMPT 0 lt cr gt PROMPT 0 lt cr gt lt lf gt ECHO 0 lt cr gt ECHO 0 lt cr gt lt lf gt SCKSUM 1 lt cr gt P
32. 1962 RPM Note that the text must be enclosed by double quotes and that text and or variables must be separated by at least one blank space 4 6 1 1 Printing Decimal Numbers Variables are normally printed as decimal integers in a field which is 12 characters wide Formatting can be used to adjust the field width or to print decimal points To change the width of the field follow the variable name with the width enclosed in square brackets Referring to the above example P SPEED VFB 5 RPM will cause the BDS5 to print SPEED 1962 RPM If you try to print a number and do not have enough space in the format for the number then the BDS5 will fill the format width with X s For example P SPEED VFB 3 RPM will result in SPEED XXX RPM again assuming the speed is 1962 RPM 4 6 1 2 Printing Decimal Points You can also use the 55 to print a decimal point The BDS5 performs calculations with integers because it is much faster than floating point math However it is often desirable to convert integers to floating point numbers especially when printing out information for the operator This allows you to make the integer math of the BDS5 transparent to the operator For our example suppose you would prefer to print out the speed in KRPM thousands of RPM CHAPTER 4 USER PROGRAMS You can use print formatting to convert the program units RPM to KRPM with the following print command
33. 2 3 2 4 Motion Link Overview 2 4 2 4 1 Menus and Windows 2 4 2 4 1 1 Program scree eee 2 4 2 4 1 2 Variables iones 2 4 2 4 3 Capture oe RI eme 2 5 DAMA SCOPC is ie itd 2 5 24153 Options eiie tte tendens 2 5 244 1 6 Help onn ono 2 6 2 4 1 7 D hties ehe teens 2 6 2 42 Bditor ciues a usta sua 2 7 24 21 Ele een UE 2 7 24 2 2 Bd iain prep 2 7 2423 GOTO ise Ire 2 8 2 4 2 4 Insert Delete 2 8 2 4 2 5 CUSO erede ede 2 8 2426 ha Demons 2 8 2 4 3 Types Of Data 2 2 2 2 2 2 9 2 4 4 Using IBM PC Compatibles 2 9 2 5 Motion Link Setup Program 2 9 2 6 Processor Modes 2 9 2 6 1 Prompts oie Io eT 2 9 2 6 2 Descriptions of Modes 2 10 BDS5 2 6 2 1 Interactive Mode 2 10 2 6 2 2 Run Mode 2 uu enn 2 12 2 6 2 3 Monitor Mode 2 12 2 6 2 4 Single Step Mode 2 12 2 6 2 5 Trace Mode 2 12 2 6 2 6 Other Modes 2 13 CHAPTER 3 PROGRAMMING LANGUAGE 3T InttodUuCtOn eerte te 3 1 3 2 Instr ctions eeiam etn 3 1 3 2 1 Comments
34. Nominal 115 VAC Input 160 VDC 160 VDC Current 115 VAC 1 1 AMPS RMS 1 1 AMPS RMS 1 10 BDS5 CHAPTER SYSTEM DESCRIPTION Table 1 4 Specifications Cont PSR4 5 2XX 160 253 VAC L L INPUT DESCRIPTION PSR4 5 212 PSR4 5 220 Current Cont RMS 3 Phase 12 0 AMPS 20 0 AMPS Single Phase 10 0 AMPS 16 0 AMPS Peak 2 0 sec 3 Phase 24 0 AMPS 40 0 AMPS Single Phase 20 0 AMPS 32 0 AMPS Peak 50 0 msec 3 Phase 50 0 AMPS 80 0 AMPS Single Phase 42 0 AMPS 64 0 AMPS Control AC Line Input Voltage 90 132 VAC 90 132 VAC Main DC Bus Output Voltage Nominal 115 VAC Input 325 VDC 325 VDC Current 115 VAC 1 1 AMPS RMS 1 1 AMPS RMS CHAPTER 1 SYSTEM DESCRIPTION BDS5 Table 1 5 Environmental Specifications Operating Temperature 3 6 amp 10 AMP Units Convection Cooled 20 Amp Units Internal Fan Cooled Storage Temperature Humidity Non Condensing 0 to 45 0 to 45 20 C to 70 G 10 to 90 For operation ambients above 45 C consult the Applications Group at Industrial Drives Table 1 6 Mechanical Specifications MODEL WIDTH HEIGHT DEPTH x NUMBER BDS5 X03 BDS5 X06 BDS5 X10 BDS5 X20 PSR4 5 X12 amp X20 1 6 THEORY OF OPERATION Drawing D 93030 shows a system overview e MICROPROCESSOR SYSTEM The 5 is a digital positioner and servo drive combined into one unit The velocity loop is 100 digital The BDS5 has battery backup RAM to remember your pro
35. SAT Monitor Satration ___ Neer po ior Son p po tone Long gt 0 vavo Aaa ____ VcMD Velocity Command ___ ve veeeyEmr ____ C 4 BDS5 APPENDIX E VARIABLE QUICK REFERENCE VARIABLE DESCRIPTION PROGRAM UNITS PROGRAM LIMITS CONDITION Externat Vetoes VEB Velocity Feedback see VMAX Maximum Speed Feo VNUM VOFF voLTs Factory vospp VXAVG AwmgeVEXT N VXDEN VXNUM WATCH WTIME X1 X250 XSI XS50 250 Y Special Neve noe Table E 2 Description Of Program Limits Long Limit 2147483648 lt x 2147483647 Long gt 0 Limit 2147483647 Short Limit lt 32767 Short gt 0 Limit 32767 E 5 APPENDIX E VARIABLE QUICK REFERENCE BDS5 E 3 INTERNAL VARIABLES The following variables are internal variables and are not normally used by customers They are set at the factory and program the 5 for the particular motor it will be controlling The Motor command changes these variables as necessary for the motor Table E 3 Internal Variables VARIABLE DESCRIPTION PROGRAM CONDITION 1 16 Internal ADVSLIP Internal ADVSPD Internal ADVLD Internal ANGLD Internal Factory none BSLIP Inductn Base Slip Factory mHz FOLDD Foldback Delay Factory sec 100 FOLDR Foldback Reset Factory sec 100 FOLDT Foldback Const Factory sec 1
36. 10 T kul gt lt o Sg w N B 2 BDS5 APPENDIX B ASCII TABLE ASCII CODE AND HEX CONVERSION CHART CONTD This side of the table is provided for Decimal to Hex Conversion The BDS5 does no support extended ASCII 128 255 Decimal to Hex Conversion B 3 BDS5 APPENDIX C SOFTWARE COMMANDS SOFTWARE COMMANDS C 1 EXPRESSIONS AND SYMBOLS The following expressions and symbols are used in defining the syntax of the instruction set lt Label gt lt Time gt lt Logical gt lt Expr gt lt Position gt lt Velocity gt One or two digits followed by a dollar sign When using GOSUB or GOTO a user variable can be used as lt Label gt if its value is between 0 and 99 Specifies time in milliseconds Must be between 0 and 2 147 483 647 about 25 days One of the following GT GE LT LE EQ or NE for greater than greater than or equal to less than less than or equal to equal to or not equal to respectively Any valid math expression Valid math expressions include user variables indirect references to user variables constants algebraic and logical math operators parentheses Examples of valid expressions are X1 X2 X3 X2 VFB VOFF X1 X2 X1 X2 X3 Any valid expression for position The result is assumed to be in position units The range is 2 147 483 647 counts If your system has position units then the limits are the pos
37. 3 7 6 Controlling the Velocity Loop with PROP PROP is a switch that controls the integration section of the velocity loop If PROP is on then the velocity loop is proportional and the integral is disabled If PROP is off then the velocity loop is fully integrating PROP is turned off at power up You can change PROP at any time Most applications run with PROP off Sometimes proportional velocity loops are used during set up See later in this chapter for more information 3 7 7 Enabling the BDS5 THE BDS5 WILL BE ENABLED AND THE MOTOR WILL TURN SECURE THE MOTOR WARNING At this point you should turn REMOTE on as described in the Installation and Setup Manual Type the following command to print the state of the REMOTE input P REMOTE REMOTE SHOULD BE 1 SHOCK HAZARD Large voltages from the AC Line and the DC Bus can cause injury Ensure that the wiring is correct See the Installation and Setup Manual WARNING BDS5 THE MOTOR MAY MOVE UNEXPECTEDLY BE PREPARED TO DISABLE THE BDS5 You should have completed Initial Check Out in the Installation and Setup Manual If not return to the Installation WARNING nd Setup Manual and complete that section This section will enable the BDS5 The system may be unstable The motor may begin oscillating or run away Be prepared to disable the BDS5 quickly You can disable the BDS5 by turning off opening the contacts of LIMIT or REMOTE
38. 5 Radius E p a 1 70 Radius Figure 3 Conventional Cam Table Setting up the BDS5 To use BDS5 camming you need to follow these steps 1 Generate a cam table and enter it into the BDS5 2 Scale the BDS5 electronic gearbox 3 Align the machine and enable camming 1 Generating a Table To generate a table start with a graph like the one in Figure 2 showing the master drive position versus the follower position Divide this graph 2 into 128 evenly spaced sections Each section 90 represents about 2 81 degrees 360 128 Now load the follower positions into the BDS5 user variables X100 X227 as shown below 270 x 180 Figure 4 Dividing Master Position Master Degrees Load Follower Position in This User Variable 12 5 22 25 351 56 225 354 38 226 357 19 227 Note that the beginning position X100 should be close to the ending position X227 This is because this is an absolute electronic cam that will always cycle back to its original starting position and begin the cam again The next position after X227 is X100 when the cam table is written it must wrap around so that position X227 and position X100 are close If the positions are not close the motor will jump and will possible trip out due to either an overspeed or a position following error 2 Scale the gearbox The 5 processes the master drive signal through the gearb
39. Compliance can be corrected by the following actions Reduce the bandwidth of the system Stiffen the machine so the load is not springy 6 7 3 Non Linear Mechanics BDSS tuning is based on linear control theory The most important requirement of a linear motor controller is that the total reflected inertia should not change substantially during operation Load inertia includes all the inertia reflected to the motor such as inertia through gearboxes and leadscrews Inertia can change in ways that are easy to understand such as the inertia of a spool of cable decreasing when the cable is unrolled It can also change in less intuitive ways such as chain drives which have load in one direction but are unloaded in the other and systems with excessive backlash where there is no load when gear teeth are not touching When the inertia changes the system has the following characteristics System performance is excellent when the motor is in some positions and unacceptable when the motor is in other positions Reducing the bandwidth eliminates the problem If the system performance is poor because of changing inertia you can make the following corrections Correct the system mechanics so that inertia 15 constant CHAPTER 6 COMPENSATION Detune that is reduce the bandwidth of the system If the times when your system will have excessively changing inertia are predictable you can write your program
40. DEL The Delete DEL command can be used to delete one line or a whole range of lines DO NOT TYPE THESE EXAMPLES For example DELETE LINES 5 6 7 8 9 AND 10 DELETE LINE 12 DELETE CURRENT LINE of these delete instructions are valid For an example that you can type in if you entered line 1 TEST LINE FOR LEARNING ABOUT THE EDITOR then type in the following command to delete that line POINT AT THE FIRST LINE TEST LINE DELETE THAT LINE Line 1 should be deleted 4 3 2 8 Size The BDS5 program memory has space for about 16000 characters If you want to see how much memory is left type CHAPTER 4 USER PROGRAMS SIZE The BDS5 will respond with 65 LEFT which means the available space is about 65 If you try to enter a program larger than the BDS5 can store an error will be generated 4 3 2 9 NEW The NEW command resets the password and clears the program The user program is stored in battery backed up RAM Normally the program is remembered indefinitely However if power to the BDS5 is lost when it is executing an Editor command there is a small chance that the program will be corrupted This can happen for example if power is lost during the Change or Delete command In this case the BDS5 will generate a USER PROGRAM CORRUPT error and the program cannot be modified or run If this happens use the NEW command to clear the user program and reset the corrupt er
41. Notice that the results of the P command are printed just below where the print command is displayed 5 2 BDS5 e Only the executed commands in IF ELIF ELSE and ENDIF sets are shown Notice that none of the commands following the first print command are shown This helps you debug your program by only showing the commands that are executing e You cannot type in commands from your terminal while the BDS5 is executing in the Trace mode You can also enter the Trace mode from your program To do this you should include TRC ON in your program To exit the Trace mode you can include TRC OFF in your program or you can press the escape key two times 5 2 2 1 Motion Link and Trace Motion Link is the software communications package provided for the IBM PC and compatibles IBM PC and compatibles can communicate at 9600 baud only in that they can receive and transmit a character at that frequency However they cannot receive an indefinite number of characters at that rate because the computers are not fast enough to process the characters This leads to a problem in the Trace mode because the BDS5 can transmit characters much faster than most PC s can process them This can lead to delays of minutes between when the BDS5 transmits a character and when the computer displays it The best way to cure this problem is to reduce the baud rate from Motion Link use the U command and power the BDS5 down and then up to cause a second au
42. PMIN and PMAX are ignored PLIM is turned on at power up If you have an application with boundaries which should not be crossed you are encouraged to use Software Travel Limits Note that you should set DIR before setting the Software Travel Limits This is because DIR relates PMAX and PMIN to clockwise and counter clockwise motion limits If you change DIR you must reset PMAX and PMIN 3 8 2 3 User Position Trip Points PTRIP1 amp PTRIP2 The BDS5 provides two user position trip points which control a switch You can use this switch to control your program The two trip points are PTRIP1 and PTRIP2 Both are in position units You can program either at any time If the position feedback PFB is greater than or equal to PTRIPI then the switch will be on If PFB is less than PTRIPI then will be off Similarly if PFB is greater than or equal to PTRIP2 then TRIP2 will be on otherwise TRIP2 will be off 3 20 BDS5 Trip points are not limits in the sense that they do not inhibit motion Trip points convert position feedback to an on or off signal Trip points are particularly useful with alarms and the HOLD command both of which are presented in Chapter 4 Position trip points require a lot of calculations As a result they slow the execution of the user program by about 4 If you are not using trip points you can disable them by typing TRIP OFF When the BDS5 is powered up trip point
43. Profile regulation allows you to synchronize the rate of profile execution according to the external input This modifies the CHAPTER 3 PROGRAMMING LANGUAGE velocity and acceleration of move commands without affecting the final position of the move The rate of the move is dependent on the frequency of an external clock which is connected to the external input in addition to the normal limits of the move ACC DEC and the velocity are set in the move command itself The external input may be a master motor to which all moves must be synchronized such as a conveyor belt motor or it may be a signal that you generate electronically As an option an analog signal can be fed directly to the BDS5 where it is converted to a pulse train and can be used as the external input Profile regulation works with MA and as well as Macro moves profile regulation is based on an accumulation of counts from the external input during the move If the external frequency changes during a move the velocity of that move will be proportional to the changing clock frequency In fact if the external input frequency goes to zero then motion will stop Note that if the external input changes rapidly the profile is not limited to ACC or DEC For example if the external frequency stopped suddenly the BDS5 would command motion to stop just as suddenly Note also that large feed forward KF 4000 is normally undesirable during regulation beca
44. RET Exit the Editor and type RUN 4 The result should be EXECUTING SUBROUTINE 5 RETURNED FROM SUBROUTINE 5 4 4 2 CONDITIONAL COMMANDS The BDS5 provides several conditional commands which allow your program to make decisions Conditional commands include Quick IF TIL IF and ELIF These commands all depend on conditions condition is an arithmetic comparison of any two numbers variables or expressions The BDS5 supports all 6 common types of arithmetic conditions Note that you should not use the gt or symbols for these conditions Instead you must use the following two character codes Table 4 1 BDS5 Conditions Greater Than Greater Than Or Equal To Less Than Less Than Or Equal To Equal To Not Equal To 4 4 2 1 QUICK IF COMMAND The or Quick IF is a single line command that allows you to specify a condition a command to be executed if the condition is true and another to be executed if the condition is false The format of the command is condition TRUE command FALSE command TRUE command is executed if the condition is true and FALSE command is executed if the condition is false Both TRUE command and FALSE command CHAPTER 4 USER PROGRAMS are optional although at least one must be present Some examples of the command are X1 GT 5 P 1 gt 5 X1 lt 5 VFB GT 3000 P HIGH SPEED P LOW SPEED 2 X2 5 LE X1 100 GOSUB 40 X1 2 2 EQ X1
45. SPACE NOT REQUIRED WHOLE LINE IS A COMMENT 3 3 VARIABLES The BDSS5 uses variables to monitor and control virtually all of its processes 3 1 CHAPTER 3 PROGRAMMING LANGUAGE 3 3 1 Variable Units Some variables have implicit units associated with their values For example all variables that monitor or control velocity have velocity units In addition there are acceleration units current units and position units Appendix E lists variable with its units Units are programmable when shipped from the factory the standard settings are as follows Table 3 1 Standard Units Acceleration RPM Second Units of Full Amplifier Output Current Units Position Units Counts Velocity Units RPM External Position Counts Units External RPM Velocity Units This assumes external source is a motor with the same resolution as the BDS5 That is external velocity units are set the same as velocity units With standard units position is expressed in resolver to digital R D converter counts if your BDS5 is configured with the standard 12 bit resolution R D converter then one revolution is 4096 counts You can change the units to whatever is convenient for your application For example you can select Radians Second instead of RPM Also units can be tailored to a specific machine For example if the BDSS is driving a lead screw velocity could be programmed in inches minute If you want to ch
46. a 1 8 4 8 Four Idling Commands 4 26 1 5 Environmental Specifications 1 12 4 9 To Execute AUTOS 4 30 1 6 Mechanical Specifications 1 12 4 10 To Execute 4 30 4 11 Common User Units sess 4 32 2 1 Cursor Control Keys 2 8 4 12 System Resolutions 4 33 2 2 BDS5 Rules for 2 10 4 13 Setting External Units in 2 3 BDSS PLompts ie secet es 2 10 Master Slave Systems 4 33 2 4 Monitor Mode Commands 2 12 4 14 English Conversion 12 bit R D Only ient 4 35 3 1 Standard Untts 3 2 4 15 Metric Conversion 12 bit 3 2 Power Up State of Programmable Units 3 4 R D Only ene isa 4 35 3 3 Rules For Math Expressions 3 9 4 16 External Units Conversion 4 36 3 4 Output 1 8 Decimal Values 3 10 4 17 BDS5 Prompts 4 41 3 5 Input 1 16 Decimal Values 3 11 3 6 PRD Ranges and Resolutions 3 15 3 7 S Curve Acceleration Chart 3 21 5 1 Multi Tasking Debug Prompts
47. each prompt from each axis is unique Table 4 17 BDS5 Prompts Non multidrop Multidrop ADDR 0 ADDR 65 4 10 6 1 Broadcast You may want to send all BDSS s on the serial line a command simultaneously This is called a broadcast You can broadcast by sending V In this case all BDS5 s execute the command During a broadcast none of BDS5 s can transmit but all will receive and execute the command 4 11 PROGRAM EXAMPLES This section lists a typical application program as well as a sample velocity drive program Use these programs as models for your own This format uses extensive comments The assumption is that you are using Motion Link so that these comments will not be transmitted to the BDS5 as they would normally take an unacceptable amount of space You are encouraged to use comments because they make the program easier to understand and correct For the velocity drive program first you must select whether the input will be analog or digital encoder equivalent Be sure to set GEARI and GEARO for your application 4 4 CHAPTER 4 USER PROGRAMS BDS5 NAME OF APPLICATION PRETZEL MACHINE DATE A E NEUMAN REVISION HISTORY 8 9 90 ADDED JOG BUTTONS 7 17 90 CORRECTED TEACH BUG ALARM DESCRIPTION A WATCH THERMOSTAT B C NOT USED VARIABLE FILL X1 WITH SPEED BACKGROUND BACKGROUND PRINTING l O DESCRIPTIONS GENERAL PURPOSE INPUTS n JOG PUSH BUTTON I2 JOG PUSH BUTTON I3 TEACH
48. lt C5 PIN 2 gt 120 OHM C5 PIN6 lt 1K 45 AA C5 PIN 7 120 OHM C5 PIN 8 C5 PIN 9 YY MICROCOMPUTER SYSTEM MICROPROCESSOR 24 VOLT DC CUSTOMER SUPPLIED vo DC C2 PIN 5 ALTERNATE POWER SOURCE FOR REMOTE HOME AND COMMON C2 PIN 15 CYCLE ONLY 624 C2 PIN 9 o OPTICAL REMOTE ISOLATOR Z C2 PIN 19 OPTICAL HOME ISOLATOR 222 C2 PIN 8 o lt OPTICAL CYCLE ISOLATOR IN COMMON C2 PIN 18 T C7 PIN 9 ONE INPUT BUFFERS oh AND PULL UP CYCLE C7 PIN 11 o o lt C7 PIN 15 oo MOTION 42 74HC14 o o GATE C7 EVEN PINS C7 STANDARD I O C8 EVEN PINS C8 PIN 33 MANDAS C8 PIN 31 o o n ors C8 PIN 29 INPUT BUFFERS t 12 AND PULL UP o o C8 PIN 25 o o C8 PIN 23 o o 5 C8 PIN 21 o o l6 C8 PIN 19 o o lt 7 C8 PIN 17 o o 18 C8 PIN 15 o o 74LS540 19 C8 PIN 13 t oo lt no C8 PIN 11 o o ni C8 PIN 9 o o ng C8 PIN 7 o o H3 C8 PIN 5 o o n4 C8 PIN 8 PIN 3 o o H5 C8 PIN 1 o o lt n6 C8 OPTIONAL I O C2 PIN 11 ANALOG DIFF CMD HI TO PULSE C2 PIN 1 CONVERTER DIFF CMD LO OPTIONAL C1 PIN 5 INA SN75175 CHA IT INA C1 PIN 10 C1 PIN 4 INB SN75175
49. set it within its bounds This error breaks execution BAD INDIRECTION SEVERITY 2 D 9 APPENDIX D ERROR CODES ERROR 86 ERROR 87 ERROR 88 ERROR 89 ERROR 90 You attempted an indirect reference to a user variable that does not exist For example X1 10000 P X X1 X X1 refers to user variable X10000 which does not exist The X X1 will generate this error This error breaks program execution if the instruction is issued from the user program USER PROGRAM FULL You attempted to load a program larger than the BDS5 can hold This occurs with the gt BDS instruction and from the Motion Link communications software Program Transmit T This error breaks program execution EMBEDDED QUOTE You entered a command with an embedded quote A space must precede an opening quote and follow a closing quote For example P BAD COMMAND has an embedded quote after the This error breaks program execution if the instruction is issued from the user program NO CLOSING QUOTE You entered a command with an odd as opposed to even number of quotes This error breaks program execution if the instruction is issued from the user program NOT FOR ALARM HOLD RECORD You have specified a switch that is not an allowable switch for an alarm or a hold or record command For example A REMOTE ON ERROR REMOTE NOT ALLOWED FOR ALARMS This line causes Error 89 since REMOTE is not allowed to fi
50. speed applications Motor AC Synchronous Another term for brushless DC motor Motor Constant The ratio of the motor torque to motor input power Motor DC A device that converts electrical direct current into mechanical energy It requires a commutating device either brushes or electronic Usually requires a source of DC power Motor DC Brushless A type of direct current motor that utilizes electronic commutation rather than brushes to transfer current Motor DC Permanent Magnet A motor utilizing permanent magnets to produce a magnetic field Has linear torque speed characteristics Motor DC Wound Field A direct current utilizing a coil to produce a magnetic field Usually used in high power applications where constant horsepower operation is desired Motor Stepping A specialized AC motor that allows discrete positioning without feedback Normally used for non critical low power applications since positional information is easily lost if acceleration or velocity limits are exceeded Load variations can also cause loss of position If encoders are used these limitations can be overcome NC Numerical Control Usually refers to any type of automated equipment or process used for contouring or positioning Negative Feedback The type of feedbacks used in a closed loop system where the output value is inverted and combined with the input to be used to stabilize or improve system characteristics N
51. standard Non UL Listed Voltage Rating 115 VAC 230 VAC Current Rating 12 Amps Phase 20 Amps Phase 50 Amps Phase 75 Amps Phase Mechanical Options No Option standard Electrical Regen Options for 12 and 20 Amp Models Only Standard Internal 40 W Regen standard External Regen 230 VAC Only 8 8 Ohms 400 W Requires ER 01 Resistor Kit External Regen 115 VAC Only 5 5 Ohms 200 W Requires ER 02 Resistor Kit External Regen 230 VAC Only 5 8 Ohms 700 W Requires ER 03 Resistor Kit Electrical Regen Options for 50 and 75 Amp Models Only No internal shunt regeneration standard Requires external regeneration resistor kit ER 2X 1 6 BDS5 CHAPTER SYSTEM DESCRIPTION 1 4 4 ER External Resistor Kit Model Number Contact Industrial Drives Application Engineering to size regeneration capability NOTE gt Resistor Rating Options Figure 1 4 External Regen Resistor Model Number Scheme Table 1 3 External Regen Resistor Model Number Scheme LEGEND DEFINITIONS Resistor Rating 8 8 Ohms 400 W 230V 12 amp 20 Amp Models Only 5 5 Ohms 200 W 115V 12 amp 20 Amp Models Only 5 8 Ohms 700 W 230V 12 amp 20 Amp Models Only 4 5 Ohms 500 W 230V 50 amp 75 Amp Models Only 4 4 Ohms 1000 W 230V 50 amp 75 Amp Models Only 2 2 Ohms 1000 W 230V 75 Amp Models Only 2 2 Ohms 2000 W 230V 75 Amp Models Only Options None available at this printing 1 4 5 Molex Assem
52. 2 D 5 APPENDIX D ERROR CODES ERROR 46 ERROR 47 ERROR 48 You attempted to insert an MCA segment after an MCI segment This error breaks program execution MCI ACTIVE You attempted to insert an MCI segment after an MCA segment in a macro move This error breaks program execution TOO COMPLEX You attempted to execute a macro move that required too many segments This error breaks program execution MCA MCI RUNNING You attempted to build a macro move while another macro move was running This error breaks program execution D 4 SOFTWARE ERRORS D 4 1 Programming Modes or Motion Modes ERROR 50 ERROR 51 ERROR 52 ERROR 53 ERROR 54 ERROR 55 D 6 DRIVE INHIBITED You attempted to execute an instruction that required the BDS5 to be enabled while it was inhibited This error will break program execution if the instruction is issued from the user program DRIVE ENABLED You attempted to execute an instruction that required the BDS5 to be inhibited while it was enabled This error will break program execution if the instruction is issued from the user program NOT FROM TERMINAL You attempted to execute an instruction from the terminal that is not allowed from the terminal This error generates no action NOT FROM PROGRAM You attempted to execute an instruction from the program that is not allowed from the program This error breaks program execution NOT FROM
53. 3 32 BDS5 RESOLUTION s is the resolution of the master motor in counts revolution If the master is a pulse train that does correspond to a motor or encoder calculate GEARI and GEARO with GEARI REV X RESOLUTION siave GEARO COUNTS MASTER where COUNTS is an arbitrary number of counts of the master signal and REV avg and RESOLUTION are as before To enable the Gearbox mode type GEAR ON If the ratio is not an integer the BDS5 does not drop pulses The BDS5 keeps track of partial pulses to eliminate dropping pulses over time If the number of pulses coming into the BDSS is at a rate that is too large then ERROR 97 GEAR OVERFLOW will be generated This error can also be caused by the ratio of GEARO to GEARI being too large Note that large feed forward gt 4000 is normally undesirable in electronic gearbox systems because it causes overshoot 3 8 13 2 Gearbox Example 1 Two BDSS s are connected in a master slave system Both have 12 bit R D converters so that one revolution is equivalent to 4096 counts Suppose we want the slave motor to rotate at one third the speed of the master motor What are the values of GEARI and GEARO GEARI RESOLUTION aye GEARO REV a 5 GEARI 3 zt NE GEARO 3 7 1 3 You can select any integer values for GEARI and GEARO that have the ratio 1 3 BDS5 3 8 13 3 Gearbox Example 2 Sup
54. 4 Macro Move Example 2 3 25 Editor2 7 MCA MCI MCD amp 3 24 Types Of Data Files 2 9 Main Program Level Task Level 5 4 29 Using IBM PC Compatibles 2 9 Auto Routine AUTOS 4 29 Motion Link Setup Program 2 9 Error Handler 4 29 Motion Segments 5 4 Motor 3 14 Index iv INDEX BDS5 Motor Current ICMD amp IMON 3 16 3 14 Move Absolute MA Command 3 21 Position Command and Feedback Move Incremental MI Command 3 22 PCMD amp PFB 3 14 MULTI idus 4 23 Position Error PE amp PEMAX 3 14 MULTTI TASKING eee 4 23 Position PRD ees 3 15 Alarms Task Levels 1 3 4 26 Sampling PCMD and 3 15 Background Task Level 6 4 30 Position Command and Feedback Enabling and Disabling Multi tasking 4 23 PCMD amp PEB es 3 14 END Commarnrd 4 23 Position Error PE amp PEMAX
55. 4 2 6 Help BDS5 HELP lt F1 gt This selection displays several pages of help for the BDS5 It lists BDS5 commands and variables with brief descriptions You can also press F1 for this help THIS HELP SCREEN lt F10 gt Displays a help screen 2 4 3 Types Of Data Files Motion Link stores retrieves displays and edits three types of data files Each type has a different file extension or file type File extension refers to the characters in the file name that follow the period For example the file TEST BDS has the file extension BDS The three types of files are BDS Programs for the BDS5 Programs are also called software Programs are transmitted to the BDS5 and can be run indefinitely VAR Variable sets for the BDS5 Variable sets are BDSS variables that define an application For example you may have different variable sets to change the tuning when the application requires it Variable files may include some or all of the BDS5 variables For example BDS5 your Motion Link disk has the file STANDARD VAR This variable file includes all of the standard or default variable settings Variable files are transmitted to the BDS5 to initialize variables before programs are run CAP Capture files contain captured communications from the BDS5 The capture features of the BDS5 allow you to collect and store up to 16 000 bytes of transmissions from the BDS5 Capture is provided to help you debug your program
56. 44739 2 Select VNUM and VDEN VNUM 447392 VDEN 10 Find ANUM and ADEN A Refer to Table 4 14 B Select 10 RPM second motor acceleration C A 10 RPM second acceleration of the 0 1 pitch lead screw translates to 1 IPM second of table acceleration D Refer to Table 4 14 under ACCELERATION UNITS for the formula ANUM ADEN 4 47392 10 1 44 7392 Select ANUM and ADEN ANUM 447392 ADEN 10000 The BDS5 does not support floating point operations You must use fractional units to make the resolution finer For example if the units for velocity need to be finer than IPM 0 1 IPM could be chosen In this case VDEN would be 100 instead of 10 Then to jog at 1 IPM the command J 10 would be required 4 9 3 Position Rotary Mode ROTARY amp PROTARY The 5 stores position in a 32 bit number This number is large enough to count many revolutions For example the 32 bit number will store the counts from a 12 bit R D converter for about 10 million revolutions before the 32 bit limit is exceeded Normally this is sufficient However some applications require the motor to rotate in one direction indefinitely Eventually the 32 bit limit will be exceeded resulting in an error The Rotary mode allows the BDS5 to support these unidirectional applications CHAPTER 4 USER PROGRAMS The Rotary mode forces all position related variables to roll over after position feedback PFB exceeds a specified limit The variabl
57. After the program is returned the Motion Link Editor is called allowing you to examine and change the program NEW PROGRAM This selection calls the Motion Link Editor allowing you to enter a new program Upon exiting the Motion Link Editor you can store the program to your computer disk and or transmit it to the BDSS 2 4 1 2 Variables The VARIABLES pull down window allows you to retrieve edit transmit and save BDSS variable files A BDSS variable file contains a list of some or all of the BDS5 variables with initial values This includes user variables and control variables Together these variables configure a BDS5 for an application EDIT This selection calls the Motion Link Editor and assumes that you want to re edit the last variable file that you edited Itisa short cut allowing you to edit without first loading a variable file from the BDS5 or from the disk If you exit the Motion Link Editor Motion Link remembers the variables you were BDS5 last editing Note that if you have selected an item from either the PROGRAM or CAPTURE menu since you last edited a variable file this selection 15 invalid FROM DISK This selection retrieves a variable file from your computer disk Motion Link will display all of the variable files currently on your disk and allow you to choose the file you want After you choose a variable file the Motion Link Editor is called allowing you to examine and change the
58. Appendix A Warranty Information 0 B 1 4 Appendix B ASCH Table iet retener piri Re FREU 0 C 1 C 16 Appendix C Software Commands sess 0 D 1 D 14 Appendix D Error Codes 2 ree o eget eere tite 0 E 1 6 Appendix E Variable Quick 0 Flo F 2 2ssssens Appendix F Command Timings neret 0 Glossary i xiv GIOSSALY oco ce vp aD dU Ue edm 0 Index i viii Index eie eee am he puesta apte 0 S EL tss p oaa BDS5 Uperade ie ttti eee RE eie ee eet ce 0 Zero in this column indicates an original page CONFIGURATION TABLE BDS5 CONFIGURATION TABLE USER S MANUAL M93102 RECORD OF REVISIONS ISSUE NO Revision CHANGED PAGES BRIEF DESCRIPTION OF CHANGE CHANGE NO 15 Mar 95 Replaces issue dated 15 Feb 95 Original Release Motion Technologies Group Thank you and congratulations for choosing Industrial Drives servo products for your motion control requirements We seek to provide our customers with quality products excellent support and outstanding value In an effort to provide you with dependable and useful documentation we offer you an opportunity to critique this manual with your comments and suggestions Your fe
59. BDS5 FIRMWARE UPGRADE NOTICE DOC BDS5 304 DOC R5 FIRM UP DOC June 17 1994 VERSION 3 0 4 UPGRADES When upgrading older systems pre version 3 0 0 with 3 0 4 Be sure to initialize the three new non volatile flags for proper operation 1 1 2 MSG 1 3 EXTDX 0 CHANGES from 3 0 3 e Enhanced the CLEARX command to allow separate clearing of all User Registers or User Flags or both Syntax CLEARX 1 2 Example CLEARX Clear both User Registers and User Flags CLEARX 1 Clear only the User Registers CLEARX 2 Clear only the User Flags Enhanced the Break B command to allow separate the optional breakink of a user INPUT command Syntax 1 Example B Break the user program B Break a user INPUT command if active The B command was designed to allow the user to break any active Input command because Printing from all tasks are suppressed until completion of the Input command Aditionally any Print while the Input command is active will HOLD the task at the Print command until the Input has finished This means that if for example a user needed to Print a message to the machine operator during an Alarm condition this would not work if an Input command was active Now with the B command the user can imbed the B I command in the program prior to any critical Print messages and thus cancel any active Input command BDS5 Firmware Upgrade Notice DOC BDS5 304 DOC R5 FIRM UP D
60. BEGIN MOVE TIL CAP EQ 0 WAIT FOR POSITION CAPTURE JT PCAP 4000 0 Note that the motor comes to rest 4000 counts after the position that was captured not 4000 counts after the JT command is executed If 4000 counts was not enough distance ERROR 42 MOVE W O TIME would be generated This means that the commanded speed change cannot be accomplished given DEC the deceleration limit Note also that you must leave an additional 10 15 milliseconds for the TIL and JT commands to be executed The JT command example given here brings the system to rest As an alternative you can change the speed to any value the motor can run as long as you do not attempt to change direction with one JT command For example the following command replaces the above JT command when you want to change speed to 100 RPM at 4000 counts past PCAP 3 29 CHAPTER 3 PROGRAMMING LANGUAGE JT 4000 100 CHANGE SPEED TO 100 RPM BEGIN DECEL SO THE SPEED IS JUST REACHING 100 RPM WHEN THE POSITION IS 4000 COUNTS PAST REGISTRATION MARK For more information about registration see Industrial Drives application note Cut to Length 3 8 11 3 Multiple JF JT Commands Many applications require that multiple Jog From JF and Jog To JT commands be executed sequentially In most cases you will have to insert a delay in your program between JT and JF commands For example if you enter 55 EN ENABLE BDS5 ACC 100000 SET A
61. CHAPTER 3 PROGRAMMING LANGUAGE The J 0 command also stops motion from any mode much like the STOP command Unlike S J 0 decelerates at the rate specified by DEC The Scommand should not be used as a part of normal NOTE program operation Use J 0 At any time when motion is commanded if the MOTION input turns off an error is generated and all motion is stopped as if the STOP command were given Also any errors with a severity of 2 or 3 will stop motion in a straight line deceleration at a rate of AMAX Appendix D lists all errors and their severity 3 8 1 5 STOP and BREAK with Control X 4X You can execute a stop and break command with the control X X character Control X or X means that you hold down the control key Ctrl on your terminal or IBM PC and press the X key This has the same effect as typing B then S from your terminal 3 8 2 Limiting Motion The BDS5 allows you to limit motion with both Software and Hardware Travel Limits 3 8 2 1 Hardware Travel Limits Hardware Travel Limits limit the range of motion If you have an application with boundaries which should never be crossed you are encouraged to use the Hardware Travel Limits with limit switches Exceeding Hardware Travel Limits is a more severe error than exceeding Software Travel Limits The BDS5 assumes that Software Travel Limits should catch normal overtravel conditions and that a Hardware Travel Limit indicates a serious problem Har
62. CHB INB oj C1 PIN 9 ENCODER TO DIGITAL BATTERY BACK UP RAM ROM BDS5 SYSTEM OVERVIEW 1 14 BDS5 CHAPTER 1 SYSTEM DESCRIPTION m 2 N o 8 ACTIVE 8 8 1 2 J HARDWARE SYS OK I WATCHDOG LED JE 75156 lt TL LED Q FAULT LED 75156 8 RD TD LED C2 PIN 17 CREAN C2 PIN 16 RELAY N D SNR C2 PIN 10 24 VOLT 01 HI OPTICAL C2 PIN 20 ISOLATOR 01LO C8 PIN 35 STATUS OUTPUT BUFFERS CS PIN27 Gi WITH OPEN C8 PIN 45 COLLECTORS S 53 C8 PIN 43 gt 03 C8 PIN 41 x 04 C8 PIN 39 gt 05 C8 PIN 37 gt 06 ULN2803A C8 OPTIONAL VO C7 PIN 21 07 C7 PIN 19 08 C7 PIN 23 CYCLE C7 STANDARD I O READY BUS BUS ABSOLUTE Pe VALUE 5 VOLTS FULL SCALE ES ON 4 M CIRCUIT C2 PIN 14 Ere COMMON S CSPINAO A PHASE 5 uud CURRENT A Ma SAMPLE 5 PIN9 B PHASE PWM 6 CURRENT POWER CURRENT Mb LOOP STAGE SAMPLE MOTOR CURRENT 2 PIN8 C PHASE CURRENT SAMPLE 1 PIN3 LOOP RESOLVER COMPENSATION 2 CARD L cce 1 0K C2 PIN 2 TACH ANN gt MONITOR C2 PIN 12 C3 PIN4 REF
63. D 2 HARDWARE FAULTS D 2 1 Firmware Faults ERROR 2 HARDWARE U P FAIL SEVERITY 4 The microprocessor cannot pass self test This fault causes the microprocessor to blink the CPU light twice and then pause The BDS5 will not communicate or run the user program Contact the factory ERROR 3 HARDWARE CHECKSUM SEVERITY 4 The microprocessor cannot pass the checksum self test This fault causes the microprocessor to blink the CPU light three times and then pause The BDS5 will not communicate or run the user program Contact the factory ERROR 4 SOFTWARE WATCHDOG SEVERITY 4 The microprocessor has failed the software watchdog self test This fault causes the microprocessor to blink the CPU light four times and then pause The BDS5 will not communicate or run the user program Contact the factory D 1 APPENDIX D ERROR CODES BDS5 ERROR 5 r5 VOLTS SEVERITY 4 The 5 volts is too low This fault causes the microprocessor to blink the CPU light five times and then pause The BDS5 will not communicate run the user program Check the 10 VDC input into the BDS5 Connector C4 pin 4 or 8 If itis below 6 5 Volts for even a short time this error will occur This happens when the logic supply is loaded too heavily or when the line voltage 5 4 5 Connector pins 2 and 3 is below 98 VAC 115 VAC less 15 D 2 2 BDS5 Faults ERROR 10 ERROR 11 ERROR 12 ERROR 13 ERROR 14 ERROR 15 D 2 REMOTE OF
64. DEC the move becomes triangular As an option directions of CW or CCW can be specified to force the motor to rotate the desired direction If direction is left out then the motor rotates whichever direction is shortest For example MRD 1000 100 CW MOVE R D TO 1000 BUT ALWAYS CW moves the motor clockwise even if the specified position 1000 is just a few counts counter clockwise The variable DIR has no effect on MRD commands The limit of position is based on the R D converter accuracy as shown in Table 3 8 Table 3 8 R D Converter Accuracy Resolution Maximum Position moves are not buffered They are not allowed when the BDS5 is jogging or if a move is in progress MRD moves can be used to improve the accuracy of homing sequences First use the BDS5 to position the motor as close as possible to the home limit switch trip point Then use the MRD command to move the motor to a specified R D position In this case the limit switch must be accurate only to one half revolution of the motor for the R D moves to be useful 3 26 3 8 9 Capturing Position Position capture is a feature where the position feedback PFB is captured when a hardware input transitions The BDS5 position capture is accurate to 25 microseconds In other words the position that 18 stored after a capture is equal to the actual position of the motor at the time of the capture within 25 microseconds Capture uses the HOME har
65. Danaher Motion Kollmorgen KOLLMORGEN Phone 1 800 777 3786 or 815 226 3100 Motion Technologies Group Technical Support Fax 540 731 5679 BDS5 FOREWORD Fongwonp The commitment to quality at Industrial Drives is our first priority In all aspects of our business research development product design and customer service we strive to guarantee total quality This pledge is founded on a solid history of innovative technological achievements dating back to 1948 One of the finest tributes to that achievement can now be seen at the Smithsonian which has on display the first stellar inertial navigation system developed by Dr Charles Stark Draper This system contains the first models of torque motors built by the founding organization of Industrial Drives During the period of 1948 to 1960 our firsts in the industry numbered more than a dozen they ranged from the simple but invaluable such as the direct drive DC torque motor and movie theater projection motors to the exotic submarine periscope drive motors for the U S Navy electric drives Curtis Wright electric brake coils and numerous other innovations For more than a decade Industrial Drives known in the early days as part of Inland Motor Division of Kollmorgen has continued to enhance its sophisticated engineering solutions to pioneer new product development The results of these and other efforts has encouraged some of the most significant innovations in
66. Example JT 610000 100 JT 100 X45 800 Disable the drive and break the program Allowed from interactive and monitor modes and the user program See Drawing C 84732 for more information Format K Move to the specified position at the specified speed If the speed is not specified it is assumed to be VDEFAULT Allowed from the interactive mode and the user program Format MA Position Velocity Example MA 10000 1000 MOVE AT 1000 MA 0 MOVE TO 0 AT VDEFAULT Define an absolute macro move section to the specified position at the specified traverse and ending speeds See Chapter 5 for descriptions of defaults Allowed from the interactive mode and the user program Format MCA Position Traverse End Example MCA 1000 100 500 MCA 2000 10 MCA 5000 MCA 7000 0 C 9 10 BDS5 MCD MCGO MCI MOTOR APPENDIX C SOFTWARE COMMANDS Define a macro move dwell section for the specified time This is only valid when the previous macro move section ended at zero speed When used with the profile regulation mode time is inversely proportional to external input frequency Allowed from the interactive mode and the user program Format MCD Time Example MCD 500 DWELL 0 5 SECONDS Execute a macro move This is only valid when the last macro move section ended at zero speed Allowed from the interactive mode and the user program Format MCGO Define an incremental macro move section for
67. For example the program section beginning at label 25 could be re written so that it watched a position trip point X1 2000 25 GT X1 2000 RET NOT REDUCE SPEED IF gt SETPOINT REST 25 PROGRAM THE SAME Hu What value to use for the setpoint varies from one application to another These values must be set by experience On many applications the input will not CHAPTER 3 PROGRAMMING LANGUAGE request a speed reduction near an endpoint so that this may not be a problem 3 8 12 External Inputs External inputs are normally from a master motor As a standard these inputs are in digital encoder format Examples of master motors include the encoder like output from another BDS5 output from an actual encoder or a customer synthesized encoder signal The external input can control motion in the two BDS5 Master Slave modes electronic gearbox and profile regulation The BDS5 acting as the slave accepts commands from these external sources The external input can also come from a feedback encoder which is mounted to the motor this encoder is occasionally used to improve the accuracy of the BDSS External inputs are connected to Channel A and Channel B inputs of the Encoder Equivalent Connector Your program has direct access to the external input through the variables VEXT and PEXT The frequency of the external input is provided in VEXT VEXT is in external velocity units VX
68. For our example the first TIL command can be replaced with W 2 and the second can be replaced with W 3 3 9 11 4 Changing Profiles During Motion Position dependent jogs can also be used to change the speed or endpoints of an MA MI MCI or MCA command that is already in progress For example suppose you want to change the speed of a profile depending on an input you could write the following program to reduce the speed when I1 is 1 BDS5 X1 10000 X1 STORES THE ENDPOINT BEGIN AT 5000 RPM TIL SEG EQ 0 GOSUB 25 25 WATCHES 11 TO CHANGE SPEED MA X1 5000 B 25 EQ 0 RET CHANGE ONLY IF 1 1 1000 REDUCE SPEED TO 1000 RPM WAIT UNTIL SPEED IS 1000 RPM JT X1 0 USE JT TO GET TO ORIGINAL ENDPOINT AT NEW SPEED WAIT FOR MOTION TO STOP B DONE TIL SEG EQ 2 TIL SEG EQ 0 You must be careful not to begin the motion too late in the profile For example suppose I1 became 1 after the profile was well into deceleration and the speed was say 200 RPM In this case the JT command would generate an error because by the time it was executed the motor position would be past X1 the original endpoint This is because the unit would accelerate up to 1000 RPM before the JT command was executed In general you must limit the time during which you are looking for the speed change After this point the profile must either continue along the original profile or the endpoint must be extended
69. GATEMODE PROMPT GEAR TRIP O1 O8 PROP REG ROTARY 55 STATMODE TRC TQ The output word OUT is set to zero shortly after power up 3 3 9 Initial Settings of Control and User Variables This section briefly discusses the standard initial and power up settings for all control and user variables The learning process is simplified by using the standard settings which disable certain functions Note that here initial means as shipped from the factory However initial does not imply factory settable you can change values that are set initially at the factory but you cannot change factory settable variables ABAUD Enable autobauding Initially set to 1 and left at 1 for preliminary operation 3 4 ACC ADDR ADEN AMAX ANUM BAUD CAP CAPDIR CLAMP DEC DIR FAULT GATEMODE BDS5 Acceleration rate initially in RPM Sec Initially set to 100000 Address for multidrop applications Initially set to 0 for non multidrop Acceleration units denominator Initially set to 1000 for RPM Sec Limits DEC and ACC acceleration and deceleration rates initially in RPM Sec Initially set to 100000 Acceleration units numerator Initially set to 4474 for RPM Sec Baud rate for serial communications Automatically set by autobaud Normally you do not need to set BAUD Enable position Capture mode Set to 0 on power up and normally left at Zero for preliminary operation Direction
70. HI TACH SCALING 1000 RPM V 4700pf gt gt COMMON V C3 PIN 10 REF LO C1 PIN 1 l CHA gt OUTA C3 PIN 7 SIN HI gt gt OUTA RESOLVER C3 PIN 1 SIN LO TO DIGITAL E CONVERTER C3 PIN 9 COS HI DIGITAL cus E EO ENCODER 75174 C1 PIN 7 C3 PIN 3 cos LO 2 OUTB C1 PIN 3 CHZ gt OUTZ 75174 C1 PIN8 gt OUTZ 1 15 Ie vit AdOO BDS5
71. INPUT ENTER NEW POSITION X1 3 NEW POSITION 1 3 P ACTUALLY X1 X1 B Notice the bracketed 3 following X1 in the INPUT command This causes the operator input to be multiplied by 1000 103 before it is stored in The print statements that follow display X1 in inches as the operator would prefer to see it then in mils as the BDS5 motion commands process it CHAPTER 4 USER PROGRAMS 4 6 4 SERIAL Switch You can use the SERIAL switch to make sure that the serial port is not busy before you execute a command If SERIAL is on the serial port is ready Otherwise the serial port is not ready For example suppose you do not want to execute an INPUT command if the serial port is busy It might be busy from a print command or from a previously executed input command In that case use these commands SERIAL EQ ON INPUT ENTER SPEED X1 4 7 IDLING COMMANDS There are four idling commands Hold H Dwell D Wait W and INPUT This section discusses the first three The INPUT command was discussed above Hold Dwell and Wait cause the user program to wait for an event before executing the next command Hold waits for switches Dwell waits for a timer and Wait waits for a motion segment 4 7 1 HOLD H The HOLD command waits for a switch to be either on or off You specify the HOLD command with the switch and the desired state For example H ON HOLD UNTIL INPUT I1 IS ON HOLD UN
72. N N 0 0 0 Binary Mask 4 16 I O Number 16 15 14 13 12 11 10 9 N I O On N N N N N N N Binary Mask 0 0 0 0 0 0 0 0 Since the condition must be in hex or decimal it can be expressed as 0000000000011001 BINARY equals 19 HEX or 25 DECIMAL which equals 1 8 16 DECIMAL Now the mask and the condition can be used in a TIL instruction in the format TIL IN amp mask EQ condition For our example TIL IN amp 39H EQ 19H THIS USES HEX CONSTANTS or TIL IN amp 57 EQ 25 THIS USES DECIMAL BOTH WORK This accomplishes the same function as the TIL instruction which refers to inputs one at a time However using the IN word allows the function to be done in a less cumbersome manner 4 6 INTERFACING WITH THE OPERATOR This section covers interfacing via the serial port Connector C5 Often it is necessary to have the BDS5 send information to the operator or ask the operator for information For example it may be useful to output speed and position or ask the operator for a new speed command This is easily accomplished using BDS5 serial I O instructions 4 6 1 PRINT P The PRINT P command prints text and variables to the terminal Text and variables may be freely BDS5 intermixed limited only by the 80 character maximum instruction length The following command prints the speed on the terminal P SPEED VFB RPM Assuming VFB is 1962 the BDS5 will respond with SPEED
73. ON 2 07 2 03 GEAR ON XI2X241 2 37 2 62 GEAR ON VDEFAULT 1000 Profile calculation time only Note The drive is Enabled EN for all timing tests ACC DEC 100 000 amp SCR V 2 Time msec Time msec INSTRUCTION Ver 2 0 5 Ver 3 0 5 MI4060100 60 65 MI 40960 1000 6 80 7 02 MI 40960 1000 7 00 8 70 MI 40960 1000 6 20 641 MI 40960 1000 MI 40960 MI 40960 5 80 5 97 GEAR ON MI 40960 5 10 5 39 REG ON VDEFAULT 1000 Profile calculation time only Note The drive is Enabled EN for all timing tests ACC DEC 100 000 amp SCRV 2 eme uum er _ INSTRUCTION Ver 2 0 5 Ver 3 0 5 MCI 1000 1000 200 11 00 11 12 MCI 1000 0 MCGO PXI PXIIS GOSUB 120 amp 120 amp 3 40 2 56 RET EET EQ 1 OI ON IF1EQO 9 46 1 1 ELIF 1 EQ 0 1 2 ELSE X1 3 ENDIF aos T m na VDEFAULT 1000 Profile calculation time only Note The drive is Enabled EN for all timing tests TIMING METHOD 1 TIMING METHOD 2 Divide the number of loops counted X1 into With an oscilloscope measure the amount of 10 seconds 10 X1 to get the single loop time Perform this operation twice once with the lt instruction gt and once without the lt instruction gt Subtract the amount of time it takes to run this program with the lt instruction gt from the time to run without the lt instruction gt The result is the amount of time it takes to execute the instruction
74. Obsolete MC2 Rev 2 and later DESCRIPTION OF CHANGES Added MONITOR switch to force Monitor mode during program run Added a serial port ECHO switch Added MSG switch to control the Power up and Monitor messages Added a fix for the Serial watchdog took 35 sec to print Added a random number command RAND Added Print Append command and PAS Changed the RUN command to work from user program Added Real Time Trace commands and TPLA Y Added an Electronic Cam mode CAM and PCAM Enhanced NORM command to enable Camming Moved position interrupt code around to make CAM work properly This reduced the loop delay and increased BDS5 stability i e bandwidth Stopped CONTINUE from working with CAM Made drive disable also disable Camming Added LPF and LPFHZ to the DUMP TL command Added Extended User Registers for X251 X750 Added CLEARX command Fixed the 16 bit R D problem Fixed motion bug due to multiple J 0 commands Eliminated micro register test to make more room for code Fixed bug that ignored Escape when background was continuously printing Fixed bug where error messages occasionally printed the wrong line number Added code to initialize the new Dallas Bat RAMS to prevent power up and program crash problems Register based instructions will execute 3 msec slower EXTDX VERS
75. P ILIM CHAPTER 3 PROGRAMMING LANGUAGE ILIM should now be 10 Return ILIM to its original value normally 100 and type ILIM 100 Print ILIM to make sure the change was carried out properly 3 3 7 Programming Conditions Most variables can be changed but some can be changed only under certain conditions For example the maximum acceleration level AMAX can be changed only when the BDS5 is disabled Attempting to change AMAX with the BDS5 enabled will generate an error The conditions under which a variable can be changed are called programming conditions Some variables should never need to be changed after the BDS5 has left the factory these variables are called factory settable Attempting to change a factory settable variable will generate an error The programming conditions of all variables are listed in Appendix E Limits and programming conditions for all variables are shown in Appendix E NOTE 3 3 8 Power up and Control Variables Most control variables and all user variables are stored in non volatile their values are not lost when the BDS5 is powered down In general control variables are remembered except the switches Table 3 2 shows the condition of all BDS5 programmable switches on power up 3 3 CHAPTER 3 PROGRAMMING LANGUAGE Table 3 2 Power Up State of Programmable Switches REMEMBER FROM LAST POWER UP CAPDIR ABAUD CLAMP DIR LPF DEP MULTI XS1 XS50 EXTLOOP PL FAULT PLIM
76. POSITION PUSH BUTTON 14 CONTACTOR INTERLOCK SWITCH PLC INTERFACE 16 REQUEST PUSH BUTTON I7 THERMOSTAT wa a Ma aW GENERAL PURPOSE OUTPUT O1 COOLING FLUID PUMP T 02 SPINDLE MOTOR PLC INTERFACE DEDICATED I O T CYCLE CONNECTED TO PLC NOT USED HOME CONNECTED TO HOME LIMIT SWITCH LIMIT CONNECTED TO OVERTRAVEL LIMIT SWITCH MANUAL NOT USED MOTION CONNECTED TO STOP PUSH BUTTON 7 READY CONNECT TO PLC STATUS NOT USED VARIABLES X1 STORE NUMBER OF CYCLES RUN X2 STORE LAST POSITION RUN TO X3 INTERMEDIATE CALCULATION X4 LOOP COUNTER X5 LOOP COUNTER X6 X250 NOT USED a Wa Ya w a 4 42 BDS5 CHAPTER 4 USER PROGRAMS USER SWITCHES XS1 XS50 USED APPLICATION PROGRAM POWER UP POWER UP LABEL PLIM OFF SOFTWARE LIMITS NOT USED HERE CONTINUE YOUR POWER UP PROGRAM HERE END A I7 OFF THERMOSTAT INPUT 17 OPENED P PROCESS BEING CLOSED DOWN DIS DISABLE THE BDS5 B BREAK PROGRAM EXECUTION VARIABLE INPUT ENTER NEW SPEED X1 END AUTO AUTO LABEL WRITE YOUR AUTO PROGRAM HERE END MANUAL MANUAL LABEL WRITE YOUR MANUAL PROGRAM END a WRITE MORE OF YOUR PROGRAMS HERE END BACKGROUND WRITE YOUR BACKGROUND PRINTING ROUTINE HERE END a ERROR ERROR HANDLER WRITE YOUR ERROR HANDLER HERE B END OF SAMPLE PROGRAM 4 43 CHAPTER 4 USER PROGRAMS BDS5 VE
77. POWER UP 4 29 4 8 8 2 Error Handler ERRORS 4 29 4 8 8 3 Auto Routine 4 29 4 8 8 4 Manual Program MANUAL 4 30 4 8 8 5 Typical AUTO MANUAL Programs 4 30 4 8 9 Background Task Level 6 4 30 4 8 9 1 Restrictions of Background 4 32 4 9 Units 4 32 4 9 1 User Units ise ner rtt 4 32 4 9 1 1 Current Units esee 4 32 4 9 1 2 Other User Units 4 33 BDS5 4 9 1 3 External Un1t 4 33 4 9 2 Machine Specific Untts 4 35 4 9 3 Position Rotary Mode ROTAR Y amp PROTARY 4 37 4 9 3 1 Choosing PROTARY PNUM and PDEN ebd 4 37 4 9 3 2 Rotary Mode and Absolute Moves 4 38 4 10 Serial Communications 4 38 4 10 1 Autobauding sees 4 38 4 10 1 1 Setting the BDS5 to Autobaud 4 38 4 10 1 2 Autobauding and MOTION 4 38 4 10 1 3 Enabling Autobaud with ABAUD 4 38 4 10 1 4 Baud Rate BAUD 4 39 4 10 2 Prompts oerte 4 39 4 10 3 Serial Watchdog 4 39 4 10 4 Transmit Receive Programs 4 39 4 10 4 1 BDS Command Receiving from the BDSS5 2 eene 4 39 4 10 4 2 The gt BDS Command Transmitting to t
78. Sec 4 47392 x Machine Acceleration In Your Units Table 4 15 Metric Conversion 12 bit R D Only POSITION UNITS PNUM PDEN 651 8971x Motor Movement In Radians Machine Movement In Your Units VELOCITY UNITS VNUM VDEN Motor Velocity In Rad Sec 712 047 x Machine Velocity In Your Units ACCELERATION UNITS ANUM ADEN Machine Acceleration Your Units 0 712047 x Motor Acceleration Rad Sec CHAPTER 4 USER PROGRAMS The procedure to determine PNUM and PDEN is as follows A Select Table 4 14 revolutions or 4 15 radians B Select a convenient amount of motor movement in revolutions or radians C Calculate the corresponding machine movement in your user units D Perform the operation indicated in the table under POSITION UNITS and set PNUM PDEN equal to this value E If your R D converter resolution is 14 bits multiply PNUM by 4 Multiply PNUM by 16 for a 16 bit system The procedure to determine VNUM and VDEN is as follows A Select Table 4 14 RPM or 4 15 radians second B Select a convenient amount of motor velocity in RPM or radians second C Calculate the corresponding machine velocity in your user units D Perform the operation indicated in the table under VELOCITY UNITS and set VNUM VDEN equal to this value E If your R D converter resolution is 14 bits multiply VNUM by 4 Multiply VNUM by 16 for a 16 bit s
79. Slave mode to make the BDS5 a velocity drive See Appendix G for more information If the analog input is going to be used for feedrate override use profile regulation The analog external input is connected to the analog input of the Customer I O Connector 3 8 13 Electronic Gearbox Electronic gearbox is one of two BDS5 Master Slave modes Refer to Figure 3 8 for a diagram of the two modes Electronic gearbox is used to link two motors together so that the velocity of one is proportional to the velocity of the other The constant of proportionality can be negative allowing the velocities to be in opposite directions 3 8 13 1 Gear Ratio GEARI amp GEARO In electronic gearbox the command signal comes from the external input The pulses are multiplied by a gear ratio to form the position or velocity command The ratio is defined by two variables input gear teeth GEARI and output gear teeth GEARO GEARI must be between 32767 GEARO must be between 1 and 32767 If the sign of GEARI is changed then the direction of rotation will be reversed If the master is a motor or encoder calculate GEARI and GEARO with GEARI _ REV RESOLUTION GEARO REV RESOLUTION MASTER MASTER where REV is an arbitrary number of revolutions MASTER of the master motor REV vg is the corresponding number of revolutions of the slave motor RESOLUTION is the resolution of the slave motor in counts revolution and
80. The BDS5 should print the value of which has been continuously incrementing since you typed RUN 10 Next enter a new value for X2 and notice that the program prints out a new value for which is larger than the value it printed at the beginning of the variable input task This is because the variable input task was idle while you were entering the new value Since the higher priority task 4 27 CHAPTER 4 USER PROGRAMS is idle the lower priority 11 will run and continuously increment X1 4 8 7 1 Using Variable Input with Profiles You can use the variable input routine while the BDS5 is executing motion profiles However you must be careful if you are changing parameters of motion Specifically if you are changing two or more parameters which you want to take effect at the same time you must write your program to store those values away For example suppose you are using the variable input routine to prompt for speed and distance You might use a program like this TASK LEVEL 4 VARIABLES INPUT INPUT NEW DISTANCE X1 INPUT INPUT NEW SPEED X2 END VARIABLE TASK LEVEL 5 20 MI X1 X2 GOTO 20 If you type RUN 20 this program will continuously move the motor X1 distance at X2 speed even after you press V to start the variable input routine However after you have entered a new value for X1 the variable input routine will be idled waiting for you to enter X2 In this case the next MI c
81. all multiplications and divisions are done before any additions or subtractions Parentheses are provided to override this precedence Type in the following examples 1 2 3 THIS PRINTS 7 9 IS DONE BEFORE THIS PRINTS 9 1 2 3 Math expressions must obey the rules listed in Table 3 3 Table 3 3 Rules for Math Expressions No spaces are allowed Any valid variables can be used Any valid constants can be used Indirect user variables can be used Any math operator can be used Parentheses can be nested to 2 levels Integer math is used for all operations Expressions are evaluated left to right Valid math expressions can be substituted for numbers in most instructions few examples of math expressions in assignment instructions follow 1 500 1 5 100 CHAPTER 3 PROGRAMMING LANGUAGE X1 5000 10 X1 7 3 28 22 All set X1 to 500 Furthermore variables can be used in the expression X1 20 X2 30 X3 X1 X2 fills X3 with 600 All operations are done with integer math Fractional results from division are rounded to the nearest integer Also expressions are evaluated from left to right These two conditions can cause unexpected results Consider the following expressions P 53 100 280 THIS PRINTS 280 P 280 100 53 THIS PRINTS 159 P 280 53 100 THIS PRINTS 148 Mathematically these three expressions are equivalent they calculate 5396 of 280 which is exactly 14
82. and torque in either direction This means that the motor can accelerate run and decelerate in either direction Friction A resistance to motion caused by surfaces rubbing together Friction can be constant with varying speed coulomb friction or proportional to speed viscous friction or present at rest static friction Full Load Current The armature current of a motor operated at its full load torque and speed with rated voltage applied Full Load Speed The speed of a motor operated with rated voltage and full load torque Gain The ratio of system output signal to system input signal Hall Sensors BDS5 GLOSSARY A feedback device which is used in a brushless servo system to provide information for the amplifier to electronically commutate the motor The device uses a magnetized wheel and hall effect sensors to generate the commutation signals Holding Torque Sometimes called torque it specifies the maximum external force or torque that can be applied to a stopped energized motor without causing the rotor to rotate continuously Home Position A reference position for all absolute positioning movements Usually defined by a home limit switch and or encoder marker Normally set at power up and retained for as long as the control system is operational Host Computer An auxiliary computer system which is connected to a controller or controllers The host computer in distributed control systems
83. and the maximum belt speed of 275 inches minute is equivalent to 780 kHz on the encoder If the belt is at maximum speed the profile of the motor is to rotate one revolution at a peak speed of 400 RPM Solution Connect the conveyor belt motor encoder to the input channel of the BDS5 as shown in the Installation and Setup Manual Wiring C1 The following program should be executed REG ON ENABLE PROFILE REGULATION SET THE MAX EXTERNAL REGKHZz780 FREQUENCY TO 780 MOVE ONE REVOLUTION AT 1400 RPM MI 4096 400 In the case above the MI move will generate a one revolution move at a speed proportional to the external input frequency with 400 RPM the maximum rate when the external input frequency is 780 kHz Note that the belt speed virtually never reaches 275 inches minute However REGKHZ must be higher than the worst case maximum belt speed For example the above program can be modified to allow an even larger belt speed REG ON ENABLE PROFILE REGULATION SET THE MAX EXTERNAL REGKHZz1560 FREQUENCY TO 1 56 MHZ MOVE ONE REVOLUTION 800 RPM MI 4096 800 Notice that REGKHZ was doubled However since the speed of the move was also doubled to 800 RPM the commanded move is identical BDS5 3 8 15 Encoder Feedback Some special applications demand more accuracy than can be provided with a resolver based system For these cases you can mount an encoder to the motor and
84. at the factory Factory variables program the 5 for the particular motor it will be controlling The MOTOR command changes these variables as necessary for the motor E 2 STANDARD VARIABLES Table E 1 Standard Variables VARIABLE DESCRIPTION PROGRAM CONDITION s Factory 1 See table at end of selection for description of long and short E 1 APPENDIX E VARIABLE QUICK REFERENCE BDS5 VARIABLE DESCRIPTION PROGRAM UNITS PROGRAM LIMITS CONDITION None Lmt Monitor LIMIT Inpa Noe E 2 BDS5 APPENDIX E VARIABLE QUICK REFERENCE VARIABLE DESCRIPTION PROGRAM PROGRAM LIMITS CONDITION MOTION _ Monitor MOTION Tu Ne _ IN SpeciatConstant o Nee __ OFF Speta conas Never _ JOK2EN OKwemeBDss Ne s _ ON Special Constant Nee _ PCAP Capture Position Ne Pos PEMD Position Command Ne es PDEN Pe odio ____ pem P PL PL o Enable Position Loop PLIM Enable Soft Limits PMAX Soft Upper Limit PROMPT Enable Prompts None PROTARY Rotary Distance Aways Pos PENL Final Position Never ros PMIN Soft Lower Limi P None PRD PosiiontromeD Neer Coms OS OS OS OS OS OS OS OS OS S E 3 APPENDIX E VARIABLE QUICK REFERENCE BDS5 VARIABLE DESCRIPTION PROGRAM UNITS PROGRAM LIMITS CONDITION READY Enable Drive Ne s _ REG m
85. can be used TIL 11 14 15 1 16 EQ 4 ALGEBRAIC MATH 4 15 CHAPTER 4 USER PROGRAMS BDS5 TIL 11 amp 14 amp 15 amp 1 16 EQ 1 LOGICAL MATH Notice the use of 1 I6 This is a logical NOT because if I6 equals 1 then 1 I6 is 0 and if I6 equals 0 1 I6 is 1 The logical NOT is useful when checking to see if inputs are off If more than a few inputs must be tested then referencing them one at a time can be cumbersome As an alternative IN can be used This can be demonstrated with the example above If the program must wait for inputs 1 4 and 5 to be on and input 6 to be off logical math can be used to mask the inputs that are not supposed to be tested inputs 2 3 and 7 16 A mask is a binary word with a 0 for each input that is not tested and a 1 for each that is In this example the mask would be Input Number 8 7 6 5 3 2 4 1 Test Input N N Y Y Y N N Y 0 0 0 0 Binary Mask 1 1 1 1 Input Number 16 15 14 13 12 11 10 9 Test Input N N N N N N N N Binary Mask 0 0 0 0 0 0 0 0 Since the mask must be in hex or decimal it can be expressed as 0000000000111001 BINARY equals 39 HEX or 57 DECIMAL which equals 1 8 16 32 DECIMAL Now that the mask is known the condition must be determined The condition is formed much like the mask In this case there is a binary 1 for each input that must be on and a binary 0 for each input that is either off or masked T O Number 8 7 6 I O On N
86. can see the velocity changing Because VFB is updated very rapidly the speed can appear to vary even when the motor is rotating at a fairly constant speed This is because the VFB shows the speed averaged over only 1 millisecond The speed from one millisecond to the next normally varies a few RPM The long term speed that is measured over a few seconds normally varies much less about 0 01 VFB is in velocity units VE is velocity error VE is the difference between VCMD and in velocity units VAVG is the average of VFB over the previous 16 milliseconds Occasionally the normal sample to sample variation of VFB is undesirable In these cases use VAVG 3 7 3 2 Velocity Limits VMAX amp VOSPD VMAX is the BDS5 maximum velocity It depends on the motor and the resolution of the R D converter For standard systems with 12 bit R D converters VMAX is less than or equal to 7500 RPM For 14 bit systems VMAX is limited to 3000 RPM 16 bit 3 15 CHAPTER 3 PROGRAMMING LANGUAGE systems are limited to 750 RPM VMAX is set at the factory VMAX is in velocity units VOSPD is the maximum velocity for your system The BDS5 generates an overspeed fault if VFB is ever greater than VOSPD You can set VOSPD to any level below 1 2 VMAX This allows you to limit the speed of your system to any level below VMAX When an overspeed occurs the BDS5 is disabled immediately You should set VOSPD to at least 1096 or 1596 above you
87. command This example assumes that the speed is already 2000 RPM when the JF command is executed ASSUME PRESENT SPEED IS 2000 RPM JF 50000 1000 2000 RPM COMMAND ENTERED HERE 1000 RPM Figure 3 6 Jog From JF Command The next graph shows the effect of the Jog To JT command This example also assumes that the speed 1s 2000 RPM when the command is executed ASSUME PRESENT SPEED IS 2000 RPM JT 50000 1000 BDS5 2000 RPM COMMAND ENTERED HERE 1000 RPM 50000 COUNTS Figure 3 7 Jog To JT Command Position dependent commands must be used with care If you specify a position that has already passed the BDS5 will generate ERROR 42 MOVE W O TIME Also if the Jog To command is given so that ACC or DEC prohibits the profile from reaching final speed before the specified position the BDS5 will generate ERROR 42 ERROR 41 MOVE NEEDS MOTION is generated if Jog To or Jog From are commanded when the velocity is 0 Finally a position dependent jog that attempts to change the direction of rotation will generate an error of these errors stop motion 3 8 11 1 Registration The 5 allows you to combine the position capture with the Jog To command to implement index to registration One example of index to registration is a conveyor belt on which items are placed in random positions An optical sensor detects the item upstream of the operation BDS5 controlling the con
88. commands from the user program are suppressed and the monitor prompt 2 12 BDS5 gt is displayed Print commands typed in from the Monitor mode are executed immediately To enter the Monitor mode press the escape key while a program is running Pressing the escape key again will change modes back to the Run mode STOP BREAK and KILL all return the BDS5 to the Interactive mode 2 6 2 4 Single Step Mode The Single Step mode is provided for debugging and it allows you to execute a program one step at a time The single step prompt s gt is printed out followed by the line that is about to be executed the next command Any command allowed from the terminal in the Monitor mode is also allowed from the terminal in the Single Step mode These commands allow you to probe the BDS5 variables while debugging your program If you press the enter key without a command entered then the next command in the user program is executed To stop the program enter the S B or K command To turn off the Single Step mode and allow the program to execute normally press the escape key twice once to get into the Monitor mode and again to get into the Run mode or type SS OFF Single Step mode is enabled by turning SS on either from the program from the Interactive mode before running the program or from the Monitor mode After SS is on the BDS5 will enter the Single Step mode when the user program is executed SS can also be turned
89. desired field width For example CHAPTER 4 USER PROGRAMS BDS5 X1 255 Similarly P X1 X1 H P Xiz X1 H3 XS1 0 P USER SWITCH 1 IS XS1 S will cause the 5 to print results in X1 FFH X1 FFH Two s complement notation is used when printing in hex This means that printing negative hex values requires the full field width of 9 characters When printing in hex format the field must be wide enough to include the appended 4 6 1 4 Printing Binary Numbers To print a variable in binary format follow the variable name with a B enclosed in square brackets The variable will be printed in a field 33 characters wide including an appended B indicating binary of the leading zeros will be printed The default field width of 33 can be reduced by following the B with the desired field width For example X2 127 P X2 X2 B P 2 X2 B10 will cause the BDS5 to print 2 0000000000000000000000001111111B X2 001111111B 4 6 1 5 Printing Switches Formatted printing can also be used to display switches any variable with a value of 0 or 1 either as Y or N or as on or off This allows you to communicate with the operator better than just printing 0 or 1 The switch format on or off is printed with a bracketed S S following the variable XS1z1 P USER SWITCH 1 IS XS1 S These commands would result in USER SWITCH 1 IS ON 4 18 USER SWITCH
90. eee FILENAME GlOSSAEy eei e ne em edendum GLOSS DOC nume M nae INDEX DOC 55 Uperade Notices ei nest ttem teta NUGCVR DOC NUGHIST DOC VERRE HERE Se ie REO NUPGRDI DOC SEO hU ilte OI deo iere htec NUPGRD2 DOC ea ibue pb Pe NUPGRD3 DOC NUPGRD4 DOC deemed tmu Rn utere NUPGRDS5 DOC
91. follows A Select a convenient number of counts per second on the external input B Calculate the corresponding machine velocity in your user units 4 36 BDS5 Perform the operation indicated in Table 4 16 under EXTERNAL VELOCITY UNITS and set VXNUM VXNUM equal to this value Example A machine has a motor coupled to a 0 1 inch pitch lead screw which drives a table A 0 1 inch pitch lead screw means the table moves 0 1 inch per motor revolution The R D resolution is 12 bits The user units for table motion you desire are Position Units mils 1 mil 0 001 inch Velocity Units inches minute IPM Acceleration Units inches minute second IPM second Objective Find PNUM and PDEN Find VNUM and VDEN Find ANUM and ADEN Solution Find PNUM and PDEN A Select Table 4 14 B Select a motor movement of 1 revolution C 1 revolution of the 0 1 pitch lead screw translates to 0 1 inch or 100 mils of table movement D Refer to Table 4 14 under POSITION UNITS for the formula PNUM PDEN 4096 1 100 2 40 96 Select PNUM and PDEN PNUM 4096 PDEN 100 E Since a 12 bit R D converter is used calculations in step E are not needed Find VNUM and VDEN A Select Table 4 14 B Select 10 RPM motor velocity BDS5 C 10 RPM of the 0 1 pitch lead screw translates to 1 IPM of table velocity D Refer to Table 4 14 under VELOCITY UNITS for the formula VNUM VDEN 4473 92 10 1
92. from the gearbox However if you typed CONTINUE J 200 the CONTINUE would disable the electronic gearbox while commanding the motor to continue at whatever speed it was going when the command was executed Then the J 200 command would bring about a controlled deceleration to 200 RPM CONTINUE normally looks at the velocity command for 1 millisecond If the velocity command is generated from the electronic gearbox or a regulated profile the velocity can vary considerable The CONTINUE command allows you to specify a time period up to 1 second over which velocity command is averaged For example if you entered CONTINUE 50 the CONTINUE command would change the velocity command to the average velocity command over the previous 50 milliseconds CONTINUE always sets SEG to 1 The 5 provides several control loops These loops or control algorithms allow you to select the best control method for your applications 3 9 CONTROL LOOPS There are four sections of control loops that are of interest input output feedback and tuning variables The input is compared to the feedback to generate an error The error signal is modified using the tuning variables to generate the output The tuning variables can be modified to produce higher levels of performance unfortunately higher performance brings with it greater noise susceptibility and reduced stability The system designer must optimize noise and performance for the applic
93. from the publisher While every precaution has been taken in the preparation of this book the publisher assumes no responsibility for errors or omissions Neither is any liability assumed for damager resulting from the use of the information contained herein This document is proprietary information of Danaher Motion Kollmorgen furnished for customer use ONLY No other uses are authorized without written permission from Danaher Motion Kollmorgen Information in this document is subject to change without notice and does not represent a commitment on the part of Danaher Motion Kollmorgen Therefore information contained in this manual may be updated without notice due to product improvements etc and may not conform in every respect to former issues This product is covered by U S Patents 4 447 771 4 479 078 4 490 661 Other foreign patents pending U L is a trademark of Underwriter s Laboratories N E C is a trademark of the National Electric Code Kollmorgen GOLDLine BDS4 BDS5 and PSR4 5 are trademarks of Danaher Motion Kollmorgen Dangerous voltages currents temperatures and energy levels exist in this product and in the associated servomotor s Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt to install setup and operate this equipment Ensure that the motor drive and the end user assembly are all properly grounded per NEC requirements
94. given move performed repetitively can be duplicated Resolution The smallest positioning increment that can be achieved Frequently defined as the number of steps or feedback units required for a motor s shaft to rotate one complete revolution Resolver A position transducer utilizing magnetic coupling to measure absolute shaft position over one revolution Resonance The effect of a periodic driving force that causes large amplitude increases at a particular frequency Resonance frequency RFI Radio Frequency Interference Ringing Oscillation of a system following sudden change in state Glossary xi GLOSSARY BDS5 Rise Time The time required for a signal to rise from 10 of its final value to 90 of its final value RMS Current Root mean square current In an intermittent duty cycle application the RMS current is equal to the value of steady state current which would produce the equivalent resistive heating over a long period of time RMS Torque Root Mean Square Torque For an intermittent duty cycle application the RMS torque is equal to the steady state torque which would produce the same amount of motor heating over long periods of time Robot A reprogrammable multifunctional manipulator designed to move material parts tools or specialized devices through variable programmed motions for the performance of a variety of tasks Robot Control A computer based motion control device to
95. high speed eliminating the need for the medium speed traverse The following program illustrates this JOG 5000 RPM TO GET TO HOME WAIT FOR CAPTURE TO OCCUR 0 STOP MOTION MA PCAP 200 RETURN TO PCAP TIL CAP EQ 0 APPROXIMATE HOME J 1 JOG AT A LOW SPEED TIL HOME CAN BE FOUND ONCE HOME IS CHROSSED STOP TIL HOME EQ 0 J 0 The capture position is accurate to 25 microseconds The resulting error is proportional to speed For example for a 12 bit R D converter if the capture were done while the motor was rotating at 5000 RPM the error would be limited to about 1 degree If this is not close enough you can jog the few bits until the switch is tripped or you can use the MRD as discussed above 3 8 10 Clamping Clamping stops BDS5 motion when the position error exceeds a set point This is used to determine that the motor usually through a lead screw has run a part into a mechanical stop The profile stops and the part is held with limited torque This is sometimes referred to as Feed to Positive Stop The stop is detected by watching position error when position error exceeds the variable PECLAMP the part is assumed to have run into a stop When a stop has been detected the BDS5 will hold the current at ILIM which should be set to the proper holding current ILIM can be increased or decreased after the stop has been detected To enable clamping turn CLAMP on PECLAMP can be change
96. in desired velocity or position is achieved in the minimum possible time with little or no overshoot Daisy Chain Glossary iii GLOSSARY BDS5 A term used to describe the linking of several RS232C devices in sequence such that a single data stream flows through one device and on to the next Daisy chained devices usually are distinguished by device addresses which serve to indicate the desired destination for data in the stream Damping An indication of the rate of decay of a signal to its steady state value Related to setting time Damping Ratio Ratio of actual damping to critical damping Less than one is an underdamped system and greater than one is an overdamped system DC Adjustable Speed Drive equipment required to adjust the speed or torque of DC motor s by controlling the voltages applied to the armature and or field of the motors DC Drive An electronic control unit for running DC motors The DC drive converts AC line current to a variable DC current to control a DC motor The DC drive has a signal input that controls the torque and speed of the motor Dead Band A range of input signals for which there is no system response Decibel dB A logarithmic measurement of gain If G is a systems gain ratio of output to input then 20 log G gain in decibels dB Demag Current The current level at which the motor magnets will be demagnetized This is an irreversible effect which will a
97. in the BDSS The filter can be modeled as two cascaded low pass single pole filters both with a 3 dB frequency of 200 Hz LPFHZ should be set as high as possible since it degrades the system performance 6 7 CHAPTER 6 COMPENSATION BDS5 For example the following sequence sets the low pass filter to 250 Hz and enables the drive LPFON ENABLE LOW PASS FILTER LPFHZ 250 SET BREAK FREQ TO 250 HZ If the low pass filter is on the TUNE command may not work Il NOTE 6 8 BDS5 APPENDIX WARRANTY INFORMATION WARRANTY INFORMATION Industrial Drives a Kollmorgen Division warrants The terms and conditions of this Warranty are that equipment delivered by it to the Purchaser will provided with the product at the time of shipping or be of the kind and quality described in the sales in advance upon request agreement and or catalog and that the equipment will be free of defects in design workmanship and The items described in this manual are offered for material sale at prices to be established by Industrial Drives and its authorized dealers 1 BDS5 Appen B ASCII TABLE The chart on the following pages is an ASCII Code and Hexadecimal conversion chart The 5 doesnot support extended ASCII 128 255 APPENDIX B ASCII TABLE 1 APPENDIX B TABLE BDS5 ASCII CODE AND HEX CONVERSION CHART gt gt gt gt Q gt gt
98. internal error Contact the factory This error breaks program execution and disables the BDS5 GENERAL INTERNAL This is an internal error Carefully write down the entire line that is printed with the error and contact the factory This error breaks program execution and disables the BDS5 STACK OVERFLOW This is an internal error Carefully write down the entire line that is printed with the error and contact the factory This error breaks program execution and disables the BDS5 INTERNAL 1 9 These are internal errors Contact the factory These errors break program execution and disable the BDS5 UNKNOWN This is an internal error If this error exists in the error history upon initial power up clear it with ERR CLR Contact the factory if this error occurs during operation This error breaks program execution and disables the BDSS BDS5 SEVERITY 3 SEVERITY 3 SEVERITY 3 SEVERITY 3 SEVERITY 3 SEVERITY 3 SEVERITY 3 BDS5 APPENDIX E VARIABLE QUICK REFERENCE prennix E VARIABLE QUICK REFERENCE E 1 INTRODUCTION This appendix lists all the variables on the 5 All variables are shown with the required programming conditions For example ABAUD has the programming condition ALWAYS This means ABAUD can be changed at any time Other variables require the 5 to be enabled or disabled Others such as feedback variables are never programmable FACTORY variables can only be changed
99. interpolation the BDS5 is able to generate a 32 768 point CAM The interpolation algorithm will split each CAM table point into 256 linearly interpolated mid point positions based on the master input this is why the gear ratio must be chosen so that each revolution of the Master Cam input generates 32 768 counts of PCMD to the CAM table This scaling is easily accomplished by programming the GEARI variable to 32 768 and then programming the number of counts generated by one revolution of the master input CAM into GEARO A example would be as follows The master input device is a 2 000 line encoder Each revolution of this encoder would produce 8 000 2 000x4 counts of position command If it took two revolutions of the mater to make one turn of the CAM then the master input would receive 16 000 8 000x2 counts of position command per turn of the CAM this means that the variable GEARO should be programmed to 16 000 Note The variable GEARO must be number between 0 and 32 767 The variable GEARI must be a number between 32 768 and 32 767 BDS5 MASTER SLAVE The next page will provide a more detailed block diagram of the Electronic Gearbox Profile Regulation and Electronic CAM master slave modes of the BDS5 13 14 ELECTRONIC GEARBOX
100. linear or rotational velocity of a motor or other object in motion Speed Regulation For a speed control system speed regulation is the variation in actual speed expressed as a percentage of set speed BDS5 GLOSSARY SPS Steps Per Second A measure of velocity used with stepping motors Stall Torque The torque available from a motor at stall or zero rpm Static Torque The angle the shaft rotates upon receipt of a single step command Stator The non rotating part of a magnetic structure In a motor the stator usually contains the mounting surface bearings and non rotating windings or permanent magnets Stiffness The ability to resist movement induced by an applied torque It is often specified as a displacement curve indicating the amount a motor shaft will rotate upon application of a known external force when stopped Synchronism A motor rotating at a speed correctly corresponding to the applied step pulse frequency is said to be in synchronism Load torques in excess of the motor s capacity rated torque will cause a loss of synchronism Tachometer An electromagnetic feedback transducer which produces an analog voltage signal proportional to rotational velocity Tachometers can be either brush or brushless Tachsyn A brushless electromagnetic feedback transducer which produces an analog velocity feedback signal and commutation signals for a brushless servo motor The tachsyn is functi
101. lt cr gt lt lf gt gt A Stop command will stop motion at AMAX and break the program The interactive prompt will be returned indicating that the BDS5 has stopped running the program gt 9 S lt cr gt lt lf gt Break command will stop at AMAX and break program The interactive prompt will be returned indicating that the BDS5 has stopped running the program gt B B lt cr gt lt lf gt M esaet 22 A Kill command will disable motor and break program The interactive prompt will be returned indicating that the BDS5 has stopped running the program gt K Ke lt cr gt lt lf gt Cee Sending a command not allowed in the monitor mode will return the following response gt J 1000 lt cr gt J 1000 lt cr gt lt lf gt lt er gt lt lf gt lt lf gt lt bell gt ERR 63 J 1000 lt 22 sp gt NOT AT THIS LEVEL lt cr gt lt lf gt gt gt P SEG 1 lt cr gt SEG 1 lt cr gt lt lf gt O lt cr gt lt lf gt gt ASSUME 1024 gt lt gt P PFB lt cr gt lt lf gt lt 8 sp gt 1024 lt cr gt lt lf gt gt gt P PFB 4 lt cr gt P PFB 4 lt cr gt lt lf gt 1024 lt cr gt lt lf gt gt PPB 5 P PFB 5 lt cr gt lt lf gt lt sp gt 1024 lt cr gt lt lf gt gt gt P PFB 3 P PFB 3 lt cr gt lt lf gt XXX lt cr gt lt lf gt gt THE XXX MEANS THAT PF
102. lt cr gt lt lf gt gt 19 gt 3 lt gt P PFB 3 lt cr gt lt lf gt XXX lt cr gt lt lf gt om gt P PFB 4 lt cr gt P PFB 4 lt cr gt lt lf gt 1024 lt cr gt lt lf gt Any programmable variable user and dedicated be programmed with a value by using the BDS5 equate function X1 1000 X1 1000 lt cr gt lt lf gt Main The 5 equate function will work with either an Equal Sign a Space X1 1000 X1 1000 lt cr gt lt lf gt The Run command can be used to enable the BDS5 multitasking by typing RUN Notice that once the BDSS has started running that the prompt does not return gt RUN lt cr gt RUN lt cr gt lt lf gt The RUN command can also start a specific program label gt RUN lt cr gt RUN lt cr gt lt lf gt If an error occurs it will not print out if a prompt is present until a lt cr gt is received gt lt cr gt lt cr gt lt lf gt lt bell gt ERR 17 FEEDBACK LOSS lt cr gt lt lf gt an 20 If the host was sending a command to the BDS5 an error occurred before the command was finished the BDS5 will ignore the command and respond with the following sequence gt lt gt lt cr gt lt lf gt w NOW AN ERROR OCCURS TYPE IN A COMMAND AND A lt gt gt P PFB lt cr gt lt cr gt lt lf gt ERROR MSG WAITING COMMAND IGNORED lt cr gt lt lf gt lt cr gt lt lf gt lt lf
103. memory This means you can execute jogs or simple moves after the Macro BDS5 move is calculated the MCGO command will still execute the move properly 3 8 7 2 Macro Move Example 1 As an example of Macro moves consider the following profile 1000 RPM 200 RPM 0 10000 11000 COUNTS COUNTS COUNTS Figure 3 4 Macro Move Example 1 There is no way to use MA or MI to accomplish this profile so Macro moves must be used The following sequence will generate the move shown in Figure 3 4 ACC 20000 DEC 20000 MCI 10000 1000 200 MOVE 10000 COUNTS TRAVERSE 1000 RPM AND END AT 200 RPM MOVE 1000 MORE COUNTS TRAVERSING AT 200 RPM THE FINAL SPEED OF THE PREVIOUS MOVE AND END AT 0 RPM BEGIN MOTION MCI 1000 0 Every subsequent MCGO will generate a similar move 11000 counts long 3 8 7 3 Macro Move Example 2 The profile can be made slightly more complex by adding a 0 5 second dwell and a return to the original position on the end This profile is demonstrated below CHAPTER 3 PROGRAMMING LANGUAGE 10000 COUNTS 11000 COUNTS Figure 3 5 Macro Move Example 2 Note that this diagram is a shorthand schematic of motion This curve is plotted as velocity versus time for forward motion the first 5 segments and for the dwell However return motion is shown as negative motion returning to the origination time Obviously time does not go backwards This method of diagrammi
104. memory into the editor starting at the cursor You must position the cursor to the proper place before you make this selection SAVE MARKED BLOCK AKAW Use this selection after you have marked a block This selection saves the marked block to a file on your disk Motion Link will ask you for the file name after you make this selection 2 4 2 3 GOTO FIND A STRING Q F This selection finds a string in the editor Motion Link will prompt you to enter the string REPEAT LAST FIND L This selection repeats the last FIND A STRING GOTO A LINE NUMBER Q I This selection moves the cursor to the specified line Note that you can transmit your program to the BDS5 without comments Since comment lines can be ignored by Motion Link when your program is transmitted the line numbers of your program in the editor may not agree with the line numbers of your program in the BDSS Because of this Motion Link will ask you if you want to count comments If you are trying to find a line number from a BDS5 error message and you transmitted your 2 7 CHAPTER 2 GETTING STARTED program without comments specify that you DO NOT want Motion Link to count comment lines Otherwise specify that you DO want comment lines counted SHOW SIZE OF EDITOR Q O This selection displays how much space is left in the Motion Link Editor Use this selection if you are concerned that your program is filling up the editor The Motion Li
105. numbers represent the equipment desired for your application Also verify the compatibility between components of the servo system The model numbers are as follows 1 3 CHAPTER 1 SYSTEM DESCRIPTION BDS5 1 4 4 BDS5 Model Number BDS5A 240 00010 605C 2 ABC DEFGH UL Designator _ Voltage and Current Ratings ser Program Options irmware Version Motor and Winding D Resolution Figure 1 1 BDS5 Model Number Scheme Table 1 1 BDS5 Model Number Scheme LEGEND DEFINITION UL Designator UL Listed standard Non UL Listed Voltage Rating 115 VAC 230 VAC Current Rating 3 Amps Phase 6 Amps Phase 10 Amps Phase 20 Amps Phase 30 Amps Phase 40 Amps Phase 55 Amps Phase Mechanical Options 0 indicates standard feature Standard Communication Options RS 232 standard RS 422 RS 485 Input Options Encoder Input standard Analog Input Pulse Input No Input I O Options 8 I O standard 32 0 Accuracy Options 8 ARC min standard R D Resolution R D Resolution 2 12 Bit 4096 counts rev 4 14 Bit 16384 counts rev Firmware Version Firmware Version Assigned by Industrial Drives not normally specified when ordering Most current firmware supplied unless otherwise specified User Program User Program This is reserved for systems that are programmed by Industrial Drives This is not normally specified when ordering BDS5 1 4 2 Compensation Module Model Number 03 20
106. of position capture Set to 1 on power up The value of this variable does not matter if CAP is 0 Enables Clamp mode Set to 0 on power up and normally left at for preliminary operation Deceleration rate initially in RPM Sec Initially set to 100000 Sets BDS5 direction If 1 then positive motion is clockwise If 0 then positive motion is counter clockwise This is set to 1 on power Fault is automatically set and cleared by the BDS5 You can change its state during operation though you do not need to change it during initial operation Enable Gate mode Set to 0 on power up and normally left at zero for preliminary operation BDS5 GEAR GEARI GEARO IDEN ILIM INUM KC KF CHAPTER 3 Enable electronic gearbox Set to 0 on power up and normally left at 0 for preliminary operation KV Number of teeth on the input gear for electronic gearbox Initially set to 1 Value of this variable does not matter if GEAR is 0 Number of teeth on the output gear for electronic gearbox Initially set to 3 Value of this variable does not KVI matter if GEAR is 0 Current units denominator Initially set to 100 for percent Peak current limit The initial value is listed on the Test and Limits TL sheet which should be enclosed with LPF your system Normally set to IMAX However you may want to reduce it for protection The motor can normally run under no load wi
107. offset and digitally adjustable servo tuning parameters The optional analog input permits you to use the BDS5 as an analog velocity drive FEED FORWARD GAIN The digital feed forward gain reduces following error and motion initiation delay thereby increasing machine throughput DIAGNOSTICS The BDS5 offers a complete set of error diagnostics When an error occurs the BDS5 displays an English BDS5 language error message The BDS5 remembers the last 20 errors even through power loss In addition the BDS5 lets you write your own error handler During a fault condition you can use the error handler to set outputs alert an operator and shut down your process smoothly The BDS5 offers trace and single step modes so that you can debug your program The BDS5 has complete fault monitoring including travel limit switches feedback loss and software position limits as well as hardware safety circuits watchdogs and checksums for more reliable and safer operation The 5 has up to 32 I O sections that you connect via ribbon cable to standard OPTO 22 compatible 1 boards or to INDUSTRIAL DRIVES I O 32 The I O 32 provides either fixed 24 volt or removable industry standard optically isolated I O in a GOLDLINE style package e SERIAL COMMUNICATIONS The BDS5 s serial communications provide a powerful link to other popular factory automation devices such as PLC s process control computers and smart termin
108. on Multi Tasking Overview High priority means that if two tasks both need to run at the same time then the commands from the task with highest priority will execute first For example Alarm has the highest priority If Alarm and Alarm B are fired at the same time Alarm A will run until it is complete then Alarm B will run until it is complete 4 8 1 Multitasking and Autobauding If you set the BDS5 to autobaud multi tasking will not be enabled until communications have been established This means that the BDS5 will not operate if a terminal or computer is not present Therefore you normally will want to disable autobauding by turning ABAUD off Turn ABAUD off if you plan to use multi tasking The BDS5 will remember that ABAUD is NOTE off through power up 4 8 2 MULTI If you want to disable Alarm C the variable input routine and background type MULTI OFF For example if you have a time critical section of code you may turn MULTI off at the beginning of the section and then back on at the end of the section CHAPTER 4 USER PROGRAMS 4 8 3 END Command Tasks are normally terminated with the END command END signifies the end of the task whereas Break B implies that all tasks stop executing For example if you end an alarm with the Break command the entire program stops running and the BDS5 returns to the Interactive mode However if you end an alarm with the END command the alarm stops b
109. on and off from the program This is useful if there are certain sections that you want to single step through Turning SS off from the program returns the BDS5 to the Run mode 2 6 2 5 Trace Mode The Trace mode is provided for debugging When in trace the BDS5 prints statements before they are executed The trace prompt t is printed out followed by the line that is about to be executed and the line is then executed This process is repeated for each command trace prompt is not a true prompt in that you are not allowed to enter a command after the prompt is issued This is why it does not have the gt that the other prompts use to indicate that the BDS5 is waiting for a command The trace is enabled by turning TRC on When TRC is on the BDS5 will enter the Trace mode when the user program is executed TRC can be turned on and off from the Interactive mode before executing the program or from the program itself It can be turned BDS5 CHAPTER 2 GETTING STARTED on from the Monitor mode Pressing the escape key from the Trace mode will exit to the Monitor mode and turn TRC off If TRC is turned off from the program the BDS5 will exit to the Run mode If both TRC and SS are on then the BDS5 will be in Single Step mode 2 6 2 6 Other Modes The other modes shown in Figure 2 2 include the Edit modes Edit Insert Change and Find and the communication modes Program Load Program Dump and System Dump These mode
110. only from the user program Format TIL lt Expr gt Logical lt Expr gt Instruction Example TIL PFB GT 100 P PFB TIL X1 X2 NE X4 X5 5 GOSUB 100 TIL VFB LT 100 DELAY EXECUTION Tune the motor to a new load This command is used if the motor needs to be re tuned The tuning parameters KP KV KVI and KPROP determine the motor stability and response time Often when the motor load is changed tuning parameters need to be reset The Tune command specifies Bandwidth and Stability Higher bandwidth will produce faster response time Higher stability will produce less overshoot but noisier performance Allowed from the interactive mode and the user program Format TUNE Bandwidth Stability Where Bandwidth is 5 10 15 50 Hz and stability is 1 2 or 3 Example TUNE 25 2 APPENDIX SOFTWARE COMMANDS BDS5 ZPE lt BDS gt BDS Wait for a specified motion profile segment to start before continuing program execution W is an idling command that is if you are using multi tasking W suspends the task but lets other tasks proceed Allowed only from the user program Format W lt Segment gt Where Segment is a motion segment Examples W 3 WAIT FOR SEGMENT 3 TO START W 0 WAIT FOR MOTION TO STOP Clear the position error This command is useful when enabling the position loop when position error has been allowed to accumulate Allowed from the interactive and monitor modes and the user program
111. position of the entire Macro move Like MI and MA the entire Macro move must begin and end at zero speed although beginning and ending speeds of individual sections are not constrained to 0 RPM Dwell segments can be embedded in Macro moves 3 8 7 1 MCA MCI MCD amp MCGO There are two kinds of Macro moves Macro Absolute MCA and Macro Incremental MCI Dwells can be inserted using the Macro Dwell MCD command When the move is completely specified the Macro Go MCGO can be used to execute the move MCGO can be executed as many times as desired once calculations for the entire move are complete Both Macro Absolute and Macro Incremental moves are specified in a similar manner You must specify either the end position for Absolute moves or the 3 24 BDS5 distance for Incremental moves You also can specify up to two velocities If two velocities are specified then the first is the traverse speed and the second is the ending speed If one velocity is specified then it is assumed to be the ending speed In this case the BDS5 uses the larger speed either the beginning or ending speed for the traverse speed velocities are specified greater than zero The BDS5 determines the direction based on the specified position If no velocities are specified then the BDS5 continues the Macro section at the beginning speed until the specified position is reached If you want to include a dwell in the middle of a Macro mo
112. steady state running conditions KF should never be larger than 16384 In addition larger KF makes the system more responsive to commands Unfortunately large values of KF cause overshoot KP must be reduced to reduce overshoot If you need to minimize position error when the motor is turning you will need to optimize KF and KP Typically KF ranges from 2000 to 10000 TQ should be off when PL is turned on The system becomes unstable when PL and TQ are both on If you do not turn TQ off before turning PL on the BDS5 will force TQ off 3 38 BDS5 When PL is turned on TQ is turned off automatically ANN NOTE 3 9 2 Velocity Loop The velocity loop takes its input from the position loop if PL is on If PL is off motion commands directly control the velocity command VCMD The feedback is VFB velocity feedback and the difference of these two signals is VE velocity error Velocity error can be used in two control loops proportional and integrating 3 9 2 1 Proportional Velocity Loop If a proportional velocity loop is selected then the velocity error is multiplied by KPROP the proportional constant to generate ICMD the current command Proportional velocity loop is selected when the PROP switch is on PROP is turned off on power up Proportional velocity loops are much easier to stabilize than integrating loops so they are often used during machine setup However they also allow steady state velocity error
113. the controlled parameter is mechanical velocity Master Slave Motion Control A type of coordinated motion control where the master axis position is used to generate one or more slave axis position commands Mechanical Time Constant BDS5 GLOSSARY The time for an unloaded motor to reach 63 2 of its final velocity after the application of a DC armature voltage Microstepping An electronic control technique that proportions the current in a step motor s windings to provide additional intermediate positions between poles Produces smooth rotation over a wide speed range and high positional resolution Mid Range Instability A phenomenon in which a stepping motor can fall out of synchronism due to loss of torque at mid range speeds The loss of torque is due to interaction between the motor s electrical characteristics and the driver electronics Some drivers have circuitry to eliminate or reduce this phenomenon Most Significant Bit The bit in a binary number that is the most important or that has the most weight Motor AC A device that converts electrical alternating current into mechanical energy Requires no commutation devices such as brushes Normally operated off commercial AC power Can be single or multiple phase Motor AC Asynchronous or Induction An AC motor in which speed is proportional to the frequency of the applied AC Requires no magnets or field coil Usually used for non precise constant
114. the following command P PGMCKSUM this prints in decimal P PGMCKSUMD7 this prints in decimal with SCKSUM 1 P PGMCKSUM H this prints inhex P PGMCKSUM H D7 this prints in hex with SCKSUM 1 Notice that H has a checksum of 256 decimal or Oh so the checksum of PGMCKSUM is the same as the checksum for PGMCKSUM H Remember that once the Serial Checksum is turned on it can only be turned off with a valid checksum The following string will turn off the Serial Checksum SCKSUMZ043 cr where 43 equals the checksum of the string SCKSUM 0 The Serial Checksum is case sensitive P 48 lt gt print the feedback position p pfbC8 lt cr gt print the feedback position When entering a command with Serial Checksum enabled backspaces bs will correct a typo and will not themselves effect the checksum Also after entering the BDS5 internal editor mode ED the serial checksum will be momentarily turned off Upon exiting the editor mode Esc BDS5 will resume serial checksum operation To enter the editor type ED89 cr NEW BDS5 CHECKSUM COMMANDS Firmware version 3 1 0 and later SCKSUM 011 Used to enable the serial checksum option This option will require all serial strings transmitted to the BDS5 to be followed by an eight bit checksum format of the checksum is two ASCII hex characters To turn the Serial Checksum off the following string m
115. the servo industry We developed the application of servo motors and drives in the Machine Tool market We were the first with water cooled servos the integral brake the flux forcing concept and the brushless motor We developed the electronically commutated electric car motor Industrial Drives pioneered rare earth magnet development for the servo motor industry Between 1974 and 1980 Industrial Drives continued to lead the industry in servo application innovations Our commitment to engineering excellence never waivered In fact that commitment grew stronger with the development of brushless submarine and submersible motors visiting the Titanic graveyard multi axis electronic drives and antenna pedestal drives delivering unprecedented accuracy and revolutionizing the entire industrial automation process The decade of the 1980 s brought continued advancements in technology and penetration of new markets requiring precise motion control Already in the fifth generation of brushless products Industrial Drives continues to lead the way with digital servo positioning capability and our newest motor offering the GOLDLINE Series incorporating the very latest high energy rare earth magnets neodymium iron boron Once again we are setting the standards that others only hope to duplicate Recently acknowledged by the Frost and Sullivan Foundation a leading market specialist in the motion control industry Industrial Drives and it
116. these changes you should update the configuration file ML CNF with this selection This file is read by Motion Link when you type ML from DOS TL FROM DISK This selection is an internal function BDS5 TL FROM BDS5 This selection is an internal function 2 4 1 6 Help BDS5 HELP F1 This selection displays several pages of help for the BDS5 It lists BDS5 commands and variables with brief descriptions You can also press F1 for this help INTRO HELP This selection displays introductory information about Motion Link LAST COMMAND F3 This selection recalls your last command You can also use the function key F3 to recall your last command VARIABLE INPUT V If you have included a variable input routine in your BDS5 program that is used VARIABLES and your program is running this selection will initiate that routine You can also press V hold the control key down and press V for this function STOP MOTION X This selection breaks your BDS5 program and stops motion It works even if your program is not in the Interactive or Monitor mode You can also press X for this function 2 4 1 7 Utilities RUN DEPO01 SIMULATOR This selection allows the computer to simulate Industrial Drives DEP Data Entry Panel RUN BDS5 SETUP PROGRAM This selection provides utilities to test I O drive feedback communication and dedicated switches Refer to Section 2 6 for more information EXIT TO DOS
117. to the Installation and Setup Manual for communications format 4 10 4 1 lt BDS Command Receiving from the BDS5 The BDS command is used to send the BDS5 user program through the serial port to the terminal or computer The transmission can be stopped by sending an escape character You should not rely on the BDS5 to store all your programs Keep back up copies elsewhere The lt BDS command will cause the BDS5 to transmit the entire user program to your computer It cannot be issued in the Program mode For example from the terminal type and the BDS5 will respond by printing out the entire user program 4 10 4 2 The gt 5 Command Transmitting to the BDS5 The gt BDS command is used to send a new user program through the serial port to the BDS5 The transmission is ended by sending an escape character Note that this command writes over the contents of 4 39 CHAPTER 4 USER PROGRAMS the user program stored in the BDS5 This command allows the program to be directly entered presumably by a computer to the BDS5 It cannot be issued in the program mode The gt 5 command writes over the entire user program NOTE The BDS5 issues the l gt prompt to indicate that it is ready to load a new program line If you are loading from a computer you must wait for the prompt before beginning to transmit a new line The gt 5 command is password protected If a password was set in the BDS5 Editor then it must be
118. to execute an instruction that requires the Editor password This occurs with the gt BDS command In this case you must follow the command with the password FACTORY SETTABLE SEVERITY 2 You attempted to change a variable that is protected These variables are set at the factory This error breaks program execution if the instruction is issued from the user program D 4 7 Errors From IF TIL and GOSUB Commands ERROR 115 ERROR 116 IF w o ENDIF SEVERITY 2 The program executed an IF command to begin an IF BLOCK but could not find the corresponding ENDIF to end the IF block This error breaks program execution IF NOT STARTED SEVERITY 2 BDS5 ERROR 117 ERROR 118 ERROR 119 APPENDIX D ERROR CODES An ELSE ELIF or ENDIF was encountered when there was no IF This will occur among other times if you use a GOTO to branch to the middle of an IF ELIF ELSE ENDIF block This error breaks program execution TIL FOLLOWS TIL The or TIL instruction was used to execute a conditional TIL This error breaks program execution TOO MANY GOSUBS The last GOSUB was one GOSUB too many The BDS5 has 4 levels of subroutines This error breaks program execution RETURN w o GOSUB The BDS5 encountered a RET when it was not expecting one This occurs when there are more returns than GOSUBs This error breaks program execution D 4 8 Power Up Marker Not an Error ERROR 199 DRIVE POWERED UP This
119. travel limits This variable is set to 1 on power up This variable is normally set to 0 during preliminary operation Positive software travel limit Initially set to 100 If PLIM is O the value of this variable does not matter Negative software travel limit Initially set to 100 If PLIM is 0 the value of this variable does not matter Set to 1 on power up and almost always left at 1 When set to 0 all prompts such as gt which are normally sent to the screen are not printed This allows you to print customized messages Position units numerator Initially set to 1 Enable proportional velocity loop This variable is set to 0 on power up and usually left at 0 for preliminary operation External position units denominator Initially set to 1 Value of this variable does not matter during initial operation External position units numerator Initially set to 1 Value of this variable does not matter during initial operation Enable Profile Regulation mode Set to 0 on power up and normally left at Zero for preliminary operation REGKHZ SCRV 55 STATMODE 1 TMR2 TMR3 TMR4 TRC TRIP TQ VDEN VDEFAULT VNUM BDS5 Profile regulation frequency Initially set to 1000 Value of this variable does not matter if REG is 0 Set S curve level Initially set to 2 Enable Single Step mode Set to 0 on power up and normally left at 0 for preliminary operation Set mode o
120. user program control e Fixed a problem with EXTLOOP A problem was found where the position error was being calculated when the drive was disabled This could cause a PE OVERFLOW error if IPEXT PCMDI gt PEMAX The position error is now only calculated if the drive is enabled e Added PCMD PEXT when EXTLOOP 1 and drive disabled External Position loop mode was enhanced where when the drive is disabled the variable PCMD is set equal to PEXT This prevents a possible PE OVERFLOW error when enabling the drive without first executing a NORM command The NORM command sets PCMD PEXT when EXTLOOP 1 and it sets PCMD PFB when EXTLOOP 0 e Fixed front panel LED initialization on power up The FAULT LED and ACTIVE LED were being briefly set to the wrong state on power up This was corrected e Fixed A Syntax error in ERRORS would cause re execution of ERRORS infinite loop Now the BDS5 will break the user program on any syntax error in ERRORS e Fixed An invalid command nonexistent would execute ERRORS if it existed Now the BDS5 will not allow any program execution until the invalid command has been removed e Fixed An error occurring while in Monitor mode will print the error message and then return to Monitor mode Any printing from the ERRORS routine will be suppressed Syntax error in ERRORS would cause re execution of ERROR infinite loop BDS5 TIMING TESTS e um _ INSTRUCTION Ver 2 0 5 Ver 3 0 5 O1
121. variables X165 X227 with the down side of the counter 3 loop beginning X X1 X164 X1 164 100 X12 X1 1 increment the loop counter 2 LE 227 GOTO 3 test loop keep going until X227 Now it s time to start the CAM 4 PLIM OFF Standard line to enable GEAR OFF Disable GEAR so we can enable CAM EN NORM 0 CAM Normalize and enable CAM GEAR ON Now we can enable GEAR VOFF 20 Use offset speed of 20 RPM to go through cam cycle B Break back to Immediate mode 55 SERIAL COMMUNICATIONS 1 DOC BDSSCOMI DOCRev3 June 03 1993 The following chart shows the various ASCII codes and formats that will be used in all examples in this document CONTROL CODE DEFINITIONS Name Hex Bell Backspace Line Feed Carriage Return or Enter Escape Space xx NumberofSpaces lt gt 2 3 Comment Statements Comments Repeating or Additional Data BDS5 EXAMPLE FORMATS examples will have the following format Initial Prompt Host Command BDS5 Echo Response Data lt gt Final Prompt 17 The 5 is designed to easily interface with a human via standard dumb terminal and is also designed to interface to a general purpose computer Part of this design involved the selection of unique prompts for each of the BDS5 s 9 modes These unique prompts will allow the computer to determine the BDS5 s current mode BDS5 NON MULTIDROP PROMPTS
122. 00 IBASE Inductn Base Amps Factory IMAG Induc Mag Current Factory IND Select Induction Factory IZERO Zeroing Current Factory MADV Enable Manual Adv Factory MANG Internal MSLIP Manual Slip Factory None POLES Motor Poles Factory Poles 128 SGOOSE Induction Angle Factory None SLIP Induction Slip Never None SLOPE Inductn Slip Slope Factory 1 10 VADVTBL Angle Table Max Factory VEL VBASE Inductn Base Speed Factory VEL E 6 BDS5 APPENDIX F COMMAND TIMINGS COMMAND TIMINGS This appendix gives approximate timings of representative commands Command times are difficult to predict because they depend on many factors including whether the 5 is enabled whether profile motion has been commanded whether electronic gearbox or profile regulation have been enabled and so on The times listed here are based on these conditions 1 The 5 is enabled 2 PLIM PL and LPF are on 3 TQ and PROP are off 4 No profiles are being calculated That is the BDS5 is enabled but not in motion 5 GEAR and REG are off Acceleration profiles increase the execution time by 4096 5095 If the GEAR mode is enabled increase execution time by 1096 to 2096 Profile regulation increases execution time by as much as 20 As you can see if either gear or profile regulation is enabled and the BDS5 is executing the acceleration or deceleration portion of a motion profile then the times can be 6046 greater than those
123. 1 IS OFF In addition you can print a switch as Y or N if you follow the switch with a bracketed Y Y For example XS1 Y will print either Y or N depending on whether XS1 is 1 or 0 respectively This format is useful with the input command which we will discuss later The input command allows the operator to respond with Y or N and stores 1 or 0 in a BDS5 variable This print format allows you to print the previous answer on the screen the way it was entered 4 6 1 6 Printing Expressions The P instruction is not restricted to printing only variables In general any numeric expression can be formatted and printed All the following examples are valid P MINUS 1 IN HEX IS 1 H P X1 X3 IS THE RESULT OF ADDING X1 AND X3 P SENSE OF DIRECTION IS DIR 2 1 2 P DISTANCE TO GO IS PFNL PFB 3 INCHES P HIGH BYTE OF IN IS IN amp OFOH 10H H3 4 6 1 7 Printing ASCII Characters The BDS5 will also convert numbers to ASCII format before printing You can do this by following the variable or expression with a bracketed C This will cause the BDS5 to print out the character BDS5 for which the number is code For example X6 65 P THE NUMBER X6 2 IS THE ASCII CODE FOR X6 C will result in THE NUMBER 65 IS THE ASCII CODE FOR A If the number is greater than 127 that is the eighth bit is set the BDS5 removes the eighth bit before transmitting the character Fo
124. 21 E INPUT Limits 4 20 2 T3 M IND INPUT and Decimal Point 421 Firmware Errors 5 9 2 INPUT z qana 4 20 Firmware Faults Area 1 3 13 INSERT I 48 Foldback Current 3 17 Dianna nhau eee Four Idling Commands heen as T4 26 Insert Del te e rere ct eite rettet 2 8 Install on a Floppy Disk 2 2 Install on a Hard Disk 2 2 E G 7 Instr ctions E 3 1 Comments iis eie ote Ug rng 3 1 Index iii BDS5 INDEX Integrating Velocity Loop 3 38 Manual Program MANUAL 4 30 Interactive Mode 2 10 Power Up Routine POWER UP3 4 29 Interfacing with the Operator 4 16 Typical AUTO MANUAL Programs 4 30 INPUTS 4 20 Manual Program MANUAL 4 30 PRINT B n a wa nasa lee 4 17 Master Slave Block Diagram F4 34 REFRESH R amp RS Commands 4 20 Math RU D RE ED ent 3 8 SERIAL Switch eese 4 21 Algebraic Functions 1 3 10 3 8 J Logical Functions AND OR
125. 3 Discussing 5 functions Contact the local Industrial Drives sales application representative All Regional Sales Offices are listed in Appendix I of this manual 4 3 EDITING Writing or modifying a program is called editing There are two ways you can edit a BDS5 program 4 6 BDS5 The BDS5 has a simple editor which is built in or resident As an alternative you can edit your program on a computer and transmit it to BDS5 Motion Link is a software package designed specifically for this purpose Motion Link runs on IBM PC s and compatibles and it handles the communications between the BDS5 and the computer Motion Link also features a full screen editor Editing with Motion Link is preferred because it has more features than the resident editor and it allows you to save your program on disk Having the program on disk is a significant advantage since it is a simple matter to transmit or download the program should the BDS5 be replaced or multiple BDS5 s be programmed 4 3 1 Motion Link Editor Chapter 3 provided an in depth procedure for installing and using Motion Link This section provides you with enough information to get started in most cases Enter a simple program with the following procedure 1 Establish communication with the BDS5 as discussed in Chapter 2 2 Press the right arrow key to display the menu bar Select PROGRAM 3 Select NEW 4 Enter this program 10 P HELLO WORL
126. 39 CHAPTER 3 PROGRAMMING LANGUAGE GEARING amp PROFILE GENERATION PCMD GEARING amp PROFILE GENERATION PCMD GEARING amp PROFILE GENERATION Figure 3 9 BDS5 Control Modes 3 40 BDS5 PL 1 TQ 0 PROP 0 POSITION LOOP w INTEGRATION PL 1 TQ 0 PROP 1 POSITION LOOP w o INTEGRATION PL 0 TQ 0 PROP 0 VELOCITY LOOP w INTEGRATION BDS5 CHAPTER 3 PROGRAMMING LANGUAGE PL 0 0 PROP 1 GEARING amp PROFILE GENERATION VELOCITY LOOP w o INTEGRATION PL 0 0 PROP 1 GEARING amp PROFILE GENERATION OPEN LOOP TORQUE CURRENT PL 1 TQ 0 PROP 0 GEARING amp PROFILE GENERATION EXTERNAL pe oe EXTERNAL POSITION LOOP w INTEGRATION INPUT EXTLOOP 1 Encoder resolution must be equal to RDRES 4096 counts standard and must be mounted directly on to motor Figure 3 9 BDS5 Control Modes Contd 3 41 BDS5 4 USER PROGRAMS CHAPTER 4 USER PROGRAMS 4 1 INTRODUCTION The information in this chapter will enable you to understand the capabilities of the system You will also explore important consideraions that must be addressed before you implement your own application Examples of programming techniques will aid you to develop your own applications 4 2 PROGRAMMING TECHNIQUES User programs are combinations of BDS5 commands which are stored in the BDS5 memory These programs are stored in non volatile RAM they are no
127. 40 so that if a 40 character display is used the error message will not be printed You can display the line directly either with the Motion Link Editor GOTO A LINE NUMBER selection or or with the BDS5 Editor P command Sometimes only an entry is bad and not the whole line In this case only the bad entry is printed For example PROP 2 generates 5 8 BDS5 ERR 83 2 BAD OR OUT OF RANGE ERR 83 LINE 2 7 BAD OR OUT OF RANGE This message shows that the error occurred on line 2 You can enter the Editor and type If your BDS5 prints to a Data Entry Panel DEP 01 or any other 40 character wide display the standard 5 7 3 Error History The BDSS5 stores the twenty most recent errors in the Error History To display the entire Error History type BDS5 ERR HIST This causes the Error History to be sent to the terminal with the most recent error sent first When the BDS5 is powered up a DRIVE POWERED UP message is inserted into Error History even though this is not an actual error To clear the Error History type ERR CLR Error History remains intact even through power down CHAPTER 5 DEBUGGING 5 7 4 Displaying Error Messages The ERR command can also be used to display an abbreviated description of the error For example type ERR 50 The 5 responds with ERR 50 BDS5 INHIBITED You may display messages for errors from 1 through 999 If you type in an error numb
128. 4272 ADEN 1000 ADEN 100 4 9 1 1 Current Units The BDS5 commands current with a 12 bit digital to analog converter DAC BDS5 basic current unit is 1 4095th of full scale current Full scale current refers to the peak rating of your BDSS not the continuous rating For example the peak rating of a6 Amp 5 is 12 Amps The conversion constants that determine user current units are INUM current units numerator and IDEN current units denominator INUM IDEN ILIM basic units ILIM user units INUM and IDEN have a range of 0 to 231 For standard current units percent INUM is 4095 and IDEN is 100 For example when setting ILIM to 100 in Chapter 3 you typed ILIM 100 SET ILIM 100 The BDS5 converted the 100 to 4095 BDS5 basic units ida EUM IDEN 100 This sets ILIM to 4095 or 10046 of full current When you typed P ILIM the BDS5 converted the 4095 BDS5 basic units to 100 by multiplying by IDEN and dividing by INUM BDS5 4 9 1 2 Other User Units BDS5 basic units for position velocity and acceleration vary with the system resolution The resolution is determined by the R D converter which converts the position of the motor into a 12 14 or 16 bit number The system resolution is indicated by the model number Table 4 12 System Resolutions R D Resolution Counts in One Revolution When shipped from the factory the standard BDS5 user units are ve
129. 4A B H DIN Voltage Rating Current Rating CHAPTER 1 SYSTEM DESCRIPTION Motor and Winding Figure 1 2 Compensation Model Number Scheme A partial model number is printed on a gold and black tag on the front of the compensation module the black plastic box secured to the front of your BDS5 by two screws See Figure 1 2 for the descriptions of the model number that is what ABB and HHHH mean The model number is as follows The compensation module depends on your motor and the voltage and current rating of your BDS5 It is important that the motor the BDS5 and the compensation module model numbers all agree For example if your BDS5 model number is N CAUTION BDS5 203 00000 204A 1 101 2021 then your compensation module model number must be 203 204A and your motor must be a 204A An example of a 204A motor model number is B 204 A 21 YOU MUST HAVE THE PROPER COMPENSATION MODULE INSTALLED FOR YOUR MOTOR AND BDS5 THE COMPENSATION MODULE CHANGES IF THE AMPLIFIER RATINGS CHANGE EVEN FOR THE SAME MOTOR Failure to install the proper compensation module can cause damage to the BDS5 the motor or both 1 5 CHAPTER 1 SYSTEM DESCRIPTION BDS5 1 4 3 PSR4 5 Model Number PSR4 5A 2 20 0003 ABC DE UL Designator Do Voltage Rating Current Rating Figure 1 3 PSR4 5 Model Number Scheme Table 1 2 PSR4 5 Model Number Scheme LEGEND DEFINITIONS UL Designator UL Listed
130. 5 3 3 8 Converter Accuracy 3 26 5 2 Segments for Different Moves 5 5 3 9 Encoder Resolution sess 3 37 5 3 Error Severity Levels and Actions 5 8 4 1 BDS5 Conditions esses 4 11 6 1 Tuning Criterion see 6 1 4 2 Block IF Restrictions and Options 4 14 6 2 Allowed Tune Command 4 3 Desired Operation of Program Stability Settings eee ementi 6 4 Example 5 erp oed tees 4 14 6 3 Velocity Loop Bandwidth vs KVI 6 5 6 4 Velocity Loop Bandwidth vs KPMAX 6 5 vi BDS5 1 SYSTEM DESCRIPTION CHAPTER 1 SYSTEM DESCRIPTION 1 1 INTRODUCTION The information in this chapter will enable you to understand the BDS5 s basic functions and features These concepts will allow you to apply them to your own unique applications 1 2 PRODUCT DESCRIPTION The 5 is a full featured high performance brushless positioning servo in one compact enclosure t is the smallest totally integrated package available to motion control users The BDS5 combines a positioner a servo amplifier and an I O interface into one unit The BDS5 sets new standards for motion control with its simple BASIC like command structure and sophisticated decision making capability The BDS5 provides the outstanding servo performance that you have come to expect from I
131. 5 Encoder Feedback 3 37 3 8 16 CONTINUE neret 3 37 3 9 CONTROL LOOPS 3 37 3 9 1 Position Loop eee 3 38 3 9 2 Velocity Loop een 3 38 3 9 2 1 Proportional Velocity Loop 3 38 3 9 2 2 Integrating Velocity Loop 3 38 3 9 3 Torque Command 3 39 3 9 4 Power Up Control Loops 3 39 CHAPTER 4 USER PROGRAMS 4 1 4 1 4 2 Programming Techniques 4 1 4 2 1 Example Application 4 3 4 2 2 Application 4 3 4 2 3 Application Flowchart 4 3 4 2 4 Commented Program 4 5 4 2 5 Customer Service esses 4 6 4 3 Editing oto heo 4 6 4 3 1 Motion Link Editor 4 6 4 3 2 BDS5 Resident Editor 4 7 4 3 2 1 Editor Print D eme 4 7 43 22 Next Line 6 ecco esaet ented 4 7 4 3 2 3 Password PASS 4 7 4 324 INSERT D pw 4 8 43 3 5 te eROPU eR 4 8 432 6 CHANGE OC ete 4 8 4 3 2 7 DELETE DEL ee 4 0 4 3 2 8 S126 coe ne u rite 4 9 432 9 NEW ierit rore rener i a 4 9 4 4 Building A Program
132. 5 will be echoed back to the host This echo will allow a simple character by character verification that the data was properly received e Each ASCII command string will be terminated by an ASCII carriage return cr e Upon receiving the cr the BDS5 will acknowledge the command by transmitting a lt cr gt lt lf gt followed by system prompt gt The prompt is used to indicate what mode is currently active in BDS5 and that the BDS5 is ready to receive another command SERIAL COMMAND EXAMPLES TLIM 50 lt cr gt This would set the current limit to 50 OUT 1FH lt cr gt This would set the 8 user programmable outputs to 1F hex EN lt cr gt This would enable the BDS5 DIS lt cr gt This would disable the BDS5 J 1000 lt cr gt This would Jog an enabled axis at 1000 using the acceleration and deceleration rates programmed into ACC and DEC P PFB lt cr gt This would print the feedback position to the serial port P PFB 4 lt cr gt This would print the feedback position formatted to 4 places to the serial port terminated by a cr lf PFB H lt cr gt This would print feedback position in hex format to serial port terminated by a lt cr gt R 5 lt gt This would print the feedback position in 5 places using hex format to serial port terminated by a lt cr gt PA PFB lt cr gt This would print the feedback position to the serial por
133. 8 4 However with integer math the first expression is evaluated as 280 This is because 53 100 is evaluated first The result 0 53 is rounded to the nearest integer 1 which is multiplied by 280 Likewise in the second expression the 280 100 is evaluated as 3 which is multiplied by 53 to get the result 159 Only the third expression gives the expected result 148 In this example round off error is minimized by performing the multiplication first 3 4 3 Logical Functions AND OR Two logical math functions AND and OR can also be used in math expressions ANDing is indicated by amp operator and ORing is indicated by operator When evaluating an expression AND has the same level of precedence as multiplication and OR has the same level as addition Like hex logical math is often used when programming computers With logical functions two numbers are converted to binary representation and compared bit by bit When the numbers are ORed if either bit is set the result bit is set With ANDing both bits must be set for the result to be set Type in the following examples P 1 2 THIS IS 3 3 9 CHAPTER 3 PROGRAMMING LANGUAGE The 5 responds 3 since 00000001 Binary 1 OR 00000010 Binary 2 00000011 Binary 3 P 1 amp 2 THIS IS 0 The BDSS responds 0 since 00000001 Binary 1 AND 00000010 Binary 2 00000000 Binary 0 Logical math is generally used with hex constants Logical math is
134. 9 Capturing Position 3 26 3 8 9 1 Enabling Capture CAP amp PCAP 3 26 3 8 9 2 Capture Direction CAPDIR 3 26 3 8 9 3 Speeding Up Homing Sequences 3 26 3 5 10 Clamp o tee 3 27 3 8 10 1 Clamping and Homing 3 27 3 8 11 JOG TO JT amp JOG FROM JP 3 28 3 8 11 1 Registration ee 3 29 3 8 11 2 Registration Example 3 29 3 8 11 3 Multiple JE JT Commands 3 30 3 9 11 4 Changing Profiles During Motion 3 30 ii TABLE OF CONTENTS 3 8 12 External Inputs a 3 31 3 8 12 1 Analog Input a 3 32 3 8 13 Electronic Gearbox 3 32 3 8 13 1 Gear Ratio GEARI amp GEARO 3 32 3 8 13 2 Gearbox Example 1 3 32 3 8 13 3 Gearbox Example 2 3 33 3 8 13 4 Profiles and Gearbox 3 33 3 8 13 5 Velocity Offset VOFF 3 35 3 8 13 6 Gearbox ACC DEC and Jogs 3 35 3 8 14 Profile Regulation 3 35 3 8 14 1 REG amp REGKHZ 3 35 3 8 14 2 Profile Regulation and Counting Backwards erepti 3 36 3 8 14 3 Regulation 3 36 3 8 1
135. AULT LOGIC This section covers how to enable the BDS5 and how faults affect the operation This discussion will center around Figure 3 1 This drawing has six areas each of which is labeled with an encircled number 1 6 Note that this drawing is a functional diagram it does not directly represent the actual hardware and software used to implement these functions Your BDS5 system should be mounted and wired as described in the Installation and Setup Manual The AC Line to your 5 4 5 should not be turned on initially for examples in this chapter If the proper connections are not made or the terminal is not communicating then see the Installation and Setup Manual AC LINE SHOULD NOT BE TURNED ON WARNING CHAPTER 3 PROGRAMMING LANGUAGE BDS5 HARDWARE FAULTS OVER TEMPERATURE BUS VOLTAGE 12 VOLT SUPPLY OVER CURRENT FEEDBACK LOSS HARDWARE WATCHDOG COMPENSATION BOARD MICROPROCESSOR SOFTWARE FAULTS FOLLOWING ERROR OVERTRAVEL GEARBOX OVERFLOW INTERNAL ERRORS MOTOR PARAMETERS OUT OF RANGE FIRMWARE FAULTS UP FAIL ROM CHECKSUM ES TURN OFF SOFTWARE WDOG SET COMMUNICATION LED 5 VOLT SUPPLY ted POWER UP RESET FAULT SOFTWARE SWITCH
136. Alt X This selection terminates Motion Link and returns to DOS You can also press Alt X hold the alternate key down and press X for this function SHELL TO DOS This selection allows you to temporarily exit or shell to DOS so that you can execute a DOS command Type EXIT to return to Motion Link BDS5 2 4 2 Editor The Motion Link Editor is a full featured screen editor Use this editor to examine or edit programs and variable files or to capture data All of the editor commands can be accessed from a menu bar and pull down windows Press the F10 key to display the menu bar Then use the left and right arrow keys to select a pull down window Each editor command can be accessed with a control key or sequence You can use the control key as a shortcut in place of selecting from the window The control key sequence is listed beside each command here and in Motion Link For example the FILE PRINT selection can be accessed with P hold the control key down and press P Many selections require two control keys such as FILE FILE MERGE K R In this case hold down the control key and press and release K then press R The rest of this section will discuss each of the editor pull down windows 2 4 2 1 File SAVE FILE K S Copy the file in the editor to the disk MERGE FILE Copy a file into the editor starting at the cursor You must place the editor cursor in the proper location befor
137. B WAS TOO BIG TO FIT INTO 3 SPACES gt X1 1000 X1 1000 lt cr gt lt lf gt gt THIS SETS VARIABLE X1 TO 1000 gt X1 1000 X1 1000 lt cr gt lt lf gt gt THIS SETS VARIABLE X1 TO 1000 23 gt RUN lt cr gt RUN lt cr gt lt lf gt lt cr gt lt lf gt lt lt bell gt ERR 63 RUN lt 28 sp gt NOT AT THIS LEVEL lt cr gt lt lf gt gt THE RUN COMMAND IS ALLOWED IN THE MONITOR A X will act like a S top and a B reak command The BDS5 will respond to this command while in the monitor mode while in the interactive mode or while running program gt RUN 6 RUN 6 lt cr gt lt lf gt NOW A PROGRAM IS RUNNING AND NO PROMPT IS PRESENT NOW AN ERROR OCCURS lt cr gt lt lf gt lt gt lt bell gt ERR 17 FEEDBACK LOSS lt cr gt lt lf gt gt gt RUN 6 RUN 6 lt cr gt lt lf gt NOW A PROGRAM IS RUNNING AND NO PROMPT IS PRESENT TYPE AN ESCAPE TO ENTER MONITOR MODE esc lt cr gt lt lf gt lt lf gt ENTER MONITOR MODE PUSH ESCAPE TO EXIT lt cr gt lt lf gt gt NOW AN ERROR OCCURS BUT A PROMPT IS PRESENT SO THE ERROR WILL NOT PRINT OUT TYPE A lt cr gt gt cr gt lt cr gt lt lf gt lt gt lt bell gt ERR 17 FEEDBACK LOSS lt cr gt lt lf gt gt 24 gt RUN 6 RUN 6 lt cr gt lt lf gt NOW A PROGRAM IS RUNNING AND NO PROMPT IS PRESENT TYPE AN ESCAPE TO ENTER MONITOR MODE
138. B X3 APPENDIX SOFTWARE COMMANDS BDS5 GOTO Go to a program label Allowed only from the user program Format GOTO lt Label gt Example GOTO 25 GOTO X5 Delay Hold up execution of a task until a switch is in the specified state You can use any switch except REMOTE and XS11 XS50 XS1 XS10 are allowed H is an idling command if you are using multi tasking H suspends the task but lets other tasks proceed Allowed only from the user program Format Switch lt ON OFF gt Example H XS1 ON OFF Conditionally execute a block of instructions Allowed from the user program Format IF lt gt Logical lt gt Example IF PFB GT 100 FOLLOW WITH ELSE ETC IF X1 X2 NE X4 X545 m FOLLOW WITH ELSE ETC C 7 BDS5 INPUT JF C 8 APPENDIX C SOFTWARE COMMANDS Prompt the operator for an input variable If limits are specified then make sure operator stays within them If they are not specified then use the limits of the variable being prompted for W is an idling command that is if you are using multi tasking INPUT suspends the task until the operator presses the enter key but lets other tasks proceed Allowed only from the user program Format INPUT lt Text gt Variable decimal Min Max Where lt Variable gt is any valid programmable variable You can optionally specify maximum and minimum limits if you include one you must include the other
139. BDS5 USER S MANUAL Old Number M93102 ISSUE3 New number MB5001H BDS5 TECHNICAL MANUAL CONFIGURATION TECHNICAL MANUAL CONFIGURATION USER S MANUAL M93102 PAGE NO DESCRIPTION CHANGE NO Title Page aaa M 0 ua Technical Manual Configuration esses 0 Configuration see Ue n ERE IE RES 0 Customer Response u aa ee e ua rh T dre rhetores 0 cc Copyright nce ete D Ute 0 woe eiue imt Foreword nin Cure RUD oe DU emma 0 How Use This 1 2 0 424 40 0 0 000000000000 0 Vostri aa Ea Table f Contents n eee eG PR e rie TESE et 0 ENS Fist Of Figures one a ea eet ie tete eet e e eei 0 Vi sissies Geant Waist Of 0 1 1 1 16 Chapter 1 System Description seesesssseseseeeeeeeeen eene en 0 2 1 2 14 Chapter 2 Getting Started eate eit tte he rH 0 3 1 3 42 Chapter 3 Programming Language 0 4 1 4 44 Chapter 4 User Programs eet oett pier etti 0 5 1 5 10 Chapter 5 Debugging eU E ite Reisen 0 6 1 6 8 Chapter 6 Compensation e siethvaso EE EA EErEE eas EE 0 1 2
140. CCEL AND DECEL RATES DEC 100000 NORM 0 NORMALIZE ZERO POSITION JOG TO 100 RPM ERROR SHOULD DELAY TIL SPEED REACHES 100 RPM BEFORE EXECUTING JT COMMAND ERROR SHOULD DELAY TIL SPEED REACHES 3400 RPM BEFORE EXECUTING JF COMMAND J 100 JT 20000 400 JT 30000 0 You might think the motor will first jog to 100 RPM then to 400 RPM at 20 000 counts and finally come to rest at 30 000 counts Actually the motor will jog to about 40 RPM and continue at that speed until it 3 30 BDS5 comes to rest at 30 000 counts This is because the JF JT commands cause the motion profile to hold the velocity command constant even if an acceleration is commanded from the previous motion command The solution is to insert delays to force the program to wait until the motor reaches the final speed from the previous motion command For example the above program can be modified as follows ENABLE BDS5 SET ACCEL AND DECEL RATES ACC 100000 DEC 100000 NORM 0 NORMALIZE TO ZERO POSITION J 100 JOG TO 100 RPM TIL VCMD EQ 100 WAIT TIL SPEED REACHES 100 RPM EXECUTE JT COMMAND TIL VCMD EQ 400 WAIT TIL SPEED REACHES 400 RPM EXECUTE JT COMMAND JT 20000 400 JT 30000 0 DIS B Although delays with the TIL command work delays usually should be inserted with the WAIT W command The WAIT W command takes less space and works better with multi tasking a subject discussed in Chapter 4
141. CKGROUND P UPPER TASK IDLED DWELL 0 25 Apply DC bus power to your BDS5 and type RUN 1 The result should be MOVE PROCESSED UPPER TASK IDLED UPPER TASK IDLED UPPER TASK IDLED 4 26 BDS5 UPPER TASK IDLED ALL MOTION STOPPED Note that task level 5 immediately processes the move and then is idled until motion stops While task 5 is idled the lower level background task executes continuously 4 8 5 3 Avoiding Idling You can avoid idling the BDS5 by using the TIL command in place of Dwell Wait or Hold For example TIL SEG EQ 0 is the same as except the TIL command locks out lower priority tasks since it is not an idling command The Wait command allows lower level tasks to execute since it is an idling command 4 8 6 Alarms Task Levels 1 3 Alarms are the highest priority tasks There are three alarms A B and C A is the highest priority and C is the lowest Normally alarms are used to monitor hardware inputs but they can monitor any user switches XS1 550 and MANUAL Using an alarm relieves you of having to write your program so that it checks switches After you define an alarm the BDS5 will watch the switch and automatically execute the code that you specify should the alarm fire Alarms are specified on one line along with the switch that triggers the alarm and the transition For example the A alarm can be defined to fire when input I1 transitions from off to on with this comm
142. CONT for a short time generally 2 3 seconds while still protecting the BDS5 from overheating 3 7 8 2 Foldback Current IFOLD There are two current limits ILIM and IFOLD ICMD the commanded current is limited by either ILIM or IFOLD whichever is less You can set ILIM but you cannot set IFOLD IFOLD is controlled by the foldback software IFOLD depends on three things ICONT the continuous current rating of the BDS5 IMON the current monitor and time When the BDSS is disabled IFOLD is set to some value well above maximum current IMAX and thus well above ILIM Since current is limited by the lesser of ILIM and IFOLD IFOLD has no effect under this condition If IMON the output current stays below ICONT then IFOLD remains at its original high value If IMON is greater than ICONT IFOLD gradually decreases The greater IMON is the faster IFOLD decreases Since IFOLD starts out well above ILIM initially this has no effect However when IFOLD is less than ILIM IFOLD will limit the current This is called being in foldback If IMON remains on average above ICONT long enough IFOLD will decrease all the way to ICONT forcing IMON eventually to become less than or equal to ICONT Typically it takes at least 2 to 3 seconds for IFOLD to decrease from its original high value to IMAX At this point the BDS5 is in foldback It takes an additional 10 seconds to reduce IFOLD from IMAX to ICONT 3 17 CHAPTER 3 PROGRAMM
143. D B 5 Press the escape key to exit the Motion Link Editor 6 Follow the instructions on your computer screen Motion Link will ask you if you want to save your program Enter Y and give the name TEST as the name of your program 7 Motion Link will now ask you if you want to transmit the program to the BDS5 Enter BDS5 CHAPTER 4 USER PROGRAMS m After the transmission is complete you should receive the interactive prompt gt Type RUN 10 Your program should print HELLO WORLD gt This should provide you with enough information to enter the examples from this chapter Read Chapter 3 for a complete description of Motion Link 4 3 2 BDS5 Resident Editor If you are not using the BDS5 Editor skip ahead to the next section Building a Program The BDS5 resident editor allows you to enter small programs and make changes without Motion Link Note that you can use this editor from Motion Link just as you would use it from a terminal To enter BDS5 Editor type When you are in the Editor the BDS5 will respond with the editor prompt gt To exit Editor press escape key 4 3 2 1 Editor Print P The Print P command prints a program line or lines then goes to that line Each line in the program memory has a number Many editor instructions such as Print expect you to specify the line number or numbers that applies to the instruction Type in the foll
144. DIS J 100 The BDS5 will respond with ERR 50 J100 BDS5 INHIBITED The error number 50 the offending entry the whole line and the error message you cannot command a jog when the drive is inhibited are given on one 80 character line The error message starts at character 40 so that if a 40 character display is used the error message will not be printed You can display the line directly either with the Motion Link editor GOTO LINE NUMBER selection or Q l or with the BDS5 Editor P command Sometimes only an entry is bad and not the whole line In this case only the bad entry is printed For example PROP 2 generates ERR 83 2 BAD OR OUT OF RANGE since PROP is a switch and cannot be set to 2 If the error comes from the program the line number of the offending entry is also printed Use the Editor to enter these lines at the top of the user program 11 PROP 2 B exit the Editor and type and the response should be ERR 83 LINE2 2 BAD OR OUT OF RANGE This message shows that the error occurred on line 2 You can enter the Editor and type and the line PROP 2 will be displayed DEP01 If your BDS5 prints to a Data Entry Panel DEP 01 or any other 40 character wide display the standard error messages will not print properly The problem is that error messages are based on an 80 character wide display and the DEP 01 is only 40 characters wide To correct this problem the BDS5 provides the DE
145. F SEVERITY 2 You attempted to execute an instruction that requires the hardware input REMOTE on the signal connector to be active This error breaks program execution OVER TEMP SEVERITY 3 The thermostat on the BDS5 heatsink opened indicating overheating Overheating may be caused by excessive ambient temperature obstructed airflow broken fan etc Correct any such condition before resuming operation REMOVE ALL POWER BEFORE CHECKING THIS If everything is functioning properly a drive with a higher current rating may be required This error breaks program execution and disables the BDS5 OVER CURRENT SEVERITY 3 The BDS5 detected an overcurrent This can be caused by a shorted motor winding a shorted power transistor or a short circuit in the wiring Be sure to check all wiring before resuming operation This error breaks program execution and disables the BDS5 OVER SPEED SEVERITY 3 The BDS5 determined that the speed of the motor was greater than the variable VOSPD If this occurs occasionally it may be a nuisance fault that should be corrected by raising VOSPD by 596 or 1096 This error breaks program execution and disables the BDS5 POWER BUS SEVERITY 3 The power supply high voltage bus has either an overvoltage fault or an undervoltage fault This error breaks program execution and disables the BDSS COMP BOARD SEVERITY 3 You attempted to enable the BDS5 with the compensation board removed Replace the c
146. FB P PFB and see that it is now 1000 The NORMALIZE command cannot be used when either GEAR is on or when motion is commanded from MA MI or any other motion command R N CHAPTER 3 PROGRAMMING LANGUAGE 3 8 6 Zero Position Error ZPE Command The ZPE command zeros position error by setting PCMD to PFB without changing PFB There are occasions when this will be necessary For example if the BDSS is run for some time as a velocity loop then position error can accumulate well beyond PEMAX If the position loop is turned on with this condition a position error overflow error will occur To prevent the error you must first zero the position error then turn the position loop on by entering ZPE PL ON The ZPE command is also frequently used with clamping See the explanation of clamping later in this chapter 3 8 7 MACRO MOVES This section describes functions to implement Macro moves Macro moves are complex user defined moves that execute as one move Simple moves such as MI and MA always begin and end at zero speed and have one acceleration segment one deceleration segment and one traverse segment Macro moves allow up to 30 user definable segments for one move The moves are fully precalculated and therefore can execute very fast Like other moves ACC DEC and 5 are in effect These parameters can be changed between Macro move segments allowing more flexibility Also PFNL indicates the ending
147. GOTO 5 GOTO 5 IF X1 IS EVEN DO NOTHING IF X1 IS ODD 14 EQ 1 J 2000 415 BUTTON Note that each condition has an exact opposite EQ amp NE LE amp GT and LT amp GE are all pairs of opposites Since the command allows both TRUE command and FALSE command you have your choice of which command to use in the condition For example the two commands that follow have exactly the same effect EQ 10 B P BREAK IF X1 gt 10 X1 NE 10 P X10K B BREAK IF X1 gt 10 The command can be used to make a loop counter Suppose you want to go to subroutine 25 twenty times You could just write GOSUB 25 twenty times but it would probably be better to use a program loop The following statements show how the command can be used to control that program loop X30 z 1 X30 IS THE LOOP COUNTER 12 THE LOOP BEGINS 12 GOSUB 25 GO TO SUBROUTINE 25 INCREMENT THE LOOP COUNTER X30 LE 20 GOTO 12 EXECUTE LOOP 20 TIMES CONTINUE PROGRAM X30 X30 1 4 4 2 2 Nesting Commands You can nest one command inside another For example suppose you want to break program 4 12 BDS5 execution if X1 is less than 100 and greater than 100 You could use X1 LT 100 GOTO 20 X1 GT 100 GOTO 20 B 20 However those four commands can be replaced by just one nested command X1 LT 100 X1 GT 100 B Nesting two commands is the same as ANDing th
148. HELP QUIT ELECT THIS TO AUTOBAUD THE BDS5 AT 9600 BAUD Figure 2 1 BDS5 Introduction Screen d If you have Motion Link installed on a hard disk type CDIML5 ML Skip to Step 4 If you have Motion Link installed on a floppy disk Insert the copy of Motion Link in the A drive type A ML 4 When Motion Link responds the BDS5 should respond on your PC monitor with the message in Figure 2 1 or a similar one This screen displays the current BDS5 configuration The small box at the lower half of the screen provides five choices for the operator Autobaud BDS5 Autobaud Per ML CNF BDS5 Offline Intro Help and Quit First time users may wish to refer to the online Intro Help by pressing H Choosing to auto baud with the BDS5 allows direct interactive communication with the BDS5 The BDS5 interactive prompt is gt This means the BDS5 is waiting and ready for a command When you type you are talking to the BDS5 just as you would with a terminal For example type P HELLO WORLD and the BDS5 should response by printing HELLO WORLD You can enter any BDS5 command from Motion Link just as if your IBM PC compatible computer were a terminal The green SYS OK LED on the front of the BDS5 should turn on and remain on at all times after power up and autobauding 2 4 MOTION LINK OVERVIEW Motion Link is a full featured communications program written by Industrial D
149. Hz 8 5 kHz 8 5 kHz 1 8 BDS5 CHAPTER SYSTEM DESCRIPTION Table 1 4 Specifications Cont BDS5 2XX 160 253 VAC L L OUTPUT TO MOTOR DESCRIPTION BDS5 203 BDS5 206 BDS5 210 BDS5 220 Main DC Bus Minimum 225 VDC 225 VDC 225 VDC 130 VDC Maximum 360 VDC 360 VDC 360 VDC 225 VDC 15 20 VDC 15 20 VDC 15 20 VDC 15 20 VDC 0 25 AMPS 0 25 AMPS 0 25 AMPS 0 25 AMPS Unregulated Logic Bus 8 12 VDC 8 12 VDC 8 12 VDC 8 12 VDC 1 00 AMPS 1 00 AMPS 1 00 AMPS 1 00 AMPS Output Current RMS Convection Cooled 45 C AMB Continuous RMS 3 0 AMPS 6 0 AMPS 10 0 AMPS 20 0 AMPS Peak 2 0 sec RMS 6 0 AMPS 12 0 AMPS 20 0 AMPS 40 0 AMPS Output KVA 160 VDC Bus Continuous 45 C AMB 1 2 KVA 2 0 KVA 4 0 KVA 8 0 KVA Peak 2 0 sec RMS 2 4 KVA 4 0 KVA 8 0 KVA 16 0 KVA Internal Heat Dissipation 35 WATTS 50 WATTS 75 WATTS 150 WATTS PWM Switching Frequency 10 0 kHz 10 0 kHz 10 0 kHz 10 0 kHz Frequency 10 20 0 kHz 20 0 kHz 20 0 kHz 20 0 kHz Resolver Excitation Frequency Fan 15 VAC 1 9 CHAPTER 1 SYSTEM DESCRIPTION BDS5 Table 1 4 Specifications Cont PSR4 5 1XX 90 160 VAC L L INPUT Current Cont RMS 3 Phase 12 0 AMPS 20 0 AMPS Single Phase 10 0 AMPS 16 0 AMPS Peak 2 0 sec 3 Phase 24 0 AMPS 40 0 AMPS Single Phase 20 0 AMPS 32 0 AMPS Peak 50 0 msec 3 Phase 50 0 AMPS 80 0 AMPS Single Phase 42 0 AMPS 64 0 AMPS Control AC Line Input Voltage 90 132 VAC 90 132 VAC Main DC Bus Output Voltage
150. I also need an output at the end of the move to start the saw blade rotating You How often do these variables change Customer About once or twice a year You Do you mind typing them in from a keyboard Customer No That would be fine You What controls the start of the move Customer My PLC activates an input Can ESTOP be programmed so that it can be overridden when the cycle is almost complete You No Since ESTOP is a safety function it is always hardwired to remove power Customer Okay About how long do you think it will take You be in touch 4 2 2 Application Specification 1 Allow a variable cut length acceleration deceleration and speed Use user variables X1 X4 as follows 2 X3 X4 CHAPTER 4 USER PROGRAMS Acceleration Deceleration Speed Cut Length added to registration mark 2 Turn on an output at the end of the move This output will be connected to start the saw Use output O1 3 Allow contacts that stop the process after the present cycle is complete Use input I1 4 Walt for a start signal to begin each cycle Use input I2 4 2 3 Application Flowchart When you write flowcharts use three symbols a circle a square and a diamond A circle indicates the start or end of a program It also indicates the start or end of a subroutine A square is an execution block That is the BDS5 should do something turn on an output print a message
151. ING LANGUAGE If IMON is reduced below ICONT then IFOLD will increase the smaller IMON is the faster IFOLD will increase If IMON remains below ICONT long enough IFOLD will return to its original high value 3 7 8 3 Monitoring Current Limits There are two switches that provide information on current limiting SAT is a switch that is on if the current is limited by either ILIM or IFOLD FOLD is a switch that is on if the current is limited by IFOLD only The operation of the foldback software is as follows IMON gt ICONT then IFOLD decreases IMON lt ICONT then IFOLD increases IFOLD ILIM then FOLD is on IFOLD ILIM then FOLD is off ICMD ILIM or IFOLD ICMD lt ILIM and IFOLD then SAT is on then SAT is off ICMD is never ILIM ICMD is never IFOLD In some cases it may be desirable to know when foldback is just about to limit current below ILIM You can use IFOLD for this if IFOLD is less than ILIM the foldback software is limiting current If IFOLD is larger than ILIM but only by 596 or 1096 then foldback software is about to limit current 3 8 MOTION COMMANDS This section discusses how to control motion using the BDS5 Basic motion commands are described first Later sections discuss advanced motion control including BDS5 Macro Moves electronic gearbox and synchronizing motion 3 18 BDS5 3 8 1 Basic Motion Commands 3 8 1 1 AMAX ACC amp DEC Th
152. ION 3 0 FIRMWARE HISTORY Continued FIRMWARE VERSION OBSOLETE CURRENT S O Obsolete MC VERSION MC2 Rev 2 and later MC2 Rev 2 and later Obsolete Beta Bug Fix Shipped to some customers for test and verification of bug fixes Obsolete MC2 Rev 2 and later MC2 Rev 2 and later DESCRIPTION OF CHANGES Changed the lower limit of PEMAX 0 to 1 Force to 1 if less than 1 Enhanced the Message command MSG to also suppress error messages Fixed error handler to properly handle more than one error Fixed ERRORS to reliably execute to completion on first error An error will now force off Monitor mode to prevent program hang Fixed Jog command J that could cause software watchdog if executed during an error Functionally equivalent to BDS5 3 0 2b plus Current foldback fix INPUT command fix Clear LSTERR to 0 on EN Fixed Print problem due to program terminating with an END while in Monitor mode from KNOWN PROBLEMS On power up the program corrupt message is suppressed The TPLAY command will not display the newest trace line if the number of lines stored exceed 1000 On power up with a new uninitialized BATRAM the BDS5 will often trigger a software watchdog this is an inconvenience to the factory test people Fixed non printing error message on power up due to corrupt user program Fixed TPLAY to properly display the trace
153. IT FOR MOTION TO START This means no motion will take place until the hardware input GATE is high If the above lines were part of a program the W command would delay program execution until the GATE switch was on 5 6 HINTS The following section lists some hints addressing the most common problems Most result from a minor misuse or misunderstanding of a BDS5 function If you change your program in the Motion Link Editor and the program function does not change you may have forgotten to transmit your updated program to the BDSS If you command motion with MI MA MCGO J JT or JF and the motor does not move make sure GATEMODE is not preventing motion turn GATEMODE off if you are not certain sure CLAMP is not preventing motion turn CLAMP off if you are not certain If it is CLAMP try raising the clamp limit PECLAMP somewhat If that does not help turn CLAMP off If you now get PE OVERFLOW errors it may be because the motor is undersized See the hints for PE OVERFLOW errors below make sure REG is not preventing motion turn REG off if you are not certain If REG is on you may not be feeding in the master encoder signal properly Remember it must always BDS5 count up Check VEXT It should be greater than zero for profile regulation to work make sure ZERO is off make sure all tuning constants are well above zero Check KP KV KVI and KPROP Each should be at lea
154. ITE A SIMPLE SPECIFICATION FOR YOUR APPLICATION Write an outline of all the functions your application will require before you start programming This will serve as a specification Everyone who is involved with your system customers supervisors co workers operators should agree on the specification While last minute requests for program changes will still occur this is a reasonable step towards reducing the incidence of such requests WRITE A FLOWCHART OF YOUR PROGRAM BDS5 People who are new to programming often have a natural distaste for writing flowcharts Many view flowcharts as something between a crutch and unnecessary work Most experienced programmers have a different view The most important point about flowcharts is that they are virtually required if you need help over the telephone Always write flowcharts for programs that are longer than 20 to 30 lines 5 COMMENT YOUR PROGRAM Always comment your programs Comments help explain your program to other people Keep in mind that others may need to modify your program in the future Comments also help you remember why you chose certain ways to do things 6 AVOID SPAGHETTI CODE A program with too much branching is often called spaghetti code because of the look of the flowcharts Avoid a lot of branching especially branching up that is towards the top of your program logic in programs that branch down is more intuitive and thus less pro
155. Jogs 3 35 English Conversion 12 bit General Purpose Input Output 3 10 R D Only T4 35 Whole Word I O seen 3 10 Environmental Specifications T1 12 GOSUB and RET eee 4 11 ER External Resistor Kit Model Number 1 7 6 0 4o MEE 2 8 Error Handler ERROR9 4 29 GOTO sentia Ui 4 10 Error History eee Rete dee 5 9 ErtorLeyvels see epa 5 8 Errot E08 iei ep eie eet ene 5 8 Ad 5 8 Hardware Travel Limits a 3 19 isplaying Error Messages 5 9 Help paqa aa tained 2 6 Error History nettes 5 9 Help 2 8 Error 5 8 Hexadecimal enient 3 8 Firmware Errors 5 9 Hi 5 6 Error Severity Levels and 5 8 uir C gus ME 22252 HOLD nete 4 21 Establishing Communications 2 3 Example Application eee 4 3 How t9 Disable Multitasking Ou 1922 External Inputs 3 31 T425 Analog Input 3 32 External Resistor Model Number 5 F1 7 External Regen Resist
156. KHz Note that MACRO DWELLS MCD are regulated by the external input that when REG is on RD delays are always regulated by the external frequency even when REG is off 5 5 3 Motion Segments moves and jogs occur in segments Normal jogs have two segments accel decel and traverse Simple moves MRD MI and MA have three segments accel traverse and decel Position dependent jogs have three segments traverse to position accel decel and traverse The following table shows the different segments for BDS5 moves Table 5 2 Segments for Different Moves Accel Accel Decel Traverse Traverse Traverse Accel Decel Decel N A Traverse BDS5 Macro moves have up to 30 segments where each accel decel traverse and dwell counts as a segment In each case every move begins with the variable SEG equal to 1 As the move progresses SEG is incremented When all moves are complete SEG is set to zero You can use the SEG to determine when motion is complete since SEG is zero when the BDS5 is not commanding a profile For example 46 MA 10000 1000 TIL SEG EQ 0 P MOTION IN PROGRESS B continually prints a message until motion stops Note that when SEG is zero the BDS5 is not commanding motion However because there is a lag between the command and the response of the motor you may want to insert a short delay after SEG is zero 46 MA 10000 1000 TIL SEG EQ 0 P MOTION IN PROGRESS DWELL 100 MSEC FOR M
157. LIM 09F lt cr gt lt ack gt EN93 lt cr gt lt ack gt ADDR 65C3 lt ack gt A lt cr gt lt ack gt MI 4096 1000 lt cr gt lt nak gt MI 4096 100055 lt cr gt lt nak gt MI 4096 10006A lt cr gt lt ack gt ADDR 0 lt cr gt 4 turn off prompts no prompt returned turn off character echo gt enable Serial Checksum protocol snothing echoed or returned turn off software travel limits checksum 9F command acknowledged enable the motor checksum 93 command acknowledged enable RS 485 and enable address A ASCII 65 i decimal checksum C3 command acknowledged Axis ID set axis then disconnects until addressed select axis A checksum not required for axis select command acknowledged move incremental 4096 counts 1000 rpm with no checksum command not acknowledged move incremental 4096 counts 1000 rpm with 2 checksum of 55 bad command not acknowledged move incremental 4096 counts 1000 rpm with i checksum of 6A command acknowledged off RS 485 1 lt gt on prompts gt RS 232 prompt 1 lt gt turn prompt P PFB lt cr gt print feedback position P PFB lt cr gt lt lf gt echo 1212 12 position number leading spaces gt prompt BDS5 USER S MANUAL M93102 PRINT KEY The following filenames have been assigned PAGE 1 OF 2 PAGES DESCRIPTION ase Hee ea H
158. LOCITY DRIVE SAMPLE PROGRAM POWER UP EXECUTE ON POWER UP PL OFF DISABLE THE POSITION LOOP VNUM 447392 SETS VELOCITY UNITS TO RPM VDEN 100 ANUM 447392 SETS ACC UNITS TO RPM SEC ADEN 100000 AMAX 100000 SET THE MAX ACCEL RATE RPM SEC ACC 1000 SET THE NORMAL ACCEL LIMIT DEC 1000 SET THE NORMAL DECEL LIMIT ACC AND DEC ARE RAMP LIMITS FOR GEAR MODE ASSUMING THAT PL IS OFF I GEARI 10 THIS SETS THE GEAR MODE FOR 25 GEARO 40 APPROX 10 V 3000 RPM FOR AN ANALOG INPUT THE PROPER LEVEL OF GEARI AND GEARO DEPENDS ON THE SYSTEM AND THE INPUT FORMAT THE ADJUSTMENT OF GEARI AND GEARO IS EQUIVALENT TO A DC GAIN ADJUSTMENT OR SCALE FACTOR POT FOUND ON MANY ANALOG DRIVES NOTE THAT ACC DEC RATES ARE LIMITED BY ACC AND DEC ONLY WHEN PL IS OFF ENABLE DRIVE ENABLE ELECTRONIC GEARBOX THIS SETS THE OFFSET VELOCITY VOFF IS SET TO ZERO WHEN GEAR IS TURNED ON THERE IS NEED TO ADJUST FOR VELOCITY DRIFT IN THE INPUT THEN ADJUST VOFF TO THE PROPER LEVEL SO THAT DRIFT STOPS B DRIVE IS NOW IN ELECTRONIC GEARBOX OF SAMPLE PROGRAM 4 44 BDS5 e 5 DEBUGGING CHAPTER 5 DEBUGGING 5 1 INTRODUCTION The information in this chapter will enable you to rectify problems you may have while programming the BDS5 When you write programs you probably will inadvertently include a few errors or bugs The best step you can take to correct errors is to prevent them by following the
159. LS GENERAL PURPOSE 0 500 ERROR PROGRAM BACKGROUND Manual Switch On Run lt LABEL gt USER ERROR HANDLER Any Error That Breaks Execution BACKGROUND PRINT AND MONITOR All Other Tasks Lowest Priority Idle 4 24 BDS5 Typical Uses of Task Monitor Inputs Prompt Operator for Input Initialize BDS5 for Application Run One Cycle of Auto Program Run Manual Program Continuously General Purpose Programs Gracefully Exit on Error Condition Print Messages to the Screen BDS5 The following two tables show how to turn multi tasking on and off Table 4 6 How to Enable Multi Tasking Run any label Type RUN lt label gt 2 Run multi tasking Type RUN 3 Include a POWER UPS label and power up Table 4 7 How to Disable Multi Tasking Execute a Break from your program 2 Enter a Break from the Monitor mode 3 Cause an error that breaks execution 4 8 5 Idling Idling is a necessary part of multi tasking So far in our discussion higher priority tasks run until they are complete Actually commands from the highest priority task that is not idle execute For example if an alarm cannot run because it is waiting for some condition such as waiting for motion to stop it is idle If a task is running and it becomes idle then a lower priority task can run until the higher priority task is no longer idle A task can be idled with pre execution idling a
160. MANUAL 4 8 8 1 Power Up Routine POWER UP On power up the BDS5 checks your program to see if you entered POWER UP If you did the power up routine is executed For example enter the following program POWER UP X1 X141 B SAMPLE COMMAND Now power down your BDS5 for a few seconds and power up again After establishing communications the BDS5 should display the sign on message followed by EXECUTING POWER UP LABEL gt CHAPTER 4 USER PROGRAMS indicating that the power up routine was executed The power up label is run after the autobaud NOTE If you want your program to start automatically on power up begin it with POWER UPS If POWER UPS is not found in the program then the BDS5 powers up in the Interactive mode If the BDS5 is set to autobaud then it will not execute the power up label until communications have been established If you want to leave multi tasking active after your power up routine is done end the power up routine with the END command instead of the Break command If your routine ends with the END command then multi tasking will be enabled and the Alarms Background and other multi tasking functions will be working If you want to return to the Interactive mode after power up then end the power up routine with the Break command 4 8 8 2 Error Handler ERRORS When a serious error occurs the BDS5 breaks execution of your program and checks your program to see i
161. MONITOR You attempted to execute an instruction while in the monitor mode that is not allowed from the monitor mode This error generates no action NOT FROM RECOVERY BDS5 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 1 SEVERITY 1 SEVERITY 1 SEVERITY 2 BDS5 ERROR 56 ERROR 57 ERROR 58 ERROR 59 ERROR 60 ERROR 61 APPENDIX D ERROR CODES You attempted to execute an instruction from the error recovery the user s error handler or ERRORS that is not allowed This includes attempting to enable the BDS5 GOSUB and GOTO This error breaks execution NOT w GEAR You attempted to execute an instruction when the gear mode was enabled that is not allowed with the gear mode For example MRD MA JT and JF are not allowed with the gear mode on This error breaks execution if the instruction was issued from the program NOT w PROFILE You attempted to execute an instruction that is not allowed while the BDS5 is profiling Profiling occurs when move instructions MA MI MRD or macro moves are executing Other examples of this are the traverse segment before the accel decel portion of position dependent jogs JT JF and the accel decel portions of all jogs J JT JF This error breaks execution NOT w JOGGING You attempted to execute an instruction that is not allowed when the BDS5 is jogging This error breaks execution if the instruction was issued from the prog
162. Min is the minimum input allowed and Max is the maximum input allowed If you specify decimal the input received from the operator will be multiplied by 10 decimal BDS5 does not use floating point math internally The input command allows you to receive floating point input from the operator Example INPUT ENTER NEW SPEED X1 3 5000 5000 INPUT ENTER NEW CURRENT LIMIT ILIM In the first example if the operator entered 1 234 the BDS5 would store 1234 0 in X1 that is 1 234 is multiplied by 10 3 1000 Note that if you specify decimal Max and Min limit the value after the multiplication In the above example Max 5000 limits the operator to 5 000 Jog at a continuous speed Allowed from the interactive mode and the user program Format J lt Velocity gt Example J 1000 c X Jog but wait until the Position command PCMD crosses the specified position before beginning accel decel Speed must not be zero when executing this instruction Allowed from the interactive mode and the user program Format JF Position Velocity Example JF 10000 10 JF 100 X1 4000 APPENDIX C SOFTWARE COMMANDS BDS5 JT MA MCA Jog at a continuous speed but delay beginning accel decel so that the Position command will equal the specified position when the accel decel is complete Allowed from the interactive mode and the user program Format JT lt Position gt lt Velocity gt
163. NUM and VXDEN PEXT is the accumulation of counts from the external input PEXT can be set to any value from the terminal or from your program at any time this is equivalent to normalizing the external position PEXT is in external position units PXNUM and PXDEN If the external input comes from a motor VEXT and PEXT represent the master motor s velocity and position although you must properly calculate the external velocity and position units In this way PEXT the master position is similar to the slave position Likewise VEXT is similar to VFB If the master motor has the same resolution as the slave then set PXNUM PXDEN VXNUM and VXDEN equal to PNUM PDEN VNUM and VDEN respectively Otherwise see Chapter 4 for more information on calculating the units VXAVG is the average of VEXT over the previous 16 milliseconds Occasionally the normal sample to sample variation of VEXT is undesirable In these cases use VXAVG in place of VEXT 3 8 12 1 Analog Input The standard BDS5 is configured with digital external inputs As an option the BDS5 provides an analog external input Note however that you 3 31 CHAPTER 3 PROGRAMMING LANGUAGE cannot have both types of inputs at the same time For systems configured with analog inputs the BDS5 converts the analog input to a pulse train where 10 volts of input is equivalent to 2 MHz If the analog input is a velocity command then use electronic gearbox Master
164. O and a BDS5 label On the other hand if a single instruction is to be executed the may be more readable Usually one form results in less program space or faster execution and this may dictate which to use However if space or timing are not critical use the most readable form 4 4 2 6 Nesting IF commands You can nest IF commands For example the following program shows two levels of nesting P BOTH X1 AND X2 0 ELSE P ONLY X1 GT 0 ENDIF ELSE IF X2 GT 0 P ONLY X2GT 0 ELSE P NEITHER X1 NOR X2 0 ENDIF ENDIF B You can nest IF commands indefinitely You should be careful to include all of the ENDIF s to close each level of nested IF All of the restrictions and options that were listed earlier as applying to IF commands also apply to nested IF s The indentation shown above is not required but is present to make the program more readable The BDS5 ignores the indentation 4 4 2 7 IF s with GOTO and GOSUB You can use the GOSUB command from within a Block IF even if you have another Block IF in that subroutine In this case the IF in the subroutine is like a nested IF However be careful to return from the subroutine after you have executed the ENDIF You should never return from a subroutine from between IF and ENDIF Finally you may use a GOTO to jump completely out of an IF THEN ELSE control structure When a GOTO is executed after an IF has been executed but before an ENDIF has CHAPTER 4 U
165. OC June 17 1994 on D 500 D 500 GOTO 1 11 ON 1 1 02 AN ALARM HAPPENED 020 ee 1 nput 77 e Fixed LSTERR to work even if MSG 0 Note LSTERR will return the last error the BDS5 encountered since an Enable EN command m 2 e Fixed another factory initialization problem that would cause a software watchdog trip on entry to the User Program Editor due to the user program being uninitialized in a new BATRAM chip e Enhanced the Error Recovery Task to cancel the user INPUT command if it is active when system error occurs This prevents the Error Handler from holding further program execution after an error due to the INPUT command having control of the serial port Normally the Error Handler first needs to print an error message to the serial port and then pass execution to the ERRORS user program label if it exists e Enhanced the Error Recovery Task to cancel a Task Idling command such as H and thus allow the ERRORS task to properly execute if it exists BDS5 FIRMWARE UPGRADE NOTICE DOC B5FU305 DOC R8 FIRM UP DOC JANUARY 27 1995 VERSION 3 0 5 UPGRADES When upgrading older systems pre version 3 0 0 with 3 0 5 Be sure to initialize the three new non volatile flags for proper operation 1 1 2 MSG 1 3 EXTDX 0 CHANGES from 3 0 4 Added MONITOR Off support from the user program The user can now turn on and off the MONITOR mode under
166. OFFSET X4 WAIT FOR MOTION TO STOP TURN ON SAW OUTPUT GO TO TOP OF LOOP START OF STOP ROUTINE DISABLE BDS5 P STOP HAS BEEN ISSUED B STOP EXECUTION 4 5 CHAPTER 4 USER PROGRAMS 4 2 5 Customer Service If you need help with software or understanding BDS5 functions you can contact the Regional Industrial Drives Sales Office Ask for the Sales Applications Engineer Please observe the following procedure 1 Contact Industrial Drives for each new problem Occasionally an applications sales representative may refer you to the Engineering Department if necessary However if you call later with a new problem please ask for a applications sales representative 2 Be prepared to provide the following items a A written spec of the system b A flowchart and A hard copy of the program 3 Be prepared to take the following actions should the application sales representative determine that these actions are necessary a Strip out sections of your program to help locate a problem b Rewrite sections of your program that do not conform to the programming practices described in this chapter c Video tape your machine to help demonstrate the problem If you need help with your program please bear in mind that Industrial Drives is committed to helping you BDS5 software support is provided by 1 Helping you organize your program 2 Explaining proper programming practices
167. OTE 2 6 re establish communications Remember to power down the 5 so that it will autobaud If you want Motion Link to use the new communications setup in the future you must use the UPDATE CONFIGURATION function below to write a new configuration file on your computer disk SCREEN COLORS This selection allows you to change the colors displayed on your computer monitor If you want Motion Link to use the new colors in the future you must use the UPDATE CONFIGURATION function below to write a new configuration file CABLE DISCONNECT This selection provides a safe method of disconnecting the communication cable from a BDS5 that is powered up After you have reconnected the cable press the space bar and Motion Link will restart communications Disconnecting this cable can generate random characters Do not disconnect your communications cable without using this function Always use this selection to secure data before disconnecting the communications cable UPDATE CONFIGURATION This selection allows you to examine and write the Motion Link configuration file This file contains information about your computer such as what communications port you are using the baud rate at which your computer is transmitting and what your screen colors are All of the settings displayed in this selection can be changed by the SETUP BDS5 PASSWORD SETUP COMMUNICATIONS and SETUP SCREEN COLORS and selections After you make
168. OTION TO SETTLE OUT AT THIS POINT MOTION SHOULD BE ZERO The commands SEG EQ 0 and W 0 are similar since both delay execution until motion profiles are complete However the W 0 command is an idling command and thus allows lower level tasks to execute Also the TIL command can be followed with a statement such as the P command above which is executed continuously until motion stops If you want to synchronize to a segment the SEG variable can be used with the TIL command For example suppose you want to turn on an output after the decel of an MI move begins The following sequence can be used 47 O1 OFF TURN OFF OUTPUT 1 MI 50000 1000 BEGIN THE MOVE TIL SEG EQ 3 WAIT HERE UNTIL CHAPTER 5 DEBUGGING SEGMENT 3 IS STARTED O1 ON TURN ON OUTPUT 1 5 5 4 WAIT W The WAIT W command can also be used for synchronization The WAIT command is W followed by the segment for which you want the program to wait or a O if you want the program to wait for motion to stop WAIT is provided in addition to the TIL command because it takes less space in your program For example W 5 performs a similar function to TIL SEG EQ 3 The WAIT command provides a few special features needed for motion synchronization For example in the following program the Wait delays execution until segment 2 of the second move MI 50000 1000 BEGIN THE FIRST MOVE CALCULATE THE SECOND MOVE MI 50000 1000
169. P for format and examples Allowed from the interactive and monitor modes and the user program Playback recorded points This command prints all the variables that were recorded by the last RECORD command Normally you should use Motion Link s PLAYBACK FROM BDS5 command rather than the BDS5 PLAY command Motion Link formats plots and prints data in a much more readable form than does the BDS5 Refresh screen This command is the same as the P command except that no line feed is printed This command can be used to overprint the practice of refreshing the display by printing a line with new values over the same line with old values It is generally used for status updating See P for examples and formats Allowed from the interactive and monitor modes and the user program APPENDIX SOFTWARE COMMANDS BDS5 RD RECORD RET RS Delay program execution for a specified period of time but use the external clock to time the delay REG need not be on for RD to function properly Allowed only from the user program Format RD lt Time gt Example RD 1000 Record 1 4 variables for a specified period of time This command allows you to record most 5 variables in real time for later playback You cannot record PE REMOTE TMR1 TMR2 TMR3 TMR4 VAVG VXAVG or any user switches Allowed from the user program or from the interactive mode Format RECORD Number Time 1 to 4 Variables Where Number is the numb
170. P switch which when turned on cuts all error messages down to 40 characters If your BDS5 prints to a DEP 01 type DEP ON ERROR HISTORY The BDS5 stores the twenty most recent errors in the Error History To display the entire Error History type ERR HIST This causes the Error History to be sent to the terminal with the most recent error sent first When the BDS5 is powered up a DRIVE POWERED UP message is inserted into Error History even though this is not an actual error To clear the Error History type ERR CLR Error History remains intact even through power down DISPLAYING ERROR MESSAGES The ERR command can also be used to display an abbreviated description of the error For example type The BDS5 responds with ERR 50 BDS5 INHIBITED You may display messages for errors from 1 through 999 If you type in an error number that the BDS5 does not recognize it will respond with ERROR NOT FOUND A description of all errors is given in the BDS5 manual in Appendix D THE USER S ERROR HANDLER When an error occurs the BDS5 decides what needs to be done disable the drive print out a message and so on This is called an error handler Often an application may require that other actions be taken A common example is setting the Output O word to turn off some auxiliary machine such as a pump These actions which are very specific to the application must be handled in the user s program In effect you can write a
171. RD 3200 100 CCW MOVE CCW AT 100 RPM MRD 0 50 GO BEST WAY AT 50 RPM Normalize the Position command and position feedback to the specified position Allowed from the interactive mode and the user program when there is no commanded motion Format NORM Position Example NORM 1000 BDS5 PS PLAY APPENDIX C SOFTWARE COMMANDS Print the variables specified with optional formats on a new line Allowed from the interactive and monitor modes and the user program Format P lt Expr gt format lt Text gt Where format is the print format specifying field width and Hex output The ellipsis indicates that the P can be followed by up to 15 different expressions and text strings Format can be B Binary H Hex S ON or OFF C ASCII Character Blank Decimal Integer nn m Floating Point Output where nn 18 the total number of digits m is the number of digits after the decimal point nn m p Same as nn m except only print p digits after the decimal point p must be less than m Examples PFB VFB IMON PRINT 3 FEEDBACK VARS PFB 4 PRINT PFB IN 4 CHARS IN H PRINT INPUT IN HEX IN 5H PRINT INPUT 5 HEX CHARS 123456 4 PRINT 12 3456 1234561 4 21 PRINT 12 34 BDS5 PRINT BDS5 ON THE SCREEN XPOS PFB PRINT PFB WITH TEXT P P P P P P P P Print with status This is identical to the P command except status of the 5 is displayed on the end of the printed line See
172. REMOTE with the P command It must be 1 to activate the BDS5 If you cannot turn REMOTE on see the Installation and Setup Manual Note that some faults hide the value of the REMOTE input from the BDS5 microprocessor This does not normally matter because all faults must be cleared before the drive will enable If this condition exists the BDS5 will print REMOTE as 1 3 6 6 Relay and STATUS Control Area 6 Area 6 shows how software switch STATUS and the relay work You can configure STATUS to indicate either drive READY but not necessarily ACTIVE or drive ACTIVE The difference is in how you want to use STATUS STATUS can be used for an interlock In this case you want STATUS to indicate drive ACTIVE If the BDS5 becomes inactive for any reason including the REMOTE input turning off then STATUS will turn off As an alternative you can use STATUS to indicate that the BDS5 is ready for the REMOTE input to turn on That is if REMOTE turns on the BDS5 will be ACTIVE In this case you want STATUS to indicate drive READY The software switch STATMODE controls which state STATUS will indicate If STATMODE is on then STATUS will indicate drive READY If 3 13 CHAPTER 3 PROGRAMMING LANGUAGE STATMODE is off then STATUS will indicate drive ACTIVE The operation of STATUS is shown by the AND gate and OR gate in Area 6 If STATMODE is on then READY will turn on STATUS through the AND gate If STATMODE is off then o
173. ROMPTS EDITOR INPUT EDITOR FIND EDITOR CHANGE handshaking will be identical to the above examples except the prompts will change as shown in the above chart WAKE UP AN AXIS A ADDR 65 A lt cr gt lt cr gt lt lf gt gt 28 BDS5 SERIAL COMMUNICATIONS 2 DOC BDS5COM2 DOC Rev4 13 1993 The serial protocol is simple with full duplex echo 1 The simple ASCII protocol was chosen to allow easy communications with any ASCII device Le dump terminals hand held terminals panel mounted terminals IBM compatibles running terminal emulation software etc 2 With full duplex echo the BDS5 will transmit each character received back to the host device This allows the host to verify each character was correctly sent The BDS5 will transmit a unique prompt when it is ready to receive commands interactive prompt will be gt If a prompt is not present then the BDS5 is not listening to the serial port BDS5 PROMPTS NON MULTIDROP MULTIDROP ADDR 0 ADDR 65 gt s gt t e Al i gt f gt EDIT CHANGE A 2 t A A i A CONTROL CODE DEFINITIONS HEX Space p gt 20h 29 Some of more important serial commands that have been available in all versions of software are in the following table BDS5 SERIAL COMMANDS Firmware version 2 0 and later the serial port PROMPT is remembered on Power up lt variable gt lt expr gt U
174. S5 command will sound the bell on your terminal P AG You can also use the character format to print control characters For example P 07 C also sounds the bell The character format allows you to print variables as ASCII codes However the easiest way to print control characters is normally with the carat One reason for this is that control characters can be within text strings For example P BELL lt CONTROL gt G G SOUNDS BELL If you use the carat to specify an invalid control character such as 1 the BDS5 will print the carat and the 1 1 Only A to Z M and are allowed 4 6 1 9 Cursor Addressing Many displays allow you to address the cursor For example the DEP 01 from Industrial Drives is an 80 character display that allows you to address any location from 0 leftmost top line to 79 rightmost bottom line First send ASCII 27 followed by the address of ASCII 0 4 through ASCII 79 For example you can address the rightmost space of line one space 39 with the control character sequence The specifies cursor addressing and ASCII 39 specifies space 40 One problem with cursor addressing is that the BDS5 cannot transmit ASCII 0 A This is a common limitation for terminals If you want to address space 0 you must first address space 1 then transmit backspace ASCII 8 or H For example if the following line is executed from the use
175. SER PROGRAMS been executed all ENDIF s are automatically executed This means that you cannot jump to a label within any IF THEN ELSE structure Note that jumping out of a control structure in such a manner is a poor programming practice and should be avoided Also you may not jump to a label within an IF THEN ELSE from outside the structure You cannot GOTO the middle of an IF ENDIF set You AN should never execute a RET from between an IF and NOTE ENDIF 4 5 USING THE GENERAL PURPOSE INPUTS General purpose inputs can be used to control the program From Chapter 3 you may recall that these inputs can be referred to one at a time using variables I1 116 or collectively IN If the program must wait for a particular input to be on or off before continuing execution the TIL command can be used TIL 15 EQ 0 If this statement is executed from the program the program will delay execution until I5 is 0 If the program must wait for many inputs to be on or off then the TIL command can be expanded For example if inputs 1 4 5 and 6 must all be on either of the following TIL instructions can be used TIL 11 14 15 16 EQ 4 THIS USES ALGEBRAIC MATH TIL I1 amp I4 amp I5 amp IG EQ 1 THIS USES LOGICAL MATH BOTH WORK It is slightly more complicated if the program must wait for some inputs to be on and others off For example if inputs 1 4 and 5 must be on and input 6 must be off the following TIL instructions
176. TIL OUTPUT O2 IS OFF HOLD UNTIL PFB PTRIP1 H O2 OFF H TRIP1 ON Use the BDSS to enter the following program 29 P TURN I1 ON H11 ON P H IS NOW ON B 4 21 CHAPTER 4 USER PROGRAMS Now exit the Editor turn input I1 off and observe the action of the HOLD command by typing RUN 29 You can Hold for any switch except REMOTE and user switches XS11 XS50 User switches XS1 XS10 are allowed with the HOLD command 4 7 2 DWELL D Sometimes it is desirable to delay execution for a specified amount of time The Dwell D command is the easiest way to do this The delay is specified in milliseconds For example D 1000 DWELL 1000 MILLISECONDS delays execution for 1000 milliseconds or 1 second The Dwell command can be demonstrated by typing in the following simple program 6 P BEGIN 5 SECOND DWELL D 5000 P END 5 SECOND DWELL B Now exit the Editor and type RUN 6 The result should be BEGIN 5 SECOND DWELL END 5SECOND DWELL with 5 seconds between lines being printed Dwells can be up to 2 147 483 647 milliseconds or about 25 days 4 7 3 WAIT W When using Move commands it is often necessary to synchronize the execution of your program to motion The Wait W command can be used to wait for the specified motion segment Examples of the Wait command are 4 22 BDS5 WAIT FOR MOTION TO STOP WAIT FOR MOTION COMMAND TO BEGIN WAIT FOR SEGMENT 14 MACRO MOVE
177. XT If the external input is a system with the same resolution as your BDS5 set external units as follows Table 4 13 Setting External Units in Master Slave Systems If the command is something other than a motor of similar resolution see Machine Specific Units in the next section 4 33 CHAPTER 4 USER PROGRAMS BDS5 COUNTS FROM MASTER RESOLVER TO DIGITAL CONVERTER PFS INTERNAL FEEDBACK VFS MICRO PROCESSOR MASTER BDS5 COUNTS FROM MASTER RESOLVER TO DIGITAL CONVERTER PFS INTERNAL FEEDBACK VFS PEXT EXTERNAL CONNECTOR x4 Mg C1 DECODER FEEDBACK VEXT MICRO PROCESSOR Figure 4 3 Master Slave Block Diagram 4 34 BDS5 4 9 2 Machine Specific Units The 5 allows you to specify user units for your machine You must determine the conversion constants PNUM amp PDEN for position VNUM amp VDEN for velocity and ANUM amp ADEN for acceleration Two tables have been provided to help you calculate those constants Tables 4 14 and 4 15 are for position velocity and acceleration units based Table 4 14 English Conversion 12 bit R D Only POSITION UNITS PNUM 40 Motor Movement In Revolutions Machine Movement In Your Units PDEN VELOCITY UNITS VNUM VDEN Motor Velocity In Rev Min 447392 x Machine Velocity In Your Units ACCELERATION UNITS ANUM ADEN Motor Acceleration In RPM
178. able remove power and contact the factory If it is stable continue on with tuning Do not forget to turn PL back on when you have finished tuning Also PL is always turned on during the BDS5 power up 6 3 2 Reducing ILIM You may need to reduce ILIM before executing the TUNE command since the TUNE command causes the motor to shake at about 15 Hz and at full torque This may damage some machines Also lightly loaded motors can overspeed if ILIM is too high You should raise ILIM to the highest level that does not cause problems because the tuning may not be acceptable if ILIM is too low The effect can be that the torque the BDS5 produces is swamped out by friction If you are not sure how much ILIM is necessary reduce ILIM to a low value say 5 or 1096 and gradually raise it If the tuning is acceptable that 18 it does not ring or overshoot excessively and it does respond fast enough then you are done Do not forget to restore ILIM to its original value The TUNE command shakes the motor vigorously You may need to reduce ILIM before executing the TUNE command to protect your CAUTION machine Do not forget to restore ILIM when tuning is complete The TUNE command can cause the motor to overspeed You may need to reduce ILIM to prevent overspeed errors NOTE Do not forget to restore ILIM when tuning is complete 6 3 CHAPTER 6 COMPENSATION 6 4 TUNE COMMAND When you enter a TUNE command you specify th
179. ally consist of address and data information and miscellaneous control signals for the interconnection of microprocessors memories and other computing elements Byte A group of 8 bits treated as a whole with 256 possible combinations of ones and zeros each combination representing a unique piece of Glossary ii information CAM Profile A technique used to perform nonlinear motion electronically similar to that achieved with mechanical cams Characteristic Equation 1 GH 0 where G is the transfer function of the forward signal path and H is the transfer function of the feedback signal path Circular Coordinated Move A coordinated move where the path between endpoints is the arc of a circle Class B Insulation A NEMA insulation specification Class B insulation is rated to an operating temperature of 130 degrees centigrade Class H Insulation A NEMA insulation specification Class H insulation is rated to an operating temperature of 180 degrees centigrade Closed Loop A broadly applied term relating to any system where the output is measured and compared to the input The output is then adjusted to reach the desired condition In motion control the term is used to describe a system wherein a velocity or position or both transducer is used to generate correction signals by comparison to desired parameters Cogging A term used to describe non uniform angular velocity Cogging appears as a jerkiness e
180. als The BDS5 offers RS 232 for most terminals and RS 422 RS 485 for multidrop communications With multidrop you can put up to 26 axes on one serial line The BDS5 can autobaud from 300 baud to 19 2k baud eliminating the need to set dip switches to start communicating MOTION LINK Industrial Drives also offers MOTION LINK a powerful menu driven communications package for CHAPTER 1 SYSTEM DESCRIPTION your IBM PC c compatible computer With this package the BDS5 s programs and variables can be retrieved from or saved to a disk drive Also on line help and a full screen editor are built into MOTION LINK MENU DRIVEN SOFTWARE The BDS5 s programming language allows you to write operator friendly menu driven software By incorporating an INDUSTRIAL DRIVES Data Entry Panel or any other serial communications device the operator can be prompted for specific process data MONITOR MODE The BDS5 provides interactive communications and permits all system variables and parameters to be examined and modified at any time even during actual program execution or while the motor is running 1 4 PART NUMBER DESCRIPTION A model number is printed on a gold and black tag on the front of your BDS5 5 4 5 Compensation Card and External Regen Resistor modules The model number identifies how the equipment is configured Each component is described to explain what the model configurations are You should verify that the model
181. also useful when trying to use general purpose inputs to control the user program 3 5 GENERAL PURPOSE INPUT OUTPUT The 5 provides 16 general purpose inputs and 8 general purpose outputs On power up all outputs are turned off Inputs and outputs can both be referred to individually or collectively I2 116 represent the individual inputs and O1 2 O8 represent the outputs You can turn the third output on and the sixth off by typing ON TURN ON THE THIRD OUTPUT BIT O6 OFF TURN OFF THE SIXTH OUTPUT BIT To display the fifth input type P 15 and either 1 or 0 will be displayed 3 10 BDS5 3 5 1 Whole Word I O Inputs and outputs can also be referred to collectively In order to do this the individual inputs or outputs are referenced as the bits of a digital word hence the term Whole Word I O Whole Word references are especially useful when you are trying to set or clear many output bits at once If you are unfamiliar with logical binary math or you plan to use one bit at a time you may not be interested in Whole Word I O However it can save space and execution time when properly used Whole Word I O is done using the variables OUT and IN OUT is an 8 bit digital word representing all of the outputs with O1 as the least significant bit LSB and IN is a 16 bit digital word representing all of the inputs with I1 as the LSB Each bit has a value which depends on its positi
182. amming PCAM PCAM is the position command from the cam table This is usually the role for PCMD position command However when camming is enabled PCM represents the position from the electronic gearbox that is the position that goes into the table PC M is the output from the table PCMD is automatically in a ROTARY mode where the distance of one rotation is fixed at 32 768 counts PCAM can be printed or recorded with PC Scope In fact if you want to see your cam profile you can record PCAM and PCMD simultaneously For example the following line records both positions for 0 5 seconds RECORD 500 1 PCMD PCAM You can then use PC Scope to verify your profile Also the PS and RS commands display CAMMING if GEAR and CAM are both ON Limitations There are several limitations for camming applications These limitations reflect that many functions of the BDS5 are not useful when caming For example profile commands MI MA J JT JF MCGO are not allowed ROTARY must be OFF Any error that disables the drive also disables camming you must re normalize after such errors Error 23 SOFTWARE OVERTRAVEL disables the BDS5 and breaks the user program when camming is off this error only breaks the user program 11 CAMMING DETAILS by George Ellis 7 92 Edited by Rick Furr June 02 1993 Camming is implemented as a modification of the 5 gearbox As Figure 5 shows the standard gearbox produces PCMD by multiplying PEXT by the rat
183. an END Kill K or Break B command Again most other commands are allowed for the background task including Block IFs If the background task is present the execution time of your program increases by about 1 4 9 UNITS The BDS5 provides user units so that both you and the machine operator can work in units that are convenient The BDS5 allows you to define the units of acceleration current velocity and position for your machine Also if your BDS5 has an external input you can define the units of external position and external velocity 4 9 1 User Units The BDS5 uses internal units called BDS5 basic units that are very inconvenient to use For example velocity is in 1 65 536 counts second User unit constants scale the BDS5 basic units For example if you type VOSPD 1000 the 1000 is multiplied by VNUM VDEN before it is stored in the BDS5 memory Your BDS5 is shipped with VNUM and VDEN set so that the user velocity units are RPM However with a simple step by step procedure you can redefine the units as inches minutes degrees second or any other units that are convenient for your machine The following table shows some common user units 4 32 Table 4 11 Common User Units Current Percent INUM 4095 IDEN 100 Amps INUM 4095 IDEN FULL AMPS Position Counts PNUM 1 PDEN 1 Velocity RPM rad sec VNUM 44739 VDEN 10 12 Bit VNUM 42723 VDEN 1 Accel RPM sec ANUM 4474 12 Bit rad secxsec ANUM
184. and A I1 ON You can follow the alarm definition with the code that you want to execute when the alarm fires For example if I1 turned on it might indicate an error condition In this case you might disable the BDS5 turn off all outputs and break execution The following program would accomplish this using the A alarm BDS5 DEFINE THE ALARM DISABLE THE BDS5 TURN OFF ALL OUTPUTS BHEAK EXECUTION 4 8 6 1 Restrictions of Alarms Alarms have many restrictions 1 You cannot execute GOTO GOSUB or RET commands from an alarm 2 You cannot execute a label 3 You cannot use the REMOTE switch to fire an alarm 4 Alarms must be self contained programs they cannot mix with your program 5 They must be terminated with an END Kill K or Break B command 6 Also if all three alarms are present the execution time of your program increases by about 3 Most other commands are allowed for alarms including motion commands and Block IFs 4 8 6 2 Printing with Alarms You must be careful when executing print commands from alarms If you need to print from an alarm task always print after the critical commands have been executed This is necessary because the input command from a lower task will stop any task even a higher priority task from printing The input command stops all printing until the operator responds with a new value For example write your program like this B HOME ON FIRE ALARM WITH
185. and Otherwise if ELIF condition 1 is TRUE commands in ELIF block 1 are executed No other blocks are executed even if the conditions that follow are true Program execution continues after the ENDIF command Otherwise if ELIF condition 2 is TRUE commands in ELIF block 2 are executed No other blocks are executed even if the conditions that follow are true Program execution continues after the ENDIF command Otherwise commands in ELSE block are executed Program execution continues after the ENDIF command Note that only the first block with a true condition is executed The IF ELIF ELSE and ENDIF commands have several restrictions and options Table 4 2 Block IF Restrictions and Options 4 13 CHAPTER 4 USER PROGRAMS Each IF ELIF ELSE ENDIF set must have one and only one IF may have any number of ELIF s need not have any ELIF s may have one ELSE need not have an ELSE must have one and only one ENDIF 4 4 2 5 IF vs You can use in place of commands For example clamping applications make decisions based on the final position of the motor after a move For our example assume that the PFB should be between 50 and 50 If PFB is within range the program should turn output O1 on and print an appropriate message If it is out of range O1 should be turned off and a message should be printed The table below shows the de
186. and enter the Break command to break program execution Notice that the velocity is continuously updated but the line appears to be stationary A similar program with the P or PS commands would cause the lines to scroll to the top of the screen 4 6 3 INPUT So far printing information to the operator has been discussed This section will discuss how to prompt the operator for information using the INPUT command The INPUT command causes the BDS5 to print a message to the terminal and wait for a response from the operator The input information can be stored in any programmable variable This allows the operator to change or enter information without making any changes to the program itself You can only execute the INPUT command from the user program Type in the following example INPUT instruction INPUT ENTER NEW SPEED X2 This causes the BDS5 to print ENTER NEW SPEED Type the new speed into the terminal After you are prompted enter a number and press the enter key The number you enter is stored in the variable X2 If you press the enter key without entering a number the variable X2 is left unchanged Use the Print command to display the new value of X2 P X2 A 79 r 3 e o You can also specify an upper and lower limit for the operator entry If the above INPUT instruction were written as INPUT ENTER NEW SPEED X2 10 100 BDS5 the BDS5 would force the operator to inp
187. and therefore they are generally replaced with integrating loops when the machine is fully operational 3 9 2 2 Integrating Velocity Loop If an integrating velocity loop is selected then the velocity error is integrated and multiplied by KVI the velocity integration constant Velocity feedback is subtracted from this signal then the signal is multiplied by KV the velocity loop gain to form ICMD This velocity loop is selected when PROP is off 3 9 3 Torque Command In a few applications the BDS5 is given a torque command Actually this is a current command but at lower speeds motor torque is approximately proportional to current In this case VCMD is BDS5 multiplied by KPROP to form ICMD Note that this differs from the proportional velocity loop only in that VFB is not subtracted from VCMD The switch TQ must be on to select the torque mode and off for all other modes The position loop should be off PL off when the BDS5 is running in Torque command mode The BDS5 will turn PL off when TQ is turned on N NOTE When TQ is turned on PL is forced off 3 9 4 Power Up Control Loops The BDS5 has at power up the following settings Position loop enabled PL No feed forward KF 0 Integrating Velocity Loop PROP off TQ off These settings meet the requirements of a large number of applications Figure 3 9 shows each of the five BDS5 controller modes CHAPTER 3 PROGRAMMING LANGUAGE 3
188. ange the units see Chapter 4 Examples in this manual will assume that the BDS5 is configured with standard units 3 3 2 Three Types of Variables The BDS5 has many variables all of which are listed in Appendix E The variables can be divided into three groups monitor control and user MONITOR VARIABLES 3 2 BDS5 Monitor variables watch the system You may display their values or use them in calculations However as a rule you may not change them The BDS5 automatically changes these variables to reflect its status Position feedback PFB is an example of a monitor variable CONTROL VARIABLES Control variables allow you to change or limit some process in the BDS5 An example of a control variable is current limit ILIM ILIM limits the maximum current the BDS5 can deliver It can be changed at any time USER VARIABLES User variables allow you to store information for later use or hold intermediate results of calculations They are discussed later in this chapter 3 3 3 Variable Limits variables have limits It is important to be aware of these limits since attempting to set a variable to a value outside its limits generates an error For example ILIM must be between 0 and 100 The limits of each variable are listed in Appendix E 3 3 4 Switches Switches are variables that can be set to 0 or 1 only In other words they have limits 0 and 1 Aside from this restriction this discussion about v
189. are allowed for the variable input task including motion commands and Block IFs If the variable input task is present the execution time of your program increases by about 1 BDS5 4 8 8 Main Program Level Task Level 5 Most of the time your program will run at task level 5 All the program examples given earlier in this chapter executed at task level 5 Notice from Multi Tasking Overview that all general purpose labels 0 500 and many dedicated labels POWER UP AUTOS MANUALS and ERRORS share task level 5 The routines that follow these labels share one task level and cannot run concurrently For example you cannot run AUTO and MANUAL concurrently In other words only one task level 5 routine can run at a time Alarms and the variable input task are higher priority than task level 5 For example if an alarm fires while your program is running a task that begins at a general purpose label task level 5 task level 5 will be suspended until the alarm is complete The background program BACKGROUNDS runs at the lowest level Generally alarms respond to conditions that are more urgent than most other sections of the program Similarly background is for tasks that are not critical such as printing Multi tasking controls which task runs by executing commands from the highest priority task that is not idle The rest of this section will discuss the dedicated labels in task level 5 POWER UP ERRORS AUTOS and
190. ariables also applies to switches 3 3 5 Printing Variables variables can be displayed To display a variable on the terminal you should use P the PRINT command For example type P ILIM Since the standard setting of ILIM on most systems is 100 the terminal should display BDS5 Suppose you want to display PFB the position feedback Type P PFB The position feedback should now be displayed Assuming the motor and resolver are connected to the BDS5 rotate the motor shaft about half a revolution Now print PFB as above and notice that it has changed to reflect the new position 3 3 6 Changing a Variable Variables are changed with assignment instructions An assignment instruction begins with the name of the particular variable followed by and ending with the new value One or more spaces can be substituted for the The following examples assign or at least attempt to assign ILIM a new value ILIM 10 CORRECT ASSIGN A NEW VALUE TO ILIM ILIM 10 CORRECT THE IS OPTIONAL ILIM10 INCORRECT THERE MUST A SPACE OR A few systems are set up with ILIM less than 100 If your terminal displays a number less than 100 write it down for reference later in this NOTE chapter The following examples will change ILIM and it must be reset to its original value Type the following line on the terminal 10 Next print new value of ILIM with the P instruction
191. art and run in synchronism Pull Out Torque The maximum torque that can be applied to a stepping motor or synchronous motor running at constant speed without causing a loss of synchronism Pulse Rate The frequency of the step pulses applied to a stepper motor driver The pulse rate divided by the resolution of the motor drive combination in steps per revolution yields the rotational speed in revolutions per second PWM Pulse Width Modulation An acronym which describes a switch mode control technique used in amplifiers and drivers to control motor voltage and current This control technique is used in contrast to linear control and offers the advantages of greatly improved efficiency Quadrature Refers to signal characteristics of interfaces to positioning devices such as encoders or resolvers Specifically that property of position Ramping The acceleration and deceleration of a motor May also refer to the change in frequency of the applied step pulse train Rated Torque The torque producing capacity of a motor at a given speed This is the maximum continuous torque the motor can deliver to a load and is usually specified with a torque speed curve Regeneration The action during motor braking in which the motor acts as a generator and takes kinetic energy from the load converts it to electrical energy and returns it to the amplifier Repeatability The degree to which the positioning accuracy for a
192. atch Area 4 3 13 3 6 5 ACTIVE 5 3 13 3 6 6 Relay and STATUS Control Area 6 3 13 3 6 7 Motor 3 14 3 6 8 Output Relay netos Ro eue 3 14 3 7 Drive Control cet 3 14 3 7 1 Direction Control DIR 3 14 3 12 Positiones i o eee RES 3 14 3 7 2 1 Position Command and Feedback amp eee 3 14 3 7 2 2 Position Error PE amp PEMAX 3 14 3 7 2 3 R D Position PRD 3 15 3 7 2 4 Sampling PCMD and PEXT 3 15 BDS5 3 13 Velocity atitem iere PR DE ete 3 15 3 7 3 1 VCMD VFB VE amp VAVG 3 15 3 7 3 2 Velocity Limits VMAX amp VOSPD 3 16 37 4 Cuenta teneret 3 16 3 7 4 1 Motor Current ICMD amp 3 16 3 7 4 2 Current Limits IMAX amp ILIM 3 16 3 7 5 Enabling the Position Loop with PL 3 16 3 7 6 Controlling the Velocity Loop sth PROP neget teme 3 16 3 7 7 Enabling the 5 3 16 3 7 8 Limiting Motor Current 3 17 3 7 8 1 Continuous Current ICONT 3 17 3 7 8 2 Foldback Current IFOLD 3 17 3 7 8 3 Monitoring Current Limits 3 18 3 8 Motion Commands 3 18 3 8 1 Basic Motion Comma
193. ation Absolute Programming A positioning coordinate reference wherein all positions are specified relative to some reference or home position This is different from incremental programming where distances are specified relative to the current position AC Adjustable Speed Drive All equipment required to adjust the speed or torque of AC electric motor s by controlling both frequency and voltage applied to the motor s AC Servo Drive A servo drive used to control either or both synchronous or induction AC motors Acceleration The change in velocity as a function of time Acceleration usually refers to increasing velocity and deceleration describes decreasing velocity Accuracy A measure of the difference between expected position and actual position of a motor or mechanical system Motor accuracy is usually specified as an angle representing the maximum deviation from expected position Actuator A device which creates mechanical motion by converting various forms of energy to mechanical energy Adaptive Control A technique to allow the control to automatically compensate for changes in system parameters such as load variations Ambient Temperature The temperature of the cooling medium usually air immediately surrounding the motor or another device Amplifier Electronics which convert low level command signals to high power voltages and currents to operate a servomotor ASCII American Stan
194. ation BDS5 control loops have one or two tuning variables BDS5 loops follow the convention that larger constants provide higher gain Each BDS5 loop is 3 37 CHAPTER 3 PROGRAMMING LANGUAGE described below and shown on the drawing at the end of this chapter 3 9 1 Position Loop The Position Loop input is the variable PCMD the Position command The feedback is the position feedback The output is VCMD Velocity command and its two tuning variables are KP the position loop gain and KF the position loop feed forward gain The position loop calculates the position error PE as the difference of PCMD and PFB As a secondary command source PCMD 15 differentiated d dt PCMD The position loop then performs the following calculations VCMD KP d dt PCMD The position loop is optional If the switch PL is on then the position loop is enabled if it is off then the position loop is bypassed PL is turned on at power up The feed forward gain reduces position error at high speed Without feed forward the velocity command is generated only from position error a large position error is required to command a hi gh speed If KF is large enough then a high velocity command can be generated with little or no position error The BDSS scales so that unity feed forward occurs when KF equals 16384 In other words if KF is 16384 no position error is required to generate the velocity command in
195. bly Tools You can obtain the crimping and extraction tools from your nearest Molex distributor or by contacting Molex GOLDLINE series electronics BDS4 s BDS5 s and at 708 969 4550 PSR4 5 s use Molex MINI FIT JR series connectors HN The necessary connectors and pins are included in Hand Crimping Tool Molex Order 11 01 0122 your BDS5 and PSR4 5 connector kits Extractor Tool Molex Order 11 03 0038 1 7 CHAPTER 1 SYSTEM DESCRIPTION BDS5 1 5 SPECIFICATIONS AND RATINGS Table 1 4 Specifications BDS5 1XX 90 160 VAC L L OUTPUT TO MOTOR DESCRIPTION BDS5 103 BDS5 106 BDS5 110 BDS5 120 Main DC Bus Minimum 130 VDC 130 VDC 130 VDC 130 VDC Maximum 225 VDC 225 VDC 225 VDC 225 VDC 15 20 VDC 15 20 VDC 15 20 VDC 15 20 VDC 0 25 AMPS 0 25 AMPS 0 25 AMPS 0 25 AMPS Unregulated Logic Bus 8 12 VDC 8 12 VDC 8 12 VDC 8 12 VDC 1 00 AMPS 1 00 AMPS 1 00 AMPS 1 00 AMPS Output Current RMS Convection Fan Cooled 45 C AMB Cooled Continuous RMS 3 0 AMPS 6 0 AMPS 10 0 AMPS 20 0 AMPS Peak 2 0 sec RMS 6 0 AMPS 12 0 AMPS 20 0 AMPS 40 0 AMPS Output KVA 160 VDC Bus Continuous 45 C AMB 0 6 KVA 1 2 KVA 2 0 KVA 4 0 KVA Peak 2 0 sec RMS 1 2KVA 2 4 KVA 4 0 KVA 8 0 KVA Internal Heat Dissipation 30 WATTS 40 WATTS 60 WATTS 110 WATTS PWM Switching Frequency 10 0 kHz 10 0 kHz 10 0 kHz 10 0 kHz Motor Current Ripple Frequency 10 20 0 kHz 20 0 kHz 20 0 kHz 20 0 kHz Resolver Excitation Frequency 8 5 kHz 8 5 k
196. cations where simple indexes cannot do the job A Macro Move is a combination of up to 30 accelerations traverses and decelerations which are fully precalculated for faster execution You can program teach modes where position end points can be changed by a factory operator MASTER SLAVE ELECTRONIC GEARBOX The electronic gearbox is used to link two motors together so that the velocity of the slave is proportional to the velocity of the master The ratio can be from 32767 1 to 1 32767 and can be negative to allow the slave to move in the opposite direction Also the index on gearing feature permits phase adjustments MASTER SLAVE PROFILE REGULATION With profile regulation you can control the slave s motion profile according to an external master motor or frequency Profile regulation modifies the velocity and acceleration of the slave axis without affecting the final position of the move You can use profile regulation to implement feed rate override MOTION GATING AND REGISTRATION The 5 can precalculate moves to begin motion within one millisecond after a transition on the GATE input This provides rapid and repeatable motion initiation The BDS5 has the ability to capture the current position within 25 microseconds after a transition of the HOME input This results in fast homing and accurate registration sequences MATHEMATICS Algebraic math is provided for commands such as X1 22x X24 X3 The BDS5 ha
197. ch In this case you should reduce ILIM to a level just high enough to overcome running friction at low speed ILIM is lowered to reduce the torque exerted by the motor when the machine stop is encountered Set to a level well above the normal following error usually the position unit equivalent of several hundred counts is sufficient Then turn CLAMP on and jog at low speed toward the stop The BDS5 will run the machine into a stop and limit current to ILIM When SEG is equal to 0 the BDS5 3 27 CHAPTER 3 PROGRAMMING LANGUAGE has clamped and thus recognizes that the machine has been run into the stop Often the repeatability of this operation is unacceptable because the stop may be soft or it may wear over time Here you can use the MRD command to force the BDS5 to move to a fixed R D converter position This means that you will get a repeatable home as long as the clamp position does not vary more than one half of one revolution between different clamping operations This is not normally a problem To set the proper R D converter position for the MRD command first do the clamping operation by hand a few times Reduce ILIM and jog at low speed into the stop After the unit has clamped as indicated by SEG 0 print the R D converter position using P PRD Do this several times and record the average of PRD Now use the MRD command to back away from the stop about one half of one revolution For examp
198. ch easier to change These profiles can be changed without machining parts and without disassembling the machine With electronic cams the machine comes off line only for the few minutes it takes to load a new profile another advantage is that electronic cam profile are not subject to wear like their mechanical counterparts The profile of an electronic cam is stored in a table such a the one shown in Figure 2 This table defines the relationship between the drive and follower positions You define the table directly or take it from an existing conventional cam If the cam already exists you determine the radius of the cam profile at different angles as shown in Figure 3 Here 4 radii are shown though in practice many more are specified 1 1 1 T 1 1 1 1 1 1 Figure 2 Electronic Cam Table One of the most important features of an electronic cam is that the master drive can rotate in one direction indefinitely With conventional positioners this will eventually cause an error because the internal position counter will overflow Also the electronic cam controller must support gear ratios between the drive shaft and the follower Again the drive can rotate indefinitely and the controller must not lose counts The BDS5 has been designed with both of these criteria allowing it to serve as both a conventional positioner and as an electronic cam 4 00 Radius N N 2 75 Radius 907 2 75 Radius
199. ckage specially designed for the BDS5 This chapter also contains an overview of Motion Link and its basic functions and features The Motion Link setup program is introduced to enable the user to have easy access to the more common Motion Link procedures 2 2 COMPUTER REQUIREMENTS The 5 requires IBM PC or compatible computer with the following features e IBM PC XT AT PS 2 or compatible workstation e 512K RAM e PC DOS or MS DOS Version 2 5 or later e Either 5 1 4 or 3 1 2 Floppy Drive e Standard Video Adapter CGA MDA EGA MCGA and VGA e Serial Port for communication link with BDS5 The serial communications port may be COMI or COM2 The chart below shows the way your PC should configure COMI and COM2 This is the normal configuration COMI Address 3F8h Interrupt Request 4 COM2 PC Address 2F8h Interrupt Request 3 2 3 SOFTWARE INSTALLATION The following section will show you how to back up and copy the files from the Motion Link disk to your computer s hard disk or floppy disk 2 3 1 Backing Up the Disk s Before starting Motion Link you should back up the Motion Link disk s that came with the BDS5 This way if something happens to the master disk s you ll always have a copy Remember disks can be damaged by heat magnets pressure and dirt all extensively found in a manufacturing environment Follow the procedure below to back up your disk s 1 From DOS find ei
200. command is the user program command that executed Output Example 1 LINE 22 AT 5 this indicates program trace line was at user program line 22 from the Main program task and it was a label 5 NOTE When upgrading from an older version of firmware the following variable must be initialized to insure proper operation of the BDS5 This is because they are not forced to default power up state and therefore will assume the value of the previously unitialized memory locations the flags ECHO and MSG should be set to 1 and the flag EXTDX should be set to 0 for 250 user registers and set to 1 for 750 user registers Remember that when EXTDX is enabled it will disable the PC SCOPE and PC TRACE features of the BDS5 ECHO 1 MSG I e EXTDX 0 BDS5 TIMING TESTS INSTRUCTION O1 ON O1 OFF OUT OUT 0C8h SPECIAL CONDITION TIMING METHOD None 1 None None TIME msec Ver 2 0 5 1 90 1 90 2 86 TIME msec Ver 2 0 5 None None None None None None None None GEAR ON GEAR ON None GEAR ON GEAR amp REG ON REG ON REG ON amp IN MOTION 3 99 1 72 2 18 2 17 2 33 2 36 1 20 2 00 2 07 40960 NONE MI 40960 GEAR ON 2 58 549 MI 40960 REG ON 2 510 520 VDEFAULT 1000 TIMING METHOD 1 TIMING METHOD 2 Divide the number of loops counted X1 into 10 seconds 10 X1 to get the single loop time Perform this opera
201. control the servo axis motion of a robot Rotor The rotating part of a magnetic structure In a motor the rotor is connected to the motor shaft Serial Port A digital data communications port configured with a minimum number of signal lines This is achieved by passing binary information signals as a time series of 1 s and O s on a single line Servo Amplifier Servo Drive An electronic device which produces the winding current for a servo motor The amplifier converts a Glossary xii low level control signal into high voltage and current levels top produce torque in the motor Servo System An automatic feedback control system for mechanical motion in which the controlled or output quantity is position velocity or acceleration Servo systems are closed loop systems Settling Time The time required for a step response of a system parameter to stop oscillating or ringing and reach its final value Shunt Resistor A device located in a servoamplifier for controlling regenerative energy generated when braking a motor This device dissipates or dumps the kinetic energy as heat Single Point Ground The common connection point for signal grounds in a control wiring environment Slew In motion control the portion of a move made at a constant non zero velocity Slew Speed The maximum velocity at which an encoder will be required to perform Speed In motion control the concept used to describe the
202. coupled into sensitive electronic circuits may cause problems Encoder A type of feedback device which converts mechanical motion into electrical signals to indicate actuator position Typical encoders are designed with a printed disc and a light source As the disc turns with the actuator shaft the light source shines through the printed pattern onto a sensor The light transmission is interrupted by the patterns on the disc These interruptions are sensed and converted to electrical pulses By counting these pulses actuator shaft position is determined Encoder Absolute A digital position transducer in which the output is representative of the absolute position of the input shaft within one or more revolutions Output is usually a parallel digital word Encoder Incremental A position encoding device in which the output represents incremental changes in position Encoder Linear A digital position transducer which directly measures linear position Glossary v GLOSSARY BDS5 Encoder Marker A ounce per revolution signal provided by some incremental encoders to specify a reference point within that revolution Also known as Zero Reference signal or index pulse Encoder Resolution A measure of the smallest positional change which can be detected by the encoder Explosion proof A motor classification that indicates a motor is capable of withstanding internal explosions without bursting or allowing ig
203. ction on ADDR and multidrop communication later in this chapter for more information 4 10 1 3 Enabling Autobaud with ABAUD The autobaud software switch ABAUD is the usual way to tell the BDS5 to autobaud on power up If ABAUD is on then the system will autobaud when it is powered up or reset provided that the multidrop address ADDR is 0 After a successful autobaud the baud rate will be stored in BAUD BDS5 If you do not want your BDS5 to autobaud when the unit is powered up then turn ABAUD off This is important if you want the BDS5 to run the Power Up Label POWER UP because if ABAUD is on the BDS5 will not execute the program until communications have been established 4 10 1 4 Baud Rate BAUD If the MOTION input is on ADDR is zero and ABAUD is off then the system will check the variable BAUD for the desired baud rate If it is not a valid baud rate the BDS5 will autobaud After a successful autobaud an error is generated indicating that the baud rate was out of range on power up 4 10 2 Prompts The BDS5 issues a prompt when it is ready to receive a new command Prompts are discussed in Chapter 3 The BDS5 allows you to suppress the prompt characters by typing PROMPT OFF PROMPT is turned on at power up Prompts are particularly important when communicating with computers since the computer that is transmitting to the BDS5 must wait for a prompt before beginning a new line After the prompt is recei
204. d at any time In general clamping is done at low speeds with the current limited to some low level After the clamp has occurred the motor is assumed to be at zero speed When the clamp has occurred you can raise or lower ILIM to set the holding torque as desired You can tell whether clamp has occurred by looking at SEG the present motion segment If SEG is 0 then motion has stopped CHAPTER 3 PROGRAMMING LANGUAGE After the BDS5 stops motion the position error stays at approximately PECLAMP Before commanding any new motion you should zero the position error with the ZPE command Clamping can be used with all move and jog commands If jogs are used the motion continues until the stop is found If move commands are used then motion does not continue past the specified endpoint regardless of whether a part is found An example of clamping follows 1000 SET CLAMP 1000 POS UNITS CLAMPING MODE MOVE AT MOST 3100000 POS UNITS THE MOTOR GETS ALL THE WAY TO 100000 THEN THE STOP WAS ENCOUNTERED ASSUMED THE PART IS NOT THERE CLAMP ON MA 100000 400 wo DELAY UNTIL MOTION STOPS IF PCMD EQ 100000 P PART NOT FOUND PCMD 100000 FINAL POSITION THEN THE PART WAS NOT FOUND 3 8 10 1 Clamping and Homing Clamping can be used to home your machine by gently running the machine into a stop this eliminates the need for a home limit swit
205. dard Code for Information Interchange This code assigns a number to each numeral letter of the alphabet In this manner information can be transmitted between machines as a series of binary numbers Back EMF The voltage generated when a permanent magnet motor is rotated This voltage is proportional to motor speed and is present regardless of whether the motor winding s are energized or un energized Bandwidth The frequency range in which the magnitude of the system gain expressed in dB is greater than 3 dB Baud Rate The number of binary bits transmitted per second on a serial communications link such as RS 232 Glossary i GLOSSARY BDS5 Bit Binary Digit A unit of information equal to 1 binary decision or having only a value 0 or 1 Block Diagram A simplified schematic representing components and signal flow through a system Bode Plot A plot of the magnitude of system gain in dB and the phase of system gain in degrees versus the sinusoidal input signal frequency in logarithmic scale Brownout Low line voltage at which the device no longer functions properly Brush Conducting material which passes current from the DC motor terminals to the rotating commutator Brushless Servo Drive A servo drive used to control a permanent magnet synchronous AC motor May also be referred to as an AC Servo Drive Bus A group of parallel connections carrying pre assigned digital signals Buses usu
206. defined as KF 16384 However the larger you make KF the more you must reduce KP to eliminate overshoot and thus reduce the position loop performance If you cannot get the desired performance from the position loop then try reducing ACC and DEC to reduce overshoot This can be a good way to limit overshoot in the position loop and you may be able to raise KP slightly about 20 to improve performance 6 6 RECORD AND PLAY The RECORD command allows you to record most BDSS variables in real time for later playback You can simultaneously record up to four variables You can record any variable except PE REMOTE TMRI TMR2 TMR3 TMR4 VAVG VXAVG or any user switches You can specify the time between points from one millisecond to one minute You can record up to 1000 instances of 1 variable 500 instances of 2 variables 333 instances of 3 and 250 instances of 4 variables The format of the RECORD command is RECORD Number Time lt 1 to 4 Variables 6 5 CHAPTER 6 COMPENSATION Where number is the number of Intervals over which the variables will be recorded and time is the time in milliseconds of each interval Note Number lt 1000 for 1 Variable Number lt 500 for 2 Variables Number lt 333 for 3 Variables Number lt 250 for 4 Variables For example 405 BEGINNING LABEL EN ENABLE BDS5 RECORD 500 1 VFB RECORD VFB FOR J 1000 31 2 SECOND JOG B 31000 RPM Records the
207. ds sese teet 3 36 Restrictions of Variable Input 4 28 REG amp REGKRHEZ eee 3 35 Rings ede dou 6 2 Regulation Example 3 36 RINSING Za ISI F6 2 Profile Regulation and Counting Rotary Mode and Absolute Moves 4 38 Back Wards ose irent 3 36 Rules For Math Expressions T3 9 Profiles ixi Debe RU oues 3 20 RUN isnot Sissi eRe Hideto 4 10 Incremental Move Example 3 22 R n Mode eere 2 12 Move Absolute MA Command 3 21 Move Incremental MI Command 3 22 S Multiple Profile Commands 3 23 Eural PEND S Curve Acceleration Chart T3 21 Profile Limits nee 3 22 Sat rycs 3 20 S Curve Profile eee etes F3 21 Mc MMC YAN S DL S QUEVES cci beoe o Bec ve een dn 3 20 Profiles and Gearbox 3 33 Program 2 4 Sample Flowchart eese F4 4 v uc ue Sampling PCMD and 3 15 rogram Examples 4 41 Programming Conditions aaa 3 3 SCOPE setlists khan epi 2 5 Segments for Different Moves T5 5 rogramming Techniques 4 1 Jue Serial Communication
208. dware input as the capture trigger 3 8 9 1 Enabling Capture CAP amp PCAP The switch CAP controls capture If CAP is on then capturing is enabled When capturing is enabled the BDS5 will watch the HOME input When the HOME input changes to the state specified by CAPDIR the BDS5 will store the position in the variable PCAP After the capture the BDS5 turns CAP off This tells you that the capture is complete PCAP is in position units You can then use PCAP as you would any other monitoring variable 3 8 9 2 Capture Direction CAPDIR The capture is triggered when the HOME input changes from to 1 or vice versa If CAPDIR is 1 the capture occurs when the HOME input changes from 1 If CAPDIR is the capture occurs when HOME changes from 1 to 0 CAPDIR can be changed at any time Changing CAPDIR always turns CAP off 3 8 9 3 Speeding Up Homing Sequences One application of capture is to speed up homing sequences Homing sequences traverse very rapidly until the HOME switch is tripped Then the motor decelerates to zero and begins to traverse at a medium speed in the opposite direction until the HOME switch trips again Then the motor decelerates again to a slow speed until the HOME switch trips again Since the final speed was low the distance to decelerate is considered negligible and the motor is assumed to be at home Using capture the approximate home location can be determined when the motor is traversing at
209. dware Travel Limits disable the BDS5 rather than just stopping motion as the software limits do This means that the motor must be backed away from the limit by hand The Installation and Setup Manual discusses how to wire LIMIT Usually two limit switches are wired 3 19 CHAPTER 3 PROGRAMMING LANGUAGE in series and connected to LIMIT the contacts of these switches must be closed for the BDS5 to be enabled If the contacts open the BDS5 will be disabled the motor will coast to a stop and an error will be generated This limit is a safety device and not part of normal program operation Hardware Travel Limits are always enabled 3 8 2 2 Software Travel Limits PMAX amp PMIN Software Travel Limits limit the range of motion of the motor There are two software limits maximum and minimum If position feedback PFB moves outside the software limits an error is generated and motion stops Software Travel Limits are intended as a guard against motion that is out of range due to improper operation or programming errors PMAX is the maximum position allowed and PMIN is the minimum If PFB is greater than PMAX negative motion is allowed but positive motion is not If PFB is less than PMIN only positive motion is allowed PMAX and PMIN are in position units and can be changed at any time Software Travel Limits are enabled with PLIM which can also be changed at any time If PLIM is on software limits are active otherwise
210. e external pulse input This can be caused when the variable GEARI is too small or GEARO is too large That is the input times the ratio of GEARO GEARI was greater than the highest allowable input frequency 2 MHz This error breaks program execution and disables the BDS5 D 4 5 Communication Errors ERROR 103 BAUD RATE SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 3 SEVERITY 1 APPENDIX D ERROR CODES BDS5 ERROR 104 ERROR 105 The variable BAUD contains a value that is not supported by the BDS5 This error occurs during the autobaud sequence and so is never printed to the terminal You will only see it in the error history buffer This error has no action ABAUD amp MULTIDROP SEVERITY 1 This error is caused by attempting to autobaud while in multidrop communications which is not allowed The variable ABAUD is on indicating request for autobaud and the variable ADDR is not zero indicating multidrop communications This error occurs during the autobaud sequence and so is never printed to the terminal You will only see it in the error history buffer This error has no action SERIAL WDOG SEVERITY 3 The serial port did not receive a valid command for WTIME milliseconds when the serial watchdog was enabled that is WATCH 1 This error breaks program execution and disables the BDS5 D 4 6 Password Errors ERROR 110 ERROR 111 EDIT PASSWORD SEVERITY 1 You attempted
211. e response time and the stability level The response time is specified in the form of bandwidth The higher the bandwidth the faster the response The level of stability is specified as follows Table 6 2 Allowed Tune Command Stability Settings Slightly overdamped Critically damped Slightly underdamped The drive will be enabled and the motor will turn Make sure the motor is secured Even if the BDS5 is disabled it will enable long enough to execute the TUNE command WARNING Enable the BDS5 and type this command TUNE 30 2 The BDS5 will shake the motor and set the tuning so that the velocity loop has a bandwidth of approximately 30 Hz and is critically damped The allowed bandwidths are 5 10 15 20 25 30 40 and 50 Hz The tune command does not always provide an acceptable tuning If not you can tune the BDS5 yourself 6 5 TUNING THE BDS5 YOURSELF If you use the TUNE command and the resulting tuning variables cause the system to oscillate there are generally two reasons 1 The bandwidth in the TUNE command is set too high for the system to function properly 2 The low pass filter is set too low this only applies if LPF is on 6 4 BDS5 In either case first raise the low pass filter frequency LPFHZ to as high a level as is acceptable You may even decide to remove it by setting LPF to off If the TUNE command does not provide a suitable set of tuning variables then you hav
212. e two conditions The example above only executes the B command if both X1 lt 100 and X1 gt 100 Nesting of commands is limited by the number of entries and the maximum length of a line BDS5 commands are limited to 15 entries the example above has 9 entries XI LT 100 GT 100 and B Since each level of command nesting requires 4 entries you cannot have more than three levels of nesting Also a command must be less than 80 characters long since it must fit on a single line 4 4 2 3 TIL COMMAND The TIL is a single line command that allows you to specify a condition and a command to be executed repeatedly until that condition is true The TIL command has the following format TIL condition FALSE command FALSE command is repeatedly executed as long as the condition is false If the condition is true at the beginning of the TIL command then FALSE command is never executed In this case program execution continues to the next step An example of the TIL command would be to print a line to the operator continuously until the variable PFB is greater than 10000 This statement delays program execution until the condition is true and also refreshes the display while the program waits TIL PFB GT 10000 P WAITING FOR PFB 10000 The TIL command can be used to simply delay your program because the statement that follows the condition is optional For example this statement delays execution but does no
213. e 6 1 the graph shows the response of BDS5 TACH signal on Connector C2 Pin 2 to a square wave input when the system is critically damped Figure 6 1 Critical Damping 6 2 2 Underdamping Sometimes the system is tuned for critical damping and the system is still too slow In these cases you may be willing to accept less than critical damping For applications that can work properly with a slightly underdamped system you may reduce the stability to improve the response The graph in Figure 6 2 shows a BDS5 slightly underdamped TIME APPROX 10 Msec Div Figure 6 2 Underdamping 6 2 BDS5 6 2 3 Overdamping An overdamped system is very stable but has a longer response time than critically damped or underdamped systems Also overdamped systems are noisier than less damped systems with the same response rate The graph in Figure 6 3 shows an overdamped system Figure 6 3 Overdamping 6 2 4 Ringing When you are tuning the BDS5 you may tune it so that the response rings Ringing is caused when you attempt to tune the BDS5 for either too rapid response too high bandwidth or too much stability too much damping or both The only solution is to reduce the bandwidth or the stability or both In Figure 6 4 the graph shows a system that rings Figure 6 4 Ringing BDS5 6 3 TUNING The TUNE command shakes the motor vigorously Secure WARNING the motor before tuning The 5 is usually ship
214. e BDS5 controls acceleration with three variables AMAX ACC and DEC AMAX is the maximum acceleration allowed for almost all motion commands The only exception is electronic gearbox AMAX is the upper limit for the normal acceleration rates ACC and DEC AMAX should always be set below the acceleration level that can damage your machine Errors which stop motion will decelerate the motor at AMAX therefore your machine is subject to deceleration rates of AMAX at any time AMAX is in acceleration units which are RPM second as a default AMAX can be changed only when the 5 is disabled Set AMAX below the maximum acceleration rate that your machine can WARNING experience without damage ACC is the acceleration rate for most moves ACC is in acceleration units ACC can be changed at any time although it must be less than AMAX Attempting to set ACC to a value greater than AMAX will generate an error DEC is the deceleration rate for most moves DEC is also in acceleration units DEC can be changed at any time Attempting to set DEC to a value greater than AMAX will generate an error 3 8 1 2 EN STOP amp LIMITS Before any motion can take place the BDS5 must be enabled Type BDS5 3 8 1 3 Enabling Motion with MOTION MOTION is a hardware input that enables or inhibits motion If MOTION is on motion is enabled if MOTION is off motion is inhibited You can enable the BDS5 if MOTION is off but commanding moti
215. e FILENAME COVER Title Page cette e cetera AFMI DOC Technical Manual Configuration Configuration Table 2 DOC Customer Response e tee D RO RE DERE REES AFM3 DOC Copyright Pages icum oe E e Eid AFM4 DOC FOreWOEd cher eor Rt p RED ote 5 DOC How to Use This Manual eene nennen AFM6 DOC Table of Contents eben he pute Ure HERO RU AFM7 DOC List of Figures oe mei RU e ege AFM8 DOC T astoE Tables petant Re ERR AFM9A DOC Chapter Las aea tei et aqha ete E ishay sas 2 Deme EORNM 2 RUBER del OUR asa CH3 4 CH4 Chapter Ga aS CH5 DOC Chaptet 6 2 oe Q ulasan oe uhaspa CH6 DOC Appendix Avi s up ua RUE HER FAPPA DOC Appendix B Rao urat qkunata yy s FAPPB DOC Appendix C ete tite reti tec e e rete ntl eire FAPPC DOC Appendix FAPPD DOC Append eot te pit o ih FAPPE DOC AppendiX aee i pP tte e terea FAPPF DOC BDS5 USER S MANUAL M93102 PRINT KEY The following filenames have been assigned PAGE 2 OF 2 PAGES DESCRIPTION au h EL
216. e the option of tuning the BDS5 yourself You will need an oscilloscope Connect an oscilloscope channel to TACH MONITOR on Connector C2 Pin 2 attach the scope ground to COMMON on Connector C2 Pin 14 Use the TUNE command to get as close as possible 6 5 1 Tuning the Velocity Loop The drive will be enabled and the motor will turn Make sure the motor is secured WARNING Drawing A 84888 shows how to manually tune an integrating velocity loop This procedure sets KV and KVI First you should use the TUNE command to set KV and KVI close to optimum values Apply DC bus voltage to the BDS5 Follow the instructions shown on Drawing A 84888 The motor should start and stop every second Press the escape key to enter the Monitor mode where you can change tuning constants The tach should be on the oscilloscope showing the motor performance As the drawing notes you should increase KV for increased stability and increase KVI to make the system more responsive You need to make several decisions Is the unit underdamped Is the system response too fast Is the system ringing Is there a resonance present Then take the action listed on Drawing A 84888 in the the Installation and Setup Manual There is a close relationship between the response of the system and the variable KVI Response is often measured by the system bandwidth Bandwidth is the frequency with which the system response falls to 70 of the nominal response For
217. e user program See the IF command Format ELIF Expr Logical lt Expr gt Example ELIF PFB GT 100 Expr Logical lt gt is the condition C 5 BDS5 ELSE EN END ENDIF ERR GOSUB C 6 APPENDIX C SOFTWARE COMMANDS Part of block if Begins last block execution Allowed from the user program See the IF command Format ELSE Enable the BDS5 This command turns on the variable READY Refer to Drawing C 84732 for more information Allowed from interactive mode monitor mode and user program Format EN End a task If you are using multi tasking END ends that task If there are no special labels present in the program except POWER UP then END is equivalent to Break B If there are special labels the BDS5 becomes inactive waiting for a task to resume execution Format END Part of block if Ends block if Allowed from the user program See the IF command Format ENDIF Display an error message display the error history or clear the error history Allowed from interactive and monitor modes and user program Format ERR Error Number ERR Option Where Error Number is a valid error number and Option can be HIST or CLR Example ERR 25 DISPLAY MESSAGE FOR ERR 25 ERR HIST DISPLAY ERROR HISTORY ERR CLR CLEAR ERROR HISTORY Go to a subroutine Allowed only from the user program Format GOSUB Label Example GOSUB 25 GOSU
218. e you make this selection PRINT AP Print the contents of the editor EXIT lt Esc gt This selection exits the Motion Link Editor If you modify your program Motion Link will prompt you to save your program to your computer s disk when you exit If you are editing a program or a variable set Motion Link will normally prompt you to transmit the program or variable settings to the BDS5 You can also use the escape key for this function 2 4 2 2 Edit MARK START OF BLOCK K B This selection marks the beginning of a block If you want to move or eliminate a block of text use this selection to mark the top and the bottom of the block you want to manipulate CHAPTER 2 GETTING STARTED COPY MARKED BLOCK Use this selection after you have marked a block This selection copies the marked block into the Motion Link cut paste memory If you want to copy the block into the cut paste memory and delete it from the editor see CUT MARKED BLOCK below CUT MARKED BLOCK AKAV Use this selection after you have marked a block This selection copies the marked block into the Motion Link cut paste memory and deletes it from the editor If you want to copy the block into the cut paste memory without deleting it from the editor see COPY MARKED BLOCK above PASTE CUT COPIED BLOCK AKAP Use this selection after you have either copied or cut a block to the cut paste memory This selection copies the cut paste
219. eans of automatically restarting the program The program can be restarted using the AUTO and the CYCLE input Use the Editor to enter the following example program 12 JUNK this line generates an error B ERROR P RUNNING SIMPLE ERROR HANDLER OUT 0 turn outputs off B Now exit the Editor and type RUN 12 and the response should be ERR 80 LINE 2 JUNK INVALID COMMAND RUNNING SIMPLE ERROR HANDLER LSTLBL The BDS5 stores the last label that is executed in the variable LSTLBL You may need to know the last label that was executed to determine where the program terminated Labels are stored in LSTLBL as follows C ee O O LSTERR The variable LSTERR contains the error number of the most recent error LSTERR is especially useful in the User s Error Handler the lines that follow ERROR It allows your error handler to take special action based on a particular error number For example the error handler from above can be expanded to include LSTERR 12 JUNK this line generates an error B ERROR P SIMPLE ERROR HANDLER OUT 0 turn outputs off LSTERR EQ 28 P THIS IS AN INVALID COMMAND B Now exit the Editor and type RUN 12 and the response should be ERR 28 LINE2 JUNK INVALID COMMAND SIMPLE ERROR HANDLER THIS IS AN INVALID COMMAND PFNL and Errors If an error occurs that breaks your user program you can use PFNL to tell you the last commanded position This can be used to tell yo
220. eceleration is limited to 30 seconds If the acceleration rate is so low that this limit is exceeded then the BDS5 generates an error explaining that either ACC or DEC is too low This error is issued before the motion command begins In this case ACC or DEC must be increased or the peak speed of the move must be decreased 3 8 3 6 Multiple Profile Commands The BDS5 allows one succeeding move to be calculated while the present move is being executed This reduces inter index delay the delay between successive moves almost to zero When you are commanding motion from the Interactive mode gt be careful not to type in two move commands while another is executing motion from the original command is not complete This generates an error If you are commanding motion from your program the BDS5 automatically pauses before calculating a third motion profile thus stopping this error from occurring 3 8 3 7 Profile Final Position PFNL If you want to keep track of the end position of the present move the variable PFNL Position Final is provided This variable contains the final position of a move The variable can be used to compute the distance remaining by combining it with PFB Position Feedback P DISTANCE TO GO PFNL PFB PRINT THE AMOUNT OF POSITION TO GO TO FINISH THE MOVE 3 8 4 JOG J Command This section describes J the JOG command Jogging is useful when you want to command motion without position endp
221. ed backwards more than 30 000 counts when REG was on This error breaks program execution and disables the BDS5 RECORD NOT READY You entered a PLAY command when nothing had been recorded since the last time the BDS5 powered up D 4 2 Improper Use of Labels ERROR 70 ERROR 71 ERROR 74 D 8 LABEL NOT FOUND You attempted to branch to a label either from RUN GOSUB or GOTO that does not exist This error breaks program execution LABEL USED TWICE The user program has a label that is used more than once This error breaks program execution ERROR MUST BE LAST The user s error ERRORS must be the last label in the program buffer You cannot have labels after ERRORS nor can you use the GOTO or GOSUB commands when the BDS5 is executing the error handler The error handler is intended to provide a graceful exit during error conditions and cannot be used to restart the program You can use the IF TIL and commands to execute conditional commands in the error handler This error breaks program execution BDS5 SEVERITY 2 SEVERITY 2 SEVERITY 3 SEVERITY 3 SEVERITY 2 SEVERITY 2 SEVERITY 2 BDS5 APPENDIX D ERROR CODES D 4 3 Invalid Instructions or Entries ERROR 79 ERROR 80 ERROR81 ERROR 82 ERROR 83 ERROR 84 ERROR 85 BAD FORMAT SEVERITY 2 You entered a format that the BDS5 does not recognize For example you may have entered INPUT INPUT X1 1 3 In thi
222. edback on this reader comments form is very important to us Please answer the questions below and return the form to INDUSTRIAL DRIVES Technical Manual Department 201 Rock Road Radford VA 24141 U S A FAX 703 731 0847 Name Title Company Street Address City State Zip Telephone Fax Product Manual Part Number Please check the rating that best represents your opinion on each topic Excellent Good Fair Poor 1 Overall clarity and readability a 2 Organization of the manual u u u u 3 Information completeness a a 4 Information accuracy u u u u 5 Installation procedures u u 6 Ability to quickly find information you need u u 7 Graphics u u 8 Figures usefulness u u u 9 Tables usefulness a Q 10 Overall rating of this manual u u u u Please list any errors What did you like least about this manual What did you like most about this manual How would you improve this manual Signature Date Copyright 1993 Danaher Motion Kollmorgen rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Danaher Motion Kollmorgen except under written agreement All rights reserved No part of this book shall be reproduced stored in a retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission
223. either have to 1 rotate the drive to 90 degrees to line up with the 3 00 inch follower position or 2 move the follower to 4 00 inches to line up with the 0 degree master drive position The master and follower must line up somewhere in the cam table before you can proceed The same command both enables camming and aligns the master and follower The BDS5 uses the NORM command with as the third entry The form of the command is NORM Master Drive Position CAM This command simultaneously aligns and enable camming When camming is enabled the software switch CAM is on To disable camming you must reset the BDS5 disable the BDS5 or enter the NORM command without the CAM You cannot directly change the value of CAM Note that the BDS5 must be enabled to use NORM with the CAM entry When NORM lt Master Drive Position gt command is executed PCMD is determined by the cam table and is set to the corresponding value for PCMD PFB is set to the same value as PCAM and therefore there is no PE position error Returning to Figure 2 assume you know the follower to bed 4 00 inches The master drive should be at 0 degrees You would normalize the position as follows EN NORM 0 CAM If you are using position units the most convenient place to normalize for camming is when the master drive is at zero This is because the master drive position PCMD uses position units PNUM and PDEN which are normally scaled fo
224. er The delays incurred by printing are still present If you have print statements that delay the program when the axis is awake you will have the same delays when it is asleep even though no characters are being transmitted When you transmit its address the BDS5 wakes up and communicates The address is a backslash 3 followed by the ASCII character represented by ADDR For example if your BDS5 has the RS 485 option type ADDR 65 SET ADDRESS TO 65 ASCII A UP THIS IS AXIS PRINT ADDR ADDR 0 RESET DRIVE SINGLE DROP This example sets the address to upper case A NOTE Setting ADDR to 65 makes this axis address A and automatically puts the BDS5 in Multidrop mode This axis then waits for the NA After this BDS5 is awakened and it remains awake until it receives a A backslash puts ALL drives on the serial line to sleep If you select an axis in multidrop only that axis transmits and receives During multidrop the prompts are changed If you typed in the example from above you would have noticed the prompt in the above example going from gt to A gt after you typed in the second line prompts in a multidrop system have the axis address as the first character of the prompt This allows you to know which axis you are communicating with at all times For example the edit prompt goes from e gt CHAPTER 4 USER PROGRAMS to Ae gt In this way
225. er of intervals over which the variables will be recorded and Time is the time in milliseconds of each interval Note Number lt 1000 for 1 Variable Number lt 500 for 2 Variables Number lt 333 for 3 Variables Number lt 250 for 4 Variables Examples RECORD 1000 1 VFB RECORD VFB ONCE MSEC FOR 1 SECOND RECORD 500 10 VCMD VFB RECORD VCMD AND VFB ONCE 10 MSEC FOR 5 0 SECOND RECORD 100 1000 VCMD VFB PCMD RECORD VCMD VFB AND PCMD ONCE SECOND FOR 100 SECONDS Return from a subroutine Allowed only from the user program Format RET Refresh screen with status This command is identical to the R command except status of the drive is displayed at the end of the printed line See P for format and examples Allowed from the interactive and monitor modes and the user program C 13 14 BDS5 RUN TIL TUNE APPENDIX C SOFTWARE COMMANDS Run a program starting at the specified label Allowed from the interactive mode If no label is specified run multi tasking Format RUN lt Label gt RUN MULTITASKING Example RUN 4 RUN X1 RUN Stop motion using a deceleration of AMAX Allowed from the interactive and monitor modes and the user program Format S Continuously execute an optional instruction until condition is true If no instruction is specified then delay program execution until the condition is true lt Instruction gt cannot be another TIL Allowed
226. er that the BDS5 does not recognize it will respond with ERROR NOT FOUND A description of all errors is given in Appendix D 5 7 5 Firmware Errors Firmware errors are an indication of a serious problem with the BDS5 These errors stop communications disable the drive and flash the CPU LED The CPU LED flashes several times then turns off and pauses The number of flashes represents the error number These error numbers range from 2 to 9 See Appendix D for information on these errors Contact the factory should one of these errors occur BDS5 e 6 COMPENSATION CHAPTER 6 COMPENSATION 6 1 INTRODUCTION The information in this chapter will enable you to compensate your motor for load conditions Tuning is an important step in setting up and maintaining your BDS5 servo system This chapter defines and explains tuning in detail A flowchart is also provided for easy step by step instructions to tune the servo system 6 2 SYSTEM COMPENSATION Feedback systems like a motor controller require tuning to attain high performance Tuning is the process whereby the position and velocity loop gains are set attempting to optimize the performance of a system a BDS5 and a motor connected to a load to a three part criterion Table 6 1 Tuning Criterion Noise Susceptibility Response Stability Tuning is normally a laborious procedure requiring an experienced person However the BDS5 provides many to
227. error exceeds the value stored in PEMAX a Position Error Overflow error is generated This is a serious error disabling the BDS5 immediately Note that setting PEMAX to some value will not limit the position error The position error depends on the control loop parameters and the application Normally you want to set PEMAX to as low a level as will allow the BDS5 system to run reliably Setting PEMAX too low can generate nuisance errors since the position error has some variation during motion PEMAX is in position units Position error is limited to protect the system Excessive position error can indicate a fault condition For instance bearings wear out over the life of a motor The increased load from worn bearings can increase the position error during motion In many cases position error is the first indication of wear 3 7 2 3 R D Position PRD PRD is the output of the resolver to digital R D converter in counts PRD is not in position units If your system has the standard 12 bit R D converter then 4096 counts will equal one revolution The following table shows the R D ranges versus resolution Table 3 6 PRD Ranges and R D Resolutions R D Resolution PRD Max The 5 should be disabled at this point use the K or DIS command if it is enabled PRD can be printed on the screen From the terminal type P PRD and the R D output will be displayed on the screen Move the motor shaft by hand to several po
228. es from the BDS5 To upload non factory variables to the BDS5 simply transmit each variable followed by a Space or Equal Sign followed by the numerical value and terminated by a cr Do not transmit the next variable line until a prompt has been received The prompt indicates that the BDS5 is ready to receive the next variable or command gt BAUD 9600 lt cr gt BAUD 9600 lt cr gt lt If gt ee gt ABAUD l lt cr gt ABAUD 1l lt cr gt lt If gt gt X1 111234 lt cr gt K1 111234 lt cr gt lt lf gt LESS Not all BDS5 variables are programmable and some variables are programmable at the factory only The factory protected variables contain motor specific information 27 MULTIDROP COMMUNICATIONS Multidrop communications will allow you to have up to 32 axes on serial communications line Each axis must have an unique address The valid addresses are 0 9 and A Z The Axis Attention Character is a Backslash The Backslash when followed by a valid Axis ID will wake up the addressed axis is a special Axis Broadcast All command that will wake up all the axes to respond to any transmitter command but no axis may transmit The BDS5 prompts are slightly different from the standard RS 232 prompts The Multidrop prompts always print the Axis ID as their first character The normal first character is then slid over to the second position in the prompt The prompt terminates with a gt BDS5 MULTIDROP P
229. es that are rolled over are PCMD and PFNL The rotary distance the specified limit before roll over is stored in PROTARY PROTARY is in position units When ROTARY is on the Rotary mode is enabled If PFB is greater than PROTARY then PFB PCMD and PENL are decremented by PROTARY If PFB is less than zero then PCMD and PFNL are incremented by PROTARY Note that DIR 0 does not work well with the Rotary mode as PCMD PFB and are always less than zero You cannot change PNUM PDEN or PROTARY when ROTARY is ON In addition you must normalize so that 0 lt PROTARY before turning ROTARY ON Enable the Rotary mode by typing ROTARY ON 4 9 3 1 Choosing PROTARY PNUM and PDEN If you have a rotary application such as a printing drum set PROTARY in position user units to be the exact equivalent of one revolution of the drum PROTARY must be exact or position error will accumulate over many revolutions For example suppose the motor of an application is connected through a 5 3 gearbox For convenience assume the user units are in degrees of the table PROTARY would be one revolution of the table or 360 degrees How do you select PNUM PDEN and PROTARY The key is selecting PNUM and PDEN so that PROTARY can be represented exactly as an integer This does not mean that PROTARY must be an integer number of counts In fact it normally will not be Returning to the example a motor move
230. es that there is not a hardware watchdog fault If this LED goes out you 3 14 BDS5 should remove the BDS5 from operation and contact the factory 3 7 DRIVE CONTROL This section discusses several variables that you must be familiar with before you can control the BDS5 3 7 1 Direction Control DIR DIR is a switch that controls the algebraic sign of command and feedback variables When DIR is on clockwise position velocity and torque are all positive If DIR is off then clockwise position velocity and torque are negative DIR is turned on at power up 3 7 2 Position 3 7 2 1 Position Command and Feedback PCMD amp PFB PCMD is the commanded position It is generated internally from motion commands like the JOG command PCMD is in position units The standard position units are R D converter counts as specified in Table 3 6 PCMD is set to PFB when the BDS5 is disabled PFB the position feedback is the actual position of the motor It is updated every millisecond PFB is in position units Section 3 3 5 explained how to look at PFB and watch it as the motor turns PFB is always active even when the BDSS is disabled PFB is reset to zero when the BDS5 is powered up 3 7 2 2 Position Error PE amp PEMAX PE is position error sometimes referred to as following error It is the difference between PCMD and PE is zero when the BDS5 is disabled PE is in position units When the magnitude of the position
231. example if your velocity command was a sine wave with peaks of 100 RPM the bandwidth would be the frequency that the response fell to a sine wave with peaks of 70 RPM The relationship between velocity loop bandwidth and KVI is shown in Table 6 3 BDS5 Table 6 3 Velocity Loop Bandwith vs KVI VELOCITY LOOP BANDWIDTH If you are using a proportional velocity loop PROP 18 on then adjust KPROP until the motor is performing appropriately 6 5 2 Tuning the Position Loop Once the velocity loop is tuned you can tune the position loop Break program execution and stop motion by typing S Type in the following commands The drive will be enabled and the motor will turn Make sure WARNING the motor is secured PEMAX 30000 ZPE ZERO POSITION ERROR TO AVOID POSITION ERROR OVERFLOW WHEN ENABLING POSITION LOOP The motor should again begin turning Now adjust KP until the motor is performing appropriately Table 6 4 shows the relationship between a properly CHAPTER 6 COMPENSATION tuned position loop that is the highest setting for KP and velocity loop bandwidth Note that the position loop bandwidth will be substantially lower than the velocity loop bandwidth usually by a factor of 5 to 10 Table 6 4 Velocity Loop Bandwidth vs KPmax VELOCITY LOOP KPMAX BANDWIDTH If you want to eliminate some or all of the following error you can raise KF as high as unity feed forward Unity is
232. ey are complete If you want to break the program and stop motion precede the Break command with the Stop S command 4 4 1 4 GOTO The GOTO command is used within the program to jump to a label Before the following example of GOTO can be done another function of the Print P command should be explained From the terminal type P THIS PRINTS TEXT JUST LIKE I TYPED IT IN and the result will be THIS PRINTS TEXT JUST LIKE I TYPED IT IN When using the Print command characters between double quotes are printed back without modification Returning to the GOTO command use the Editor Insert command to enter the short program below CHAPTER 4 USER PROGRAMS P ATLABEL 2 GOTO 3 P NEVER GOT HERE 3 P ATLABEL 3 B Exit the Editor and type RUN 2 The result should be AT LABEL 2 AT LABEL 3 It is a good programming practice to avoid the use of GOTO commands in favor of Block IF s Quick IF s and GOSUB s This practice makes programs more readable and easier to modify 4 4 1 5 GOSUB and RET The third command that uses labels is GOSUB The GOSUB command goes to a subroutine at the specified label For example GOSUB 66 begins a subroutine at label 66 The RET command returns from the subroutine and begins executing the program one line below the original GOSUB command GOSUB s can be nested up to four levels For example type in the following program P EXECUTING SUBROUTINE 5
233. f STATUS output Set to 0 on power up and normally left at 0 for preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Enable Trace mode for debugging Set to 0 on power up and normally left at O for preliminary operation Enable position trip points Enable torque loop which disables velocity loop This variable is set to 0 on power up and left at for preliminary operation Velocity units denominator Initially set to 10 for RPM Default velocity for MI and MA commands Initially set to 1 RPM Velocity units numerator Initially set to 44739 for RPM BDS5 VOFF Offset velocity for electronic gearbox Reset to 0 whenever GEAR is turned on This variable should be left at 0 for preliminary operation VOSPD Overspeed setting Initially set to VMAX 1 2 This variable should be left at this value for preliminary operation but it can be reduced for protection VXDEN External velocity units denominator Initially set to VDEN Value of this variable does not matter during preliminary operation VXNUM External veloci
234. f obtaining servo type performance from an AC motor by controlling two components of motor current Glossary xiv Velocity The change in position as a function of time Velocity has both a magnitude and a direction Voltage Constant or Back EMF Constant A number representing the relationship between Back EMF voltage and angular velocity Typically expressed as V Krpm Zero A frequency at which the transfer function of a system goes to zero INDEX BDS5 INDEX NOTE F PAGE NUMBER PREFIX DENOTES A FIGURE T PAGE NUMBER PREFIX DENOTES A TABLE eA Basic Motion Commands 3 18 A Simple Profile a a aaa F3 20 AMAX ACC amp 3 18 ACTIVE Area 3 13 EN STOP amp LIMITS 3 18 Alarms Task Levels 1 3 sse 4 26 Enabling Motion with MOTION 3 19 Printing with Alarms 4 27 STOP S 3 19 Restrictions of Alarms 4 27 STOP and BREAK with Algebraic Functions 7 3 10 Control X 4 40 3 19 Allowed Tune Command Baud Rate BAUD 4 39 Stability Settings T6 4 BDS5 Conditions sese 4 11 AMAX ACC amp 3 18 055 Control F3 40 Analog Input
235. f you entered ERRORS If you did the error handler that is the routine that follows the ERROR is executed multi tasking is suspended including alarms when the error handler is being executed 4 8 8 3 Auto Routine AUTOS If you want to start a program from an external switch you should use the auto routine You can use the auto routine to interface to simple operator panels or to programmable logic controllers PLCs CYCLE Connector C7 Pin 13 is a hardware input that under the proper conditions will cause the BDSS to begin executing one cycle of the auto program The AUTO program begins at AUTO CYCLE READY is a hardware output that indicates the BDS5 is ready to run another cycle of the AUTO program The following conditions must be met for the BDS5 to execute the AUTO program When these conditions are met the CYCLE READY output Connector C7 Pin 23 will turn on Otherwise it will be off 4 29 CHAPTER 4 USER PROGRAMS Table 4 9 To Execute AUTOS Multi tasking must be enabled AUTOS must be present in the user program Noroutines can be executing at task level 5 The MANUAL input must be off The CYCLE input must be low If these conditions are met the CYCLE READY output will turn on Then when CYCLE turns on the BDS5 will begin executing the user program at AUTOS and CYCLE READY output will turn off 4 8 8 4 Manual Program MANUAL The following conditions must be met fo
236. feed the encoder s output into the external input The requirements for such a system are 1 The resolution of the encoder must match the resolution of the resolver on your BDS5 system Refer to the Installation and Setup Manual and the model number to determine the resolution of your system Select the encoder as follows Table 3 9 Encoder Resolution R D Resolution Encoder Lines Revolution 2 The encoder must be mounted directly to the motor It cannot be connected through gearboxes lead screws or any other mechanical device 3 You must turn the switch EXTLOOP on This switch configures the BDS5 to close the position loop with feedback from the external input rather than from the resolver When EXTLOOP is PE the position error is the difference of PCMD and PEXT rather than the difference of PCMD and PFB The ZPE command zero s the difference of PCMD and PEXT Also the NORM command normalizes both PEXT and PFB simultaneously 3 8 16 CONTINUE The CONTINUE command is provided as a controlled way to turn off master slave position control The CONTINUE command tells the BDS5 to keep the motor going at its present speed while simultaneously turning off REG and GEAR One use of this command is to cause a controlled deceleration CHAPTER 3 PROGRAMMING LANGUAGE to 200 RPM for example when the electronic gearbox is enabled If you just typed J 200 it would have the effect of adding 200 RPM to the command
237. frequency of the external input should always be less than REGKHZ 3 8 14 2 Profile Regulation and Counting Backwards In general if you use profile regulation the external input should count forward that is VEXT should be positive when VXNUM and VXDEN are positive The profile regulation firmware allows the input to count backwards for up to 30000 counts This is useful for applications such as conveyor belts that generally go forward but can go backward for short distances If the external input counts backwards the Profile Regulation mode works as follows The profile stops that is no motion is commanded during backward counting The backward counting must be limited to 30000 counts Otherwise ERROR 64 is generated The profile does not continue as soon as forward counting begins The forward counts must completely offset the backward counts before the profile will continue At the point where forward counts offset backward counts the profile continues as if the input had never gone backwards Profile Regulation works with standard moves MA ML and MRD Macro moves and all jogs J JT and JF 3 8 14 3 Regulation Example A machine has an axis that operates on parts passing by on a conveyor belt The profiles executed by the motor must be at a rate proportional to the conveyor 3 36 BDS5 belt speed The belt moves at about 200 inches minute encoder has been placed on the conveyor
238. g static error Compensation Lead A control action which causes the phase to lead at high frequencies and tends to decrease the delay between the input and output of a system Compensation Lead Lag A control action which combines the characteristics of lead and lag compensations Compensation Proportional A control action which is directly proportional to the error signal of a feedback loop It is used to improve system accuracy and response time Compliance The amount of displacement per unit of applied force Computer Numerical Control A computer based motion control device programmable in a numerical word address format A computer numerical control CNC product typically includes a CPU section operator interface devices input output signal and data devices software and related peripheral apparatus Control Systems or Automatic Control Systems An engineering or scientific field that deals with controlling or determining the performance of dynamic systems such as servo systems Coordinated Motion Multi axis motion where the position of each axis is dependent on the other axis such that the path and velocity of a move can be accurately controlled Requires coordination between axes Coupling Ratio The ratio of motor velocity to load velocity for a load coupled to motor through a gear or similar mechanical device Critical Damping A system is critically damped when the response to a step change
239. given in the gt BDS command Typing in these examples will erase the user program in the BDS5 Do not type them in unless your program is NOTE backed up For example if a password was not set in the Editor gt BDS will begin transmitting the new program If you press the escape key before typing anything else the process will be aborted without changing the program in the BDS5 If a password was set in the Editor then the password must follow the command For example if the password was set as SECRET type gt BDS SECRET and the BDS5 will accept programs directly from the terminal The user program is stored in battery backed up memory If the program changes because of a hardware problem the BDS5 issues a USER PROGRAM CORRUPT error The gt BDS command resets the user program memory which eliminates this condition BDS5 4 10 5 System Dump The BDS5 can transmit all variables in addition to the user program This is called a system dump and you request it with the DUMP command For example type DUMP and the BDS5 will provide pages of information including the program all BDS5 variables user variables and user switches This also includes all protected variables The system dump is provided so that the information from the dump can be directly re transmitted to any BDS5 This changes all VON PROTECTED variables The DUMP command precedes protected variables with a semicolon Thi
240. gram CAPTURE Start stop capturing communications from the BDS5 retrieve previous capture files from disk examine edit capture files SCOPE Retrieve plot print and store PC scope OPTIONS Set up communications screen colors computer configuration Provide on screen help for Motion Link and for the BDS5 UTILITIES Exit Motion Link enter a DOS command from within Motion Link use a DEPO1 Simulator or run Motion Link Setup program 2 4 BDS5 2 4 1 1 Program The PROGRAM pull down window allows you to retrieve edit transmit and save BDS5 programs EDIT This selection calls the Motion Link Editor and assumes that you want to re edit the last program that you edited It is a short cut allowing you to edit without first loading a program from the BDS5 or from the disk If you exit the Motion Link Editor Motion Link remembers the program you were last editing Note that if you have selected an item from either the VARIABLES or CAPTURE menu since you last edited a program this selection is invalid FROM DISK This selection retrieves a program from your computer disk Motion Link will display all of the files currently on your disk and allow you to choose the file you want After you choose a program the Motion Link Editor is called allowing you to examine and change the program FROM BDSS This selection retrieves the program currently stored in the BDS5
241. gram and most variables through power down RESOLVER TO DIGITAL CONVERTER The BDSS is based on Resolver to Digital converter The R D generates a tachometer signal for your convenience However the BDS5 does not use the analog tach signal e SERIAL PORT The BDS5 has a serial port for communications This port allows you to monitor the operation issue commands and transmit a program DISCRETE INPUTS The BDS5 has 23 discrete inputs including REMOTE ENABLE which is on Connector C2 only Note that two signals HOME and CYCLE can be input to the BDS5 on two connectors C2 and C7 Connector C2 provides these three signals with optical isolation Connector C7 expects non isolated TTL signals on a 26 pin ribbon cable connector Optional Connector C8 expects non isolated TTL signals on a 50 pin ribbon cable connector e DISCRETE OUTPUTS The BDS5 has 10 discrete outputs Notice that O1 appears both on Connector C2 with optical isolation and on Connector C8 e ENCODER INPUT The BDS5 accepts external inputs in encoder format This can come from a master motor in a master slave system Note that you must use a resolver even if you use a feedback encoder with the BDS5 BDS5 e ENCODER EQUIVALENT OUTPUT The BDS5 provides encoder format output derived from the R D converter e ANALOG INPUT OPTI CARD As an option the BDS5 can accept a 10 volt analog input This input is converted to digital format b
242. gt lt bell gt ERR 17 FEEDBACK LOS lt cr gt lt lf gt After an error with severity level high enough to disable drive the fault light will turn on to clear this light simply re enable the BDS5 with the Enable command The Enable command takes a few seconds to complete and returns a prompt gt EN EN lt cr gt lt lf gt lt time delay gt 21 RS 232 COMMUNICATIONS RUNNING A PROGRAM If a program is running then an ESCAPE character must be sent to get the attention of the BDS5 The monitor mode will be active on getting the attention of the BDS5 A second ESCAPE will drop the BDSS5 s attention and exit the monitor mode The monitor mode will accept a sub set of the BDS5 commands This subset includes s ERR MOTOR e ps 1 RS Jp s L E To enter the monitor mode while running a program send an lt esc gt character lt esc gt lt cr gt lt lf gt ENTER MONITOR MODE PUSH ESCAPE TO EXIT lt cr gt lt lf gt gt If the response is as follows then the lt esc gt has caused the 5 to exit the monitor mode If this 18 the case then send another lt esc gt to reenter the monitor mode lt esc gt lt cr gt lt lf gt ENTER MONITOR MODE A single lt cr gt will return the following response If there is no response then the monitor mode is not active and an lt esc gt should be sent tot he 5 to enter the monitor mode lt cr gt
243. he BDS ioiii 4 39 4 10 5 System Dump 4 40 4 10 5 1 Version Dump 4 40 4 10 6 Multidrop Communications 4 40 4 10 6 1 Broadcast sinisisi 4 41 4 11 Program Examples 4 41 CHAPTER 5 DEBUGGING 5 1 Introduction eerte has 5 1 5 2 Debugging Modes sees 5 1 5 2 1 Single Step sese 5 1 SUD TTACE Lee 5 2 5 2 2 1 Motion Link and Trace 5 2 5 3 Debugging and Multi Tasking 5 2 5 4 Removing Code sess 5 3 5 5 Synchronizing Your Program 5 4 5 5 1 Using the Timers 4 5 4 5 5 2 Regulation Timer RD 5 4 5 5 3 Motion Segments sse 5 4 3 524 WAIT CW ers iren 5 5 5 5 5 Gating Motion with GATE 5 6 u u a ete iier 5 6 23 7 Ertor Log eee eU us 5 8 Sul Error Levels ees 5 8 5 72 DEBA sein neret eee 5 8 3 73 Error HistOty 5d ee oU 5 9 5 7 4 Displaying Error Messages 5 9 5 7 5 Firmware 5 9 CHAPTER 6 COMPENSATION 6 1 Introduction eene 6 1 6 2 System 6 1 6 2 1 Critical Damping sse 6 2 6 2 2 Underdamping
244. he RUN GOTO or GOSUB commands These labels are discussed with multi tasking later in this chapter 4 4 1 2 RUN The RUN command is used to start the program from the Interactive mode For example type RUN 3 If there are no errors and if label 3 is in the user program then program execution begins at label 3 The RUN command can execute all valid general purpose labels If the label is not in the program an error is generated and no part of the program is executed You cannot use the RUN command for dedicated labels Before the program is run the BDS5 searches the entire program for some types of errors If after you enter a RUN command an error is detected the BDS5 will display the appropriate error message together with the offending line Also RUN verifies that the program has not changed since the last edit If the program has changed a PROGRAM CORRUPT error is generated The program corrupt error can be cleared though this requires that the entire program be erased with the Editor NEW command or the gt BDS command If a Program Corrupt error occurs and it was not caused by losing 4 10 BDS5 power while you were editing this may indicate a serious condition Contact the factory 4 4 1 3 Break B The Break B command is the opposite of RUN it stops program execution and normally returns to the interactive state The Break command does not stop motion Profile commands are allowed to continue until th
245. his error breaks program execution D 3 2 Macro Move JT JF Errors ERROR 40 ERROR 41 ERROR 42 ERROR 43 ERROR 44 ERROR 45 CHANGED DIRECTION SEVERITY 2 You attempted to change direction with an instruction that does not allow direction to change These instructions include JT JF and macro moves This error breaks program execution MOVE NEEDS MOTION SEVERITY 2 You attempted to execute an instruction that requires the motor to be in motion These instructions include JT JF and MCI MCA with no velocity parameter specified This error breaks program execution MOVE w o TIME SEVERITY 2 You attempted to execute a move that required more time than was available For example you attempted a JT or macro segment where the final position could not be reached because of acceleration limits You may have attempted a JT or JF when you were already well beyond the specified position This error breaks program execution MACRO NOT READY SEVERITY 2 You attempted to execute a macro move with the MCGO instruction in which the last segment of the move did not end at zero speed or the macro move memory is empty The macro move memory is cleared every time the BDS5 is turned on This error breaks program execution MCD w MACRO MOVING SEVERITY 2 You attempted to insert a macro move dwell when the previous macro move segment ended at a speed other than zero This error breaks program execution MCA ACTIVE SEVERITY
246. in your power up routine that may have the same effect 5 7 ERROR LOG The BDS5 responds to a variety of conditions both internal and external hardware and software which are grouped in a single broad category errors An error indicates that there is a problem somewhere More serious errors are grouped as faults 5 7 CHAPTER 5 DEBUGGING 5 7 1 Error Levels The BDS5 s response to an error depends on the error s severity There are four levels of severity listed below in increasing order Table 5 3 Error Severity Levels and Actions Errors which cause warnings Errors which cause a program break and stop motion in addition to Level 1 Actions Errors which disable the system and set the FAULT LED in addition to Level 2 Actions Errors which disable almost all BDS5 functions including communications and flash the CPU LED to indicate the error number These are called firmware errors When any error except a firmware error occurs a message is displayed on the screen The following items are printed the error number the offending entry and an abbreviated error message For example disable the drive and type in a jog DIS J 100 The BDS5 will respond with ERR 50 J 100 BDS5 INHIBITED The error number 50 the offending entry the whole line and the error message you cannot command a jog when the drive is inhibited are given on one 80 character line The error message starts at character
247. inating carriage return amp lt linefeed gt Also see the and RS print command PAS lt expr gt lt format gt lt text gt Print Append Status command This is identical to the PA command except it also prints drive status information RUN lt label gt Now Allowed from within program This can allow the user to restart a program from an Alarm or Error label CLEARX This command will clear all user registers and user flags to zero Note The Variable upload can be greatly sped up if all user registers and flags are zero Edit the VAR file and remove all XS1 550 ad X1 X750 lines and replace them with one CLEARX command 1 750 amp 51 550 EXTDX 01 This will enable Extended User Registers X251 X750 Note The PC SCOPE command and the Real Time Trace command can not be used while the Extended User Registers are enabled EXTDX is remembered on Power up RAND seed Random number generator command RAND X lt user register lt exprl gt lt 2 gt seed 0 31 000 This generates the random number sequence user reg 1 250 This is the user register used to store the random number lt gt This is random number boundary limit lt expr2 gt This 18 the other random number boundary limit lt 1 gt lt 2 gt lt 31 000 This internal switch indicates if the 128 point Camming mode with linear interpolation is e
248. incorrectly set or the wrong TL has been loaded Contact the factory D 3 MOTION ERRORS D 3 1 Position Calculation Errors ERROR 30 TOO MANY MOVES You typed in too many move commands MA MI MCGO from the interactive mode You can have one move executing and the other pending The error does not occur when move commands are executed from the user program because the BDSS sees that the motion buffer is full and delays execution to prevent the error This error breaks program execution ERROR 31 TOO MANY MRD MOVES You attempted to execute a motion instruction that required the profile buffer to be empty This occurs when two MRD instructions are active at once You should use a synchronizer to delay the execution of the instruction that caused the error This error breaks program execution ERROR 32 ACC DEC TOO LOW BDS5 SEVERITY 3 SEVERITY 3 SEVERITY 3 SEVERITY 3 SEVERITY 2 SEVERITY 2 SEVERITY 2 BDS5 ERROR 33 APPENDIX D ERROR CODES You entered a motion command that calculated a motion profile where either the acceleration or deceleration segment was more than 30 seconds long You must increase ACC or DEC or reduce the speed change of the move This error breaks program execution VEL OUT OF BOUNDS SEVERITY 2 You entered a motion command where the commanded velocity was out of the allowable range The range for Jog J commands is VMAX The range for other motion commands is 0 to VMAX T
249. information after the number of lines stored exceed 1000 Fixed the factory initialization problem that would cause a software watchdog trip due to the user program being uninitialized in a new BATRAM chip VERSION 3 0 x FIRMWARE HISTORY Continued 5 94 11 94 FIRMWARE VERSION OBSOLETE MC VERSION MC2 Rev 2 and later MC2 Rev 2 and later DESCRIPTION OF CHANGES Enhanced the CLEARX command to allow separate clearing of all User Registers or User Flags or both Fixed LSTERR to work even if MSG 0 Fixed another factory initialization problem that would cause a software watchdog trip on entry to the User Program Editor due to the user program being uninitialized in a new BATRAM chip Enhanced the Break B command to allow the optional breaking of a user INPUT command B D Enhanced the Error Recovery Task to cancel the user INPUT command if it is active Enhanced the Error Recovery Task to cancel a Task idling command such as H Added MONITOR OFF support from the user program Fixed a problem with EXTLOOP Added PCMD PEXT when EXTLOOP 1 and drive disabled Fixed front panel LED initialization on power Syntax error in ERRORS will break the program An invalid command will not allow any program execution An error occurring while in Monitor mode will print the error message and return to Monitor mode BDS5 UPGRADE NOTICE VERSION 3 0 0 It provides many new commands to control se
250. ing the Monitor mode in order to stop the user program with a Break B or Kill K command The method to stop program execution in this case is to issue a X 18h command This should break the user program reliably e The error handler has been enhanced to allow execution of ERROR to completion even in the event of additional errors Before this the BDS5 was designed to automatically break program execution on the second error We also found that a Software watchdog error could be triggered if an error occurred during the execution of the firmware code that sets up a Jog command This has been fixed Additional Note The Beta version of the firmware is dedicating user register X100 and X101 to capture diagnostic information during any error Please avoid using this register if possible Error Handler ERROR When a serious error occurs the BDS5 breaks execution of your program and checks your program to see if you entered ERROR If you did the error handler that is the routine that follows the ERROR is executed All multi tasking is suspended including alarms when the error handler is being executed See Chapter 10 for more information on the user s error handler Errors can also cause the BDS5 to change modes Some errors are serious enough to cause the BDS5 to break program execution Usually this has the identical effect of issuing a Break B command As an option you can write an error handling routine beginning a
251. injury Wire the BDS5 as described in the nstallation and Setup Manual BDS5 THE MOTOR MAY MOVE UNEXPECTEDLY BE PREPARED TO DISABLE THE BDS5 You should have completed Initial Check Out in the Installation and Setup Manual If not return to the Installation and Setup Manual and WARNING complete that section This section will enable the BDS5 The system may be unstable The motor may begin oscillating or run away Be prepared to disable the BDS5 quickly You can disable the BDS5 by turning off opening the contacts of LIMIT or REMOTE Turn on the AC line voltage Type in the following example EN ACC 1000 DEC 1000 MI 4000 100 This should cause the motor to rotate 4000 counts with a traverse speed of 100 RPM With the next example the motor will repeat the move Type VDEFAULT 100 MI 4000 Notice that the motor again moves 4000 counts Now to bring the motor back to the original position type MI 8000 3 8 3 5 Profile Limits With both the MA and MI commands if the traverse speed cannot be reached because ACC or DEC is too small for the specified move then the BDS5 reduces the maximum speed so that the move for all practical purposes is triangular Actually there is a very short BDS5 less than 5 milliseconds traverse segment so that the move still has three segments The maximum time for an entire move is not limited However the time for each acceleration or d
252. io GEARI GEARO PE is formed by subtracting from PCMD Usually PEXT is generated from another motor s feedback sensor In this way a master motor position PEXT controls the slave motor position PFB Figure 5 BDS5 Gearbox This method of controlling motors is limited The only profile that is allowed is one where the slave position is proportional to the master position Often applications require that a master motor will be turning at a relatively constant speed but the slave motor must execute a profile Actually the BDS5 has Profile Regulation a mode where the rate of the slave profile is tied to the master speed At first we thought this would work for camming Unfortunately each time a new profile is started there are a few milliseconds when the master position is ignored So although the rate of the profile is controlled by the master the master phase and slave phase are not locked together Over time the master position drifts with respect to the slave position 12 To implement camming a new approach had to be taken We decided to modify the gearbox by adding a look up table As Figure 6 shows PEXT is processed by the gearbox to form PCMD PCMD is then used as an index into a CAM look up table to produce a new variable PCAM When camming is enabled PCAM is used to form CAM Look up Table X100 X227 Figure 6 BDS5 Camming Interpolation The BDS5 CAM Table only has 128 points but with the help of
253. is frequently involved with controlling many remote and distributed motion control devices It may also be used for off line tasks such as program preparation storage and supervisory control and evaluation HP Horsepower One horsepower is equal to 746 watts Since Power Torque x Speed horsepower is a measure of a motor s torque and speed capability e g a 1 HP motor will produce 35 Ib in at 1800 rpm Hunting The oscillation of the system response about theoretical steady state value Hybrid Stepping Motor A motor designed to move in discrete increments or steps The motor has a permanent magnet rotor and wound stator These motors are brushless and phase currents are commutated as a function of time to produce motion Hysteresis The difference in response of a system to an increasing or a decreasing input signal Input Output The reception and transmission of information between control devices In modern control systems I O has two distinct forms switches relays etc which are in either an on or off state or analog signals that are continuous in nature such as speed temperature flow etc Idle Current Reduction A stepping motor driver feature that reduces the phase current to the motor when no motor motion idle is commanded for a specified period of time This reduces motor heating and allows high machine throughput to be obtained from a given motor Incremental Motion A motion contro
254. is not a true error ERROR 199 is used to mark the error history buffer when the BDS5 powers up D 4 9 Internal Errors ERROR 200 ERROR 201 ERROR 202 ERROR 203 FOLDBACK OUT The factory set variables that control foldback are out of bounds Contact the factory This error breaks program execution and disables the BDS5 SLIP TOO BIG The induction motor variables that control slip are out of bounds Contact the factory This error breaks program execution and disables the BDS5 USER PROGRAM CORRUPT The user program is corrupt Usually this problem is caused by installing a new battery back up RAM This can also occur if power to the BDS5 is lost while editing the program This error will break program execution See BDS5 Editor New Command to reset the user program you will need to reload your program AMPS BAD SEVERITY 2 SEVERITY 2 SEVERITY 2 N A SEVERITY 3 SEVERITY 3 SEVERITY 3 SEVERITY 3 APPENDIX D ERROR CODES ERROR 204 ERROR 205 ERROR 206 ERROR 208 ERROR 209 ERROR 211 219 ERROR 255 The BDS5 variable AMPS is invalid Contact the factory This error breaks program execution PROGRAM OVERRUN This is an internal error Contact the factory This error breaks program execution and disables the BDS5 MBUF OVRRUN This is an internal error Contact the factory This error breaks program execution and disables the BDS5 PROFILE OVERFLOW This is an
255. ition unit equivalent of 2 147 483 647 Any valid expression for velocity The result is assumed to be in velocity units C 1 APPENDIX SOFTWARE COMMANDS BDS5 C 2 lt Traverse gt lt End gt lt Text gt Constants ON OFF N Any valid expression for velocity The result is assumed to be in velocity units Traverse is used in macro moves as the middle speed of three speed moves Any valid expression for velocity The result is assumed to be in velocity units End is used in macro moves as the end speed of two and three speed moves Text is any text string of characters The control character symbol converts the succeeding character to a control character Indicates an optional parameter ON and Y are equivalent to 1 OFF and are equivalent to 0 The constants can be used in any expression and in response to the Input command APPENDIX C SOFTWARE COMMANDS BDS5 C 2 COMMANDS The following commands are the instructions used to program the 5 Comment Comments can follow any instruction Also entire lines can be comments The semicolon must be preceded by a space unless it is the first character in a line Allowed on any line including the BDS5 Editor 5 THIS IS A COMMENT FOR COMMAND THIS ENTIRE LINE IS A COMMENT Labels Labels can be 0 500 and cannot be repeated They must be decimal constants They are allowed only from the user program The following label
256. ive type Drive PWM A motor drive utilizing Pulse Width Modulation techniques to control power to the motor Typically a high efficiency drive that can be used for high response application Drive SCR A DC motor drive which utilizes internal silicon controlled rectifiers as the power control elements Usually used for low bandwidths high power applications Drive Servo A motor drive which utilizes internal feedback loops for accurate control of motor current and or velocity Drive Stepper Electronics which convert step and direction inputs to high power currents and voltages to drive a stepping motor The stepping motor driver is analogous to the servo motor amplifier Duty Cycle For a repetitive cycle the ratio of an on time to total cycle time On Time On Time Off Time Duty Cycle x 100 Dynamic Braking A passive technique for stopping a permanent magnet brush or brushless motor The motor windings are shorted together through a resistor which results in motor braking with an exponential decrease in speed Efficiency The ratio of power output to power input Electrical Time Constant The ratio of armature inductance to armature resistance Electronic Gearing A technique used to electrically simulate mechanical gearing Causes one closed loop axis to be slaved to another open or closed loop axis with a variable ratio EMI Electro Magnetic Interference EMI is noise which when
257. l term that is used to describe a device that produces one step of motion for each step command usually a pulse received Indexer Electronics which convert high level motion commands from a host computer programmable controller or operator panel into step direction pulse streams for use by the stepping motor driver Inertia The property of an object to resist changes in velocity unless acted upon by an outside force Higher inertia objects require larger torques to accelerate and decelerate Inertia is dependent upon the mass and shape of the object Inertial Match An inertial match between motor and load is obtained by selecting the coupling ratio such that the load moment of inertia referred to the motor shaft is equal to the motor moment of inertia Glossary vii GLOSSARY BDS5 Inrush Current The current surge generated when a piece of equipment such as a servoamplifier is connected to an AC line This surge is typically due to the impulse charging of a large capacitor located in the equipment Instability Undesirable motion of an actuator that is different from the command motion Instability can take the form of irregular speed or hunting of the final rest position Lead Ball Screw A lead screw which has its threads formed as a ball bearing race the carriage contains a circulating supply of balls for increased efficiency Lead Screw A device for translating rotary motion into linear motion co
258. le suppose you jog clockwise into the stop several times and record PRD each time It turns out that the average value of PRD is 1500 counts Then use the following MRD command MRD 150042048 200 CCW MOVE TO 1 2 REVOLUTION FROM 1500 COUNTS You must specify the direction CW or CCW so that the BDS5 always backs away from the stop Remember that for example J 1000 is not necessarily clockwise since the direction of jog rotation is controlled by the variable DIR You should be aware that if you replace your motor you must repeat this process since the relationship of PRD to the motor shaft position is different for each motor If you replace your motor repeat this process NOTE 3 28 BDS5 3 8 11 JOG TO JT amp JOG FROM JF In some applications JOG commands need to be synchronized with position feedback With J the standard JOG command the speed changes when the command is entered Position dependent jogs Jog To and Jog From delay the speed change until a specified position is reached You specify the position at which the change in speed begins with the Jog From JF command Similarly you specify the position at which the change in speed ends with the Jog To JT command With position dependent jogs you must specify a position and the new speed ACC DEC and SCRV are in effect Position dependent jogs are always Absolute moves not incremental The following graph shows the effect of a JF
259. locity 1 REGKHZ Motion Profile Command Generation Figure 3 8 BDS5 Master Slaving 3 34 BDS5 GEAR ON ENABLE ELECTRONIC GEARBOX NORMALLY SOME TIME WOULD PASS BETWEEN THESE COMMANDS MI 1028 10 PHASE ADJUST 90 DEGREES AT 10 RPM SYSTEM REMAINS IN GEARBOX THROUGH THE PHASE ADJUSTMENT You cannot use MA or MCA commands when GEAR is on Also you cannot use position dependent jogs JT or JF when GEAR is on 3 8 13 5 Velocity Offset VOFF VOFF velocity offset is added to the Velocity command when the gearbox is enabled VOFF is in velocity units It is normally used with the analog input to correct voltage offset in the optional analog velocity input VOFF can be changed at any time Note that VOFF is set to zero when GEAR is enabled This is done because if VOFF is large say 2000 RPM enabling the gearbox would immediately command motion VOFF is set to zero when GEAR is turned on NOTE 3 8 13 6 Gearbox ACC DEC and Jogs When the 5 is run as a velocity loop PL off acceleration and deceleration rates can be limited by the variables ACC and DEC This allows you to limit the acceleration from external velocity commands that are otherwise unlimited If you want the acceleration and deceleration to be limited by ACC and DEC type RAMP ON LIMIT ACC AND DEC WHEN PL IS OFF 3 8 14 Profile Regulation This section describes profile regulation one of the BDS5 Master Slave modes
260. locity in RPM acceleration in RPM second current in percent of full scale and position in counts The velocity and acceleration units shown on COMMON USER UNITS above are for the standard 12 bit R D converter For 14 bit resolution multiply VNUM and ANUM by 4 For 16 bit resolution multiply by 16 Do not change VDEN or ADEN variables that have units associated with them should be set after you have specified the user units This is because the values actually stored in the variables are in BDS5 basic units not user units Changing the user units will not affect the basic value stored in the variables For example if you want VOSPD to be 100 inches minute and you type VOSPD 100 when velocity units are in RPM VOSPD would be 100 RPM Then if you change the velocity units to inches minute VOSPD would remain 100 RPM it would just be converted to the equivalent of 100 RPM in inches minute If you change any user units you should reset all programmable variables that depend on those units Refer to Appendix E which lists all variables and the units associated with them 4 9 1 3 External Units External units are for the external inputs VEXT and PEXT The user units are set by VXNUM and CHAPTER 4 USER PROGRAMS VXDEN for external velocity VEXT and by PXNUM and PXDEN for external position PEXT Drawing A 84866 shows how external position and velocity come into a slave BDS5 and are displayed as PEXT and VE
261. lter the motor characteristics and degrade performance Detent Torque Glossary iv The maximum torque that can be applied to an un energized stepping motor without causing continuous rotating motion Dielectric Test A high voltage breakdown test of insulation s ability to withstand an AC voltage Test criterion limits the leakage current to a specified magnitude and frequency applied between the specified test points Differential An electrical input or output signal which uses two lines of opposite polarity referenced to the local signal ground Distributed Processing A technique to gain increased performance and modularity in control systems utilizing multiple computers or processors DNC Direct Numerical Control Technique of transferring part program data to a numerical control system via direct electrical connection in place of paper tapes Drive This is the electronics portion of the system that controls power to the motor Drive Analog Usually referring to any type of motor drive in which the input is an analog signal Drive Digital Usually referring to any type of motor drive in which the tuning or compensation is done digitally Input may be an analog or digital signal Drive Linear BDS5 GLOSSARY A motor drive in which the output is directly proportional to either a voltage or current input Normally both inputs and outputs are analog signals This is a relatively inefficient dr
262. ment of 5 revolutions would cause 3 revolutions of machine table rotation or 1080 user units degrees Returning to Table 4 14 PNUM 4096 5 PDEN 360 3 thus PROTARY would be 360 Notice that PROTARY is not exact in counts it is 5 3 of a revolution or 6826 and 2 3 counts However it is 4 37 CHAPTER 4 USER PROGRAMS exact in user units Therefore error will not accumulate as the table rotates The incorrect way to choose PNUM PDEN and PROTARY would be to select PNUM and PDEN so that PROTARY could not be represented as an integer For example we could have stated that 5 3 revolution of the motor would cause one revolution of the machine Then PNUM 4096 5 3 or about 6827 PDEN 360 In this case PROTARY would not be exactly 360 degrees actually it would be 359 98 degrees so that error would accumulate as the table turned Remember PROTARY must be an integer in user units though it can have fractional counts 4 9 3 2 Rotary Mode and Absolute Moves When the BDS5 is in the Rotary mode you must limit the final position of all absolute moves to between 0 and PROTARY If you want to move more than PROTARY you can use incremental moves For example MI 50 PROTARY is a legal command 4 10 SERIAL COMMUNICATIONS This section discusses details of BDSS serial communications This includes autobauding multidrop connections and transferring your program to and from the BDS5 If you are using Motio
263. mode When you are in the Insert mode everything you type is put directly into the program memory You exit the Insert mode by pressing the escape key or entering an empty line For example type in a line as follows Type P BEG GO TO THE BEGINNING OF THE PROGRAM I ENTER THE INSERT MODE 4 7 CHAPTER 4 USER PROGRAMS and the 5 will respond with I gt indicating that you are in the Insert mode Now type TEST LINE FOR LEARNING ABOUT THE EDITOR Press the escape key to exit the insert mode Type v the 5 should respond with 1 TEST LINE FOR LEARNING ABOUT THE EDITOR You can specify the line you want to insert directly For example enters Insert mode The next line you type is entered directly into the program as the new line 5 Subsequent lines 6 7 and so on follow line 5 4 3 2 5 Find F The Find F command will search down through the program memory for a particular word letter or string of characters For example the Find command can be used to find the word EDITOR from the Insert command above From the Editor type USE P TO GO TO TOP AND SEARCH The 5 should respond with FIND WHAT F gt then type EDITOR and the Find command will find line 1 since the word EDITOR occurs in that line Now F can be used to find the next line with EDITOR Type BDS5 FIND WHAT EDITOR F gt 5 et a g
264. mpatible baud rate was programmed into the BDS5 18 RS 232 COMMUNICATIONS INTERACTIVE MODE The interactive mode is the normal state the BDS5 will be in when it is not running a program The following are typical BDS5 response sequences The BDS5 will respond to a cr with a lt gt lt 1 gt gt character string while in the interactive mode The interactive prompt gt indicated that the BDS5 is ready for the next command gt lt gt lt cr gt lt lf gt The BDS5 generates the same response with the esc character as it does with the cr see above while in the interactive mode gt lt esc gt lt cr gt lt lf gt The Jog command or typical BDS5 command will generate the following response gt J 1000 lt gt J 1000 lt cr gt lt lf gt Was nt The Print command can be used to print the contents of any BDS5 variable Remember that variables print right justified so up to 11 Spaces could precede the value to be printed gt P SEG lt cr gt P SEG lt cr gt lt lf gt 11 sp 0 cr If The BDS5 Print command specify format to use for printing the variable only restriction is that if the format is too small X s will be printed gt P SEG 1 lt cr gt SEG 1 lt cr gt lt lf gt O lt cr gt lt lf gt ASSUME PFB 1024 gt P PFB lt cr gt P PFB lt cr gt lt lf gt lt 8 SP gt 1024
265. n Link the Industrial Drives software package for the BDS5 you do not need to read the sections on transmitting and receiving your program or on system dump Motion Link provides facilities for these functions 4 38 BDS5 4 10 1 Autobauding It is not necessary to set the baud rate on the BDS5 directly Once the BDS5 is properly connected it can determine the terminal s baud rate then set its own baud rate accordingly This is called autobauding After the BDS5 determines the correct baud rate it will store this rate away BAUD The BDS5 will flash the CPU light to indicate that it is autobauding In order for the BDS5 to determine the baud rate setting on your terminal you must press the enter key several times Press only the enter key otherwise the BDS5 will not autobaud correctly The system will only autobaud during power up 4 10 1 1 Setting the BDS5 to Autobaud There are three ways to set the BDS5 to autobaud at power up 1 Powering up with the MOTION input off 2 Turning the switch ABAUD on before the next power up 3 Setting the value of the variable BAUD to an invalid value say 1000 4 10 1 2 Autobauding and MOTION If the MOTION input is off during power up the BDSS will autobaud Note that this also sets ADDR to zero This allows you to command autobaud without being able to communicate with the BDS5 The other ways to start autobauding require that communications be set up first See the se
266. n error handler for your application The User s Error Handler begins at the special label ERROR Any error that breaks execution of your main program will restart execution from ERRORS if it exists The error handler provides instructions that need to be executed if an error interrupts your program Examples of error handler instructions include setting outputs printing messages and storing information in user variables There are several restrictions that apply to the error handler for example GOTO GOSUB and RET are not allowed Normally ERROR should be at the end of your program ERROR cannot be followed by POWER UP AUTO MANUALS or any general purpose labels 0 through 500 Software travel limits are automatically enabled on power up If you use these limits you may have short sections of your program that disable them briefly If an error occurs in one of those sections software limits will remain disabled until you enable them or until the next power up For this reason you should always enable travel limits from the User s Error Handler if they are disabled from any section of your program WARNING BE SURE TO TURN PLIM ON FOR THE FOLLOWING CONDITIONS USE ERROR TO TURN PLIM ON FOR THE FOLLOWING CONDITIONS 1 your application relies on Software Travel Limits 2 your program disables Software Travel Limits at any point even briefly ERROR is provided as a graceful end to program execution and not as a m
267. nabled Position command from CAM table The CAM table is contained in user registers X100 X227 NORM pos Used to enable the Cam at the Normalize position GEAR mode must be turned off before enabling CAM after which GEAR must be turned on to start Camming DUMP TL VERSION Added LPF and LPFHZ to DUMP TL TRECORD START STOP CONTINUE Real Time Trace Record command This can be buried in the user program to control Real Time Tracing Real Time Trace Playback command TPLAY this will dump the entire Real Time Trace buffer to the serial port TPLAY NEWEST lt lines gt this will output the newest of lines TPLAY OLDEST fines this will output the oldest of lines TPLAY lt lines gt this will output a of lines TPLAY lt 1 gt lt line2 gt this will output from linel to lt line2 gt See the Output syntax below Output Format line LINE pgm line prompt command lt line gt is the trace line number pgm line is the user program line number prompt is a modified trace prompt that in addition to indicating the trace mode and the multi drop address also indicates the multi task active indicates Alarm A was active indicates Alarm B was active indicates Alarm C was active indicates Variable was active indicates the MAIN PROGRAM 500 was active indicates BACKGROUNDS was active indicates INTERACTIVE was active e indicates MONITOR was active
268. nd post execution idling 4 8 5 1 Pre Execution Idle A task can be idled by waiting for a condition before executing acommand This is called a pre execution idle because the task is idled before executing the command that causes the idle There are two conditions that can cause a pre execution idle A task about to execute a motion command MI MA or MCGO will be idled if the motion buffer is full Also a task about to execute a printing command P PS R RS or INPUT will be idled until the previous printing command is finished For example the BDS5 can store up to two MI or MA commands This was called buffering in Chapter 3 This means that if you wrote a task with three MI commands in a row then the third MI command could not be executed until the first move was complete So that task would be idled until the first move finished If there was another lower priority task it would execute until the first move finished CHAPTER 4 USER PROGRAMS When the first move finished the first task would no longer be idled and thus would proceed Consider the following program It has two tasks a routine starting at 1 task level 5 and a background task starting at BACKGROUNDS task level 6 The background task is the lowest priority task and will only execute when the general purpose task is idle In the following example the task is idle between the second and third motion command Use the BDS5 Editor to enter this program
269. nds 3 18 3 8 1 1 AMAX ACC amp DEC 3 18 3 8 1 2 EN STOP amp LIMITS 3 18 3 8 1 3 Enabling Motion with MOTION 3 19 3 8 1 4 STOP S 3 19 3 8 1 5 STOP and BREAK with Control X 3 19 3 8 2 Limiting Motion sese 3 19 3 82 1 Hardware Travel Limits 3 19 3 8 2 2 Software Travel Limits PMAX amp PMIN cogi Eris 3 20 3 8 2 3 User Position Trip Points amp PTRIP2 u a 3 20 3 8 3 Brofiles deeper 3 20 3 8 3 1 S Cutvy6es iier 3 20 3 8 3 2 Move Absolute MA Command 3 21 3 8 3 3 Move Incremental MI Command 3 22 3 8 3 4 Incremental Move Example 3 22 3 8 3 5 Profile Limits esee 3 22 3 8 3 6 Multiple Profile Commands 3 23 3 8 3 7 Profile Final Position PENL 3 23 3 8 4 JOG J Command 3 23 3 8 5 NORMALIZE NORM Command 3 23 3 8 6 Zero Position Error ZPE Command 3 24 3 8 7 MACRO MOVES eee 3 24 3 8 7 1 MCA MCI MCD amp MCQGO 3 24 3 8 7 2 Macro Move Example 1 3 25 3 8 7 3 Macro Move Example 2 3 25 3 8 8 R D BASED MOVE MRD Command 3 26 3 8
270. nds and are limited to 2 147 483 647 milliseconds or about 25 days The 5 then counts down the timer until it reaches zero Type in this example which continuously reprints a message for 1 second 8 TMR1 1000 TIL TMR1 LE 0 P WAITING FOR 1 SECOND DELAY B and type Type in this example showing how multiple waits can be based on one timer setting 9 1 3000 SET TMH1 SECONDS P 3 SECONDS TIL 1 LE 2000 P 2 SECONDS TIL TMH1 LE 1000 P 1 SECOND TIL TMR1 EQ 0 B and type RUN 9 5 4 BDS5 5 5 2 Regulation Timer RD Fixed length delays can be added into program with the DWELL D command In some applications especially those that use profile regulation it is necessary to add a delay with a length that varies with the regulating frequency The DWELL RD command is provided for these occasions When the external input frequency is equal to REGKHZ the delay of the RD command is in milliseconds just like D command However when the external input frequency decreases the regulated dwell time lengthens so that the DWELL is proportional to the inverse of the external frequency For example 45 REGKHZ 100 SET REGKHZ TO 100 KHZ RD 2000 REG DOES NEED TO BE ON FOR RD TO OPERATE P DELAY COMPLETE B In this case the RD command causes a 2 second dwell when the external input frequency is 100 KHz and a 4 second dwell when the frequency is 50
271. nds are preceded by the trace prompt S gt Print statements are active in the Single Step mode Notice that the results of the P command are printed normally as they are in the Trace mode Pi CHAPTER 5 DEBUGGING e Only the executed commands in the IF ELIF ELSE and ENDIF sets are shown Notice that none of the commands following the first print command are shown e You can execute commands from the Single Step mode You can also enter the Single Step mode from your program To do this you should include SS ON in your program To exit the Trace mode you can include SS OFF in your program or type it from the single step prompt You can also press the escape key two times 5 2 2 Trace If the error occurs in a section of your program that is not very time critical you can use trace to help track down the error When you execute your program in the Trace mode each command is printed out just before it is executed Use the nested IF example given earlier in this chapter Enter the program set and X2 equal to 1 and turn TRC on ON Then begin execution at label 55 RUN 55 and the following lines should be displayed T 55 T IF X1 GT 0 T IF X2 GT 0 T P BOTH X1 AND X2 gt 0 T T T T T gt This example shows several characteristics of the Trace mode e All commands are preceded by the trace prefix 12 Print statements are active in Trace mode
272. ndustrial Drives Using a high performance microprocessor the BDS5 does not have to compromise on either positioner software or servo performance This single microprocessor closes all servo loops resulting ina truly integrated positioning system The BDSS has the features and performance you need in your next positioning application 1 3 FEATURES The BDS5 offers a wide feature set to accommodate real world positioning requirements e LOW COST The BDS5 is very affordable even though it is full of advanced features Use all or only a portion of these features to accomplish your application e EASY TO INSTALL The BDS5 is easy to install because the servo amplifier and the positioner are integrated into one package Many interconnects including the tachometer and encoder are eliminated e SIMPLE PROGRAMMING LANGUAGE The BDS5 uses simple BASIC like commands such as RUN GOTO for branching and GOSUB RETURN for subroutines In addition to a simple comparison statement advanced IF ELIF ELSE END IF statements result in more readable and less error prone programs You can comment every line in your program 1 1 CHAPTER 1 SYSTEM DESCRIPTION ADVANCED MOTION CONTROL MOVES The simple language does not prevent you from solving complex problems The BDSS has separate acceleration and deceleration rates as well as linear half S curve and full S curve acceleration profiles The BDS5 has Macro Moves for appli
273. ne Specific 4 35 2 Position Rotary Mode ROTARY amp ynchronizing Your Program 5 4 Gati iay 4 37 ating Motion with GATE 5 6 User Position Trip Points PTRIPI Motion 5 4 R amp 2 L AAR a 3 20 egulation Timer RD 5 4 User Switch 3 8 Using the Timers 1 4 5 4 ser Switches User Units 4 32 MATT EW nne redes a akuy 5 5 Cutrent Units tU BRE 4 32 ystem Compensation a 6 1 Critical Damping 62 External 4 33 E C Qt Other User Units esee 4 33 Overdamping eee 6 2 Rie eh eee 6 2 User Variables eee Rete 3 7 Underdamping 6 2 Indirect User Variables 3 7 oe e or eon E a 4 40 Using IBM PC Compatibles 2 9 i Version Dump 4 40 Using the General Purpose Inputs 4 15 System Resolutions s T4 33 Deine ie Der TMP 2 Using Variable Input with Profiles 4 28 T a 2 6 The gt BDS Command Transmitting I V l EERE asa Variable Input Task Level 4 4 27 Theory of Opera
274. ne to errors If you do branch up branch to the top of a major section In most programs there should only be one or two places that you branch up to Feel free to use small loops 2 or 3 lines which of course repeatedly branch to the top of the loop Avoid branching between sections 7 AVOID USER SWITCHES THAT MODIFY BLOCKS OF CODE Switches that modify functions can be difficult to understand This is commonly done when programmers attempt to use one block of code for two similar functions If possible write two different blocks of code rather than trying to use one block for two functions 4 2 1 Example Application Suppose you are working on a project that is defined by someone besides yourself It may be a co worker a supervisor a customer or an operator For this BDS5 example we will use a customer Suppose you have this conversation Customer My machine feeds plastic from a roll onto a conveyor then cuts it into sheets The length of the sheet varies There is a registration mark on each plastic sheet which is detected while the plastic is moving After this mark is detected the motor must move the plastic a variable distance and stop There is a stop input that should stop and disable the BDS5 after it completes the cycle You Are there other parameters that should be variable such as speed acceleration and deceleration Customer Now that you mention it all those parameters should be variable
275. ng at all The Monitor mode switch will cause the BDS5 to automatically enter the Monitor mode upon the execution of a BDS5 program This will in essence cause the BDS5 to always have the serial port active and waiting for a command Previously BDS5 required an esc character to be received in order to activate the serial port while a user program was running 32 APPENDIX SERIAL PORT STANDARD 5 232 amp RS 485 SERIAL CONNECTOR Cl 9 PIN DB 9 SIGNALS 4 SHIELD RECEIVE TRANSMIT COMMON MODES 8 BIT ASCII NO PARITY BDSS5 SERIAL CONNECTOR e The BDS5 has one RS 232 serial DB 9 male connector e communications format will be 8 bit ASCII with 1 start bit 1 stop bit and no parity bit The communications data rate will be from 300 to 19 200 baud bits per second This rate is programmed in the variable BAUD e This 5 can autobaud to determine the communication rate when the flag AUTOBAUD is enabled Autobauding is performed by the BDS5 receiving a series of cr e The serial connector is optionally configurable to RS 485 5 485 is enabled with the addition of RS 485 receiver driver chips and setting a valid multi drop address in the variable ADDR BDS5 MULTI DROP PROTOCOL lt address gt Multidrop Axis Address Valid addresses are 0 9 and 7 Multidrop Hang up Axis Multidrop Broadcast All 33 FIRMWARE UPGRADE NOTICE 3 02b FEBRUARY 02 1994 The Engineering departmen
276. ng motion is commonly used because it is simple if not in all respects accurate and conveys the necessary information The above sequence should be modified as follows Note that here the profile is converted to Absolute rather than Incremental this is a matter of convenience as either will work MCA 10000 1000 200 ADD A DWELL MCA 0 1000 0 RETURN TO HOME NOTE THAT VELOCITY IS sALWAYS POSITIVE Note that Macro moves have one inherent weakness If you are using user units and you specify an incremental move that translates to a non integer number of counts the Macro move will move the closest number of integer counts If the move is repeated the small error in the position command will accumulate This problem does not happen if you use MI commands 3 8 8 R D BASED MOVE MRD Command This section describes MRD the command that generates moves based on the feedback from the R D converter rather than the Position command PCMD These moves are less than one revolution and are always Absolute rather than Incremental 3 25 CHAPTER 3 PROGRAMMING LANGUAGE BDS5 With the MRD command you specify the desired R D output at the end of the move and the peak velocity For example the command MRD 1000 100 moves the motor so that the R D output is 1000 100 RPM is the traverse speed ACC DEC and are all in effect with MRD As with MI and MA if 100 RPM is too large to be attained given ACC and
277. nic 000 3 32 t5 amp PTRIP2 eee 3 20 Encoder Feedback sss 3 37 Limiting Motor Current eee 317 External cen 3 31 Continuous Current 3 17 JOG J Command ce 3 23 Foldback Current IFOLD ESSE rk eres ETE URP eset 3 17 JOG TO amp JOG FROM NICA 3 28 Monitoring Current Limits 3 18 Limiting Motion aasan 3 19 Logical Functions AND OR 3 9 MACRO MOVES eee 3 24 Low Pass Filters 6 8 NORMALIZE NORM Command 3 23 Profile Regulation eee 3 35 3 20 BASED MOVE MRD Command 3 26 Machine Specific 8 4 35 Zero Position Error ZPE Command 324 Macro Move Example 1 3 25 Motion Link and Trace 5 2 Macro Move Example 1 F3 25 Motion Link Editor 4 6 Macro Move Example 2 3 25 Macro Move Example 2 F3 25 MACRO MOVES ees 3 24 Motion Link OverviIew 2 4 Macro Move Example 1 3 25 Menus and Windows 2
278. nition to reach beyond the confines of the motor frame Fall Time The time for the amplitude of system response to decay to 37 of its steady state value after the removal of a steady state step input signal Feed Forward A technique used to pre compensate control a loop for known errors due to motor drive or lead characteristics Provides improved response Feedback A signal which is transferred from the output back to the input for use in a closed loop system Field Weakening A method of increasing the speed of a wound field DC motor reducing stator magnetic field instantly by reducing magnet winding current Filter Control Systems A transfer function used to modify the frequency or time response of a control system Glossary vi Flutter Flutter is an error of the basic cycle of an encoder per one revolution Following Error The positional error during motion resulting from use of a position control loop with proportional gain only Form Factor The ratio of RMS current to average current This number is a measure of the current ripple in a PWM or other switch mode type of controller Since motor heating is a function of RMS current while motor torque is a function of average current a form factor greater than 1 00 means some fraction of motor current is producing heat but not torque Four Quadrant Refers to a motion system which can operate in all four quadrants i e velocity in either direction
279. nk Editor can hold up to 2 000 lines and up to about 24 000 bytes SHOW FREE MEMORY This selection displays how much space is left for your BDS5 program Use this command if you are concerned that your program will fill up the BDS5 program memory 2 4 2 4 Insert Delete DELETE A WORD AT This selection deletes the next word after the cursor DELETE TO END OF LINE AQAY This selection deletes from the cursor to the end of the line DELETE A LINE AY This selection deletes the entire line that the cursor is on UNDELETE A LINE U This selection Inserts the last deleted line in the editor starting at the cursor INSERT A NEW LINE N This selection Inserts a blank line in the editor DELETE ENTIRE EDITOR This selection clears the entire Motion Link Editor 2 4 2 5 Cursor Table 2 1 shows the cursor control keys Special keys are shown between greater than and less than symbols for example the Home key is shown as lt Home gt 2 8 BDS5 Table 2 1 Cursor Control Keys TOP OF EDITOR END OF EDITOR UP ONE PAGE DOWN ONE PAGE BEGINNING OF LINE lt Home gt END OF LINE lt End gt UP ONE LINE DOWN ONE LINE LEFT ONE WORD RIGHT ONE WORD LEFT ONE CHARACTER RIGHT ONE CHARACTER A lt PageUp gt A lt PageDn gt lt PageUp gt or lt PageDn gt or C Up or E Down or X A lt Left gt or A Right or F Left or S Right or D 2
280. nly ACTIVE from Area 5 will turn on STATUS through the other leg of the OR gate The STATUS output on optional Connector C8 Pin 35 is always the same as the STATUS software switch Note however that the state of the STATUS output is undefined for 25 milliseconds after power up STATUS may turn on for up to 25 milliseconds during power WARNING UP 3 6 7 Motor Brake Industrial Drives motors can be purchased with an optional brake The brake is fail safe in that if no current is applied the brake is active If you set STATMODE to 0 you can use STATUS to control the brake Then when the BDSS is disabled or powered down the brake will be active 3 6 8 Output Relay The relay Connector C2 Pins 16 and 17 represents the state of the hardware watchdog The hardware watchdog makes a system more reliable because the watchdog is independent of the microprocessor If the processor is not working the watchdog will usually detect it though this is not guaranteed On power up the contacts are open until the BDS5 passes its power up self tests Then the contacts close and the BDS5 begins normal operation Note that if the BDS5 is set to autobaud on power up the contacts will not close until after autobauding and establishing communications One way to use the relay is to interconnect it with the main power contactor In this case a hardware watchdog fault will disconnect all power to the system The SYS OK LED indicat
281. nsisting of an externally threaded screw and an internally threaded carriage nut Least Significant Bit The bit in a binary number that is the least important or having the least weight Limits Properly designed motion control systems have sensors called limits that alert the control electronics that the physical end of travel is being approached and that motion should stop Linear Coordinated Move A coordinated move where the path between endpoints is a line Linearity Glossary viii For a speed control system it is the maximum deviation between actual and set speed expressed as a percentage of set speed Logic Ground An electrical potential to which all control signals in a particular system are referenced Loop Feedback Control A control method that compares the input from a measurement device such as an encoder or tachometer to a desired parameter such as a position or velocity and causes action to correct any detected error Several types of loops can be used in combination i e velocity and position together for high performance requirements Loop Gain Open The product of the forward path and feedback path gains Loop PID Proportional Integral and Derivative Loop Specialized very high performance control loop which gives superior response Loop Position A feedback control loop in which the controlled parameter is motor position Loop Velocity A feedback control loop in which
282. nsnsasssiueesendea nsn 4 9 2 SE rinting Control Characters 4 19 Next Line ix ancien REPE PEUT 4 7 Printi _ rinting Decimal Numbers 4 17 Non Linear Mechanics 6 7 Printing Decimal Points 4 17 NORMALIZE NORM Command 3 23 Printine E 4 18 g Expressions Printing Hex Numbers 4 17 Printing Switches 4 18 Printing ASCII Characters 4 18 OpLOnDS eese ct ERR HR DER 2 5 Printing BDSS Status sss 4 20 Other 2 13 Printing BDS5 Status 5 4 20 Other User ananassa 4 33 Printing Binary Numbers 4 18 Output 1 8 Decimal Values T3 10 Printing Control Characters 4 19 Q tput 3 14 Printing Decimal Numbers 4 17 Overdamping n rnnt nnns 6 2 Printing Decimal Points sss 4 17 F6 2 Overloading the Motor 6 6 Printing Expressions aa 4 18 P Printing Hex Numbers
283. number of milliseconds up to 1 second that you want the present speed averaged over If this time is not specified the speed is averaged over 1 millisecond Format CONTINUE CONTINUE time Example CONTINUE 100 AVERAGE SPEED FOR 1 SEC Display all the variables and the user program on the terminal or display the version Allowed from interactive Drive must be disabled Format DUMP Dump variables and program DUMP VERSION Dump firmware version APPENDIX C SOFTWARE COMMANDS BDS5 D DIS ED ELIF Delay program execution for a specified amount of time up to 2 147 483 647 milliseconds or 25 days D is an idling command that is if you are using multi tasking D suspends the task but lets other tasks proceed Allowed only from the user program Format D Time Example D 1000 DWELL FOR 1 SECOND Disable the BDS5 This command turns off the variable READY Refer to Drawing C 84732 for more information Allowed from interactive mode monitor mode and user program Format DIS Edit the user program Allowed only from interactive mode Format ED Editor Commands DEL Delete a line F Find string C Change string I Enter insert mode P Go to a line and print it NEW Clear user program SIZE Show remaining program memory PASS Change password Empty Line Go to the next line and print Escape Key Exit the insert mode editor Part of block if Conditionally begins block execution Allowed from th
284. o Load Speed Motor speed with no external load Glossary ix GLOSSARY BDS5 Open Collector A term used to describe a signal output that is performed with a transistor open collector output acts like a switch closure with one end of the switch at ground potential and the other end of the switch accessible Open Loop System A system where the command signal results in actuator movement but because the movement is not sensed there is no way to correct for error Open loop means no feedback Operator Interface A device that allows the operator to communicate with a machine This device typically has a keyboard or thumbwheel to enter instructions into the machine It also has a display device that allows the machine to display messages Optically Isolated A system or circuit that transmits signals with no direct electrical connection Used to protectively isolate electrically noisy machine signals from low level control logic Oscillation An effect that varies periodically between two values Overshoot The amount of the parameter being controlled exceeds the desired value for a step input Phase Locked Servo System A hybrid control system in which the output of an optical tachometer is compared to a reference square wave signal to generate a system error signal proportional to both shaft velocity and position Phase Margin Glossary x The difference between 180 degrees and the pha
285. oints For example J 500 causes the motor to rotate at 500 RPM indefinitely Jogs are useful for machine set up and testing ACC and DEC are in effect with Jogs as is SCRV Software and Hardware Travel Limits are also in effect Jog is the only move command that can cause CHAPTER 3 PROGRAMMING LANGUAGE motion to change direction without stopping first However since changing directions involves both 3 8 5 NORMALIZE NORM Command NORM the NORMALIZE command is required if you want to reset the BDS5 position feedback Often you may want to set the position feedback to some known value For example on power up the position feedback is set to zero After a homing sequence you may need to reset the position register This is done using NORM the NORMALIZE command For example NORM 10000 w A 3 T 2 e Lc z 5 d z POSITION command to 10000 position units 10000 e gt 8 8 B gt Ue 2 Bu o m lm za E See amp lt lt lt o g lt 20 E aga o nA lt G 5 5 6 a6 B o n B E af sz Now type in P PFB E 2 Aa B ED N me 2 3 a pe B NORM 1000 Again print P
286. ols to aid tuning making it a much simpler process than it has been in the past In a broad sense the performance of a system is characterized by its noise susceptibility response and stability These quantities tend to be mutually exclusive The system designer must decide what noise susceptibility in the form of a busy motor is acceptable Busyness is random activity in the motor and can often be felt on the motor shaft Busyness in a motor should not be confused with PWM noise PWM noise is high pitched relatively constant noise and cannot be felt on the motor shaft Response is a measure of the system s quickness Response can also be characterized by bandwidth and by rise time in response to a step command Normally designers want high bandwidth though sometimes the response is purposely degraded to reduce stress on mechanical components This is called detuning Typical velocity loop bandwidths range from 20 to 60 Hz Typical position loop bandwidths range from 0 1 to 0 2 times the velocity loop bandwidth Stability measures how controlled the system is Stability can be measured with damping ratio or with overshoot in response to a step command A discussion of different levels of stability follows 6 1 CHAPTER 6 COMPENSATION 6 2 1 Critical Damping Generally the most desirable amount of damping is Critical Damping Critically damped systems respond as fast as possible with little or no overshoot In Figur
287. ommand will be executed with the new X1 and the old X2 You can correct this problem by temporarily storing the input values in user variables and loading them all together For example the above program can be modified as follows 4 28 BDS5 TASK LEVEL 4 VARIABLES INPUT INPUT NEW DISTANCE X11 INPUT INPUT NEW SPEED X12 X1 z X11 LOAD X1 AND X2 WITH X2 X12 INPUT VALUES END VARIABLE TASK LEVEL 5 20 MI X1 X2 GOTO 20 Temporarily storing the input values in X11 and X12 guarantees that the MI command will execute with either all new or all old values Since there are no idling commands between the commands that load X1 and X2 there is no possibility for task level 5 to run until X1 and X2 are both loaded or neither is loaded In addition if the variable input routine changes variables that are used in different lines of task level 5 you probably should turn MULTI off at the beginning of the block of lines and back on at the end This prevents the variable input routine from reloading the variables in the middle of block of lines 4 8 7 2 Restrictions of Variable Input Like alarms variable input has many restrictions 1 You cannot execute GOTO GOSUB or RET commands from the variable input task 2 You cannot execute a label 3 The variable input must be self contained it cannot mix with other tasks It must be terminated with an END Kill K or Break B command Again most other commands
288. ompensation board This error breaks program execution BDS5 ERROR 17 ERROR 18 ERROR 19 ERROR 20 ERROR 22 APPENDIX D ERROR CODES FEEDBACK LOSS The BDS5 has detected that one or more wires to the resolver have been broken or the resolver connector has been removed This error breaks program execution BAD TL The BDS5 has two boards a small MC board and a larger IBD board Both boards have the current and voltage rating encoded and they must match If this error occurs because you exchanged the MC card then you should replace the original card If it occurs for some other reason contact the factory This error breaks program execution MOTION HDWR LINE The MOTION input was off at the beginning of a motion instruction or it turned off during a motion instruction This signal comes from the optional I O card This error breaks program execution TUNE FAILED The Tune command failed Either the inertia on the motor is too large for the desired bandwidth the motor is not functioning properly the bus voltage is too low or the BDS5 is not functioning properly Try reducing the desired bandwidth to correct this problem Make sure REMOTE is on If this does not work attempt to tune the system by hand 12 VOLTS The 12 volts is out of tolerance Contact the factory This error breaks program execution D 2 3 Positioner Faults ERROR 23 SOFTWARE OVERTRAVEL Software travel limits a
289. on will generate an error If you do not need to connect MOTION for your application you must hardwire MOTION on See the Installation and Setup Manual for instructions on how to hardwire MOTION Before continuing make sure that MOTION is on Type the following command to print the state of the MOTION input P MOTION MOTION SHOULD BE 1 Many times the MOTION input is controlled by the normally closed contacts of a push button This push button is often called STOP since pressing the button opens the MOTION input and forces the motor to stop Emergency Stop should not be implemented with the MOTION input Emergency Stop should be connected to a contactor that removes power from the system This is because an emergency stop which is for safety should not depend on BDS5 functions to operate properly Do not use MOTION or any other BDS5 input for Emergency Stop When Emergency Stop is activated it should directly remove power from the system WARNING 3 8 1 4 STOP S Command Any motion can be stopped using S the STOP command S has no parameters S decelerates the motor at AMAX and terminates all motion commands The S command does not disable the BDSS Normally the STOP command should only be given from the terminal or from the program in response to an error condition A better method for stopping motion from the program under normal circumstances is 70 JOG TO 0 SPEED STOP MOTION DEC NOT AMAX
290. on within the word The value in OUT or IN is the sum of the values for each bit that is turned on The value for each bit is listed in Table 3 4 Table 3 4 Output 1 8 Decimal Values Out Bits O8 O7 O6 Value 128 64 32 For example if O8 and O4 are on and all other outputs are off then OUT 128 value of 8 value of O4 136 Many bits can be set or cleared with one instruction For example OUT 7 turns on O1 O2 and O3 while turning all other outputs off One logical math statement can be used to set some bits without affecting others For example O1 ON O2 ON ON can be replaced with BDS5 CHAPTER 3 PROGRAMMING LANGUAGE OUT OUT 7 SET 3 BITS WITH LOGICAL OR which turns on O1 O2 and O3 without affecting O4 The logical AND can be used to turn off several bits OUT OUT amp 7 CLEAR 5 BITS WITH LOGICAL AND turns off O4 OS8 and does not affect O1 O3 Note that the hex representation can be especially useful when setting the higher bits O4 ON O7 ON O8 ON is the same as OUT OUT 0C8H IN is formed with I1 16 in the same way OUT is formed with O1 8 Table 3 5 Input 1 16 Decimal Values 116 15 114 113 32768 16384 8192 4096 n2 0 2048 1024 512 For example if IN were equal to 5010 that would mean I2 15 I8 I9 110 and 113 were and all others were off because 5010 is the sum of those bits 5010 24 16 128 256 512 4096 3 6 F
291. onally equivalent to hall sensors and a tachometer Torque The rotary equivalent to force Equal to the product of the force perpendicular to the radius of motion and distance from the center of rotation to the point where the force is applied Torque Constant A number representing the relationship between motor input current and motor output torque Typically expressed in units of torque amp Torque Ripple The cyclical variation of generated torque given by the product of motor angular velocity and number of commutator segments Torque to Inertia Ratio Defined as a motor s torque divided by the inertia of its rotor the higher the ratio the higher the acceleration will be Transducer Any device that translates a physical parameter into an electrical parameter Tachometers and encoders are examples of transducers Transfer Function The ratio of the Laplace transforms of system output signal and system input signal Trapezoidal Profile A motion profile in which the velocity vs time profile resembles a trapezoid Characterized by constant acceleration constant velocity and constant deceleration Glossary xiii GLOSSARY BDS5 TTL Transistor Transistor Logic Variable Frequency Drive An electronic device used to control the speed of a standard AC induction motor The device controls the speed by varying the frequency of the winding current used to drive the motor Vector Control A method o
292. ons of Background 4 32 BDSS Rules for Prompts e T2 10 Backing Up the Disk s eee 2 1 BD55 State F2 11 Basic Commands eee 4 10 Block IF Restrictions and Options T4 14 BREAK B shaq aaa as 4 10 BREAK B ace RA ES 4 10 GOSUB and RET asss 4 11 Broadcast ees 4 41 EEEE iiie 4 10 Building A Program es 4 10 4 10 Basic Command cccccccccccccccecccccccececceccecceces 4 10 RUN ii erit RE Hd 4 10 Conditional 5 4 11 Index 1 BDS5 INDEX Capture csetera Us 2 5 Debugging 2 0 24 5 1 Capture Direction CAPDIR 3 26 Single Step eese 5 1 Capturing 2 040021 3 26 ue aba ien 5 2 Capture Direction CAPDIR 3 26 4 9 Enabling Capture amp PCAP 3 26 DEP eere b ties 5 8 Speeding Up Homing Sequences 3 26 Descriptions of Modes 2 10 CHANGE C seeing 4 8 Interactive Mode 2 10 Changing a Variable sees 3 3 Monitor Mode
293. or Model Idling 4 25 Number 0002 1 7 Avoiding Idling sese 4 26 External Units 2 4 33 Post Execution Idle 4 26 External Units Conversion T4 36 Pre Execution 141 4 25 Idling Commands sees 4 21 E F DWBELD D ene een 4 22 HOED H umi REP 4 21 Fault Latch Area 3 3 13 WADEN dcn 2270 Fault Loci 3 11 4 14 esca iu E te eI E HF Vour Syston Ts Completely Unstable 6 3 Fault Latch Area 3 AEN Par ya Pa IR dre 3 13 IF s with GOTO and GOSUB 4 15 h Area IF ELIF ELSE and ENDIF Fault Logic Area 2 eese 3 13 5 eed 4 13 Firmware Faults Area 1 3 13 Incremental Move Example 3 22 Motor Br ke ere rede 3 14 j Indirect User Variables 3 7 Output ete 3 14 ves Initial Settings of Control Ready Latch Area 4 3 13 d User Variabl 3 4 Relay and STATUS Control Area 6 3 13 and User Variables Poult home ead dene p LIE 3 13 INPUT UR D 4 20 Po est 1 1 INPUT and Decimal Point 4
294. or command motion A diamond is a decision block There are two exits from a diamond one if the condition is true and the other if itis false Sample Flowchart is a flowchart for this application 4 3 CHAPTER 4 USER PROGRAMS BDS5 TURN OFF SAW OUTPUT ENABLE BDS5 SET REGISTRATION DIRECTION TO POSITIVE NORMALIZE TO ZERO SET ACC AND DEC IS STOP INPUT ON TURN ON REGISTRATION WAIT FOR START INPUT TURN OFF SAW OUTPUT START MOVE DISABLE THE BDS5 PRINT WAIT FOR STOP HAS BEEN ISSUED REGISTRATION MARK SET END POSITION TO REGISTRATION POSITION OFFSET WAIT FOR MOTION TO STOP TURN ON SAW OUTPUT Figure 4 1 Sample Flowchart BDS5 CHAPTER 4 USER PROGRAMS 4 2 4 Commented Program THIS PROGRAM DOES NOT HAVE A The following program will work for this application HEADER THAT IS THE BEGINNING SECTION WHICH HAS A LOT OF INFORMATION USE THE PROGRAM IN APPENDIX E AS AN EXAMPLE OF A PROGRAM HEADER 1 TIL 12 EQ 1 O1 OFF TIL CAP EQ 0 JT PCAP X4 0 TIL SEG EQ 0 O1 ON GOTO 5 ENDIF 10 K START OF PROGRAM TURN OFF THE SAW OUTPUT SET REGISTRATION DIR POSITIVE ENABLE BDS5 BEGIN LOOP IS STOP INPUT ON GOTO TO STOP ROUTINE NORMALIZE TO 0 SET ACC SET DEC TURN ON CAPTURE WAIT FOR START jINPUT TURN OFF SAW OUTPUT 5 WAIT FOR REGISTRATION SET END POSITION TO CAPTURED POSITION PLUS AN
295. ound task runs continuously as long as no other task is active The background task begins with BACKGROUNDS You can then follow that label with various statements usually printing commands For example enter the following program BACKGROUND P EXECUTING BACKGROUND D 500 DWELL Now you can enable multi tasking by typing RUN Notice that you did not need to specify a label If you type RUN without a label you will enable multi tasking without executing a specific label When you are done with this example press X control X to break the program and return to the Interactive mode BDS5 TYPE RUN YES BREAK COMMAND ON CYCLE X SWITCH NO POSITIVE TRANSITION SAMPLE AUTO ROUTINE AUTO MI 4096 100 END EXECUTE AUTO ROUTINE CHAPTER 4 USER PROGRAMS MANUAL SWITCH IS AN INPUT ON CONNECTOR C8 PIN 33 CYCLE SWITCH IS AN INPUT ON CONNECTOR C7 PIN 13 GO TO INTERACTIVE MODE gt SAMPLE MANUAL ROUTINE MANUAL IF 11 EQ 1 J 1000 ELIF I2 EQ 1 J 1000 EXECUTE MANUAL ROUTINE Figure 4 2 Auto Manual Mode Flowchart 4 31 CHAPTER 4 USER PROGRAMS BDS5 4 8 9 1 Restrictions of Background Like alarms background has many restrictions 1 You cannot execute GOTO GOSUB or RET commands from background 2 You cannot execute label 3 The background task must be self contained it cannot mix with other tasks It must be terminated with
296. owing example from the BDS5 Editor P BEG END The 5 will print the entire program and go to the end of the program When you specify a range the command works for all the lines in the range You can specify one line For example type P and the BDS5 will print and go to line 1 If you want to print the current line then do not specify a line For example prints the current line If you attempt to print a line that is not in the program such as line 100 of a 10 line program the Editor will issue an error like BAD ENTRY 4 3 2 2 Next Line If you enter an empty line then the BDS5 goes down one line in the program and prints that line The empty line is entered by pressing only the enter key This makes it easy to move down through the program 4 3 2 3 Password PASS The BDS5 Editor has password protection The password allows you to prevent the user program from being changed If the password is set the program cannot be changed but it can still be displayed The password can be up to six characters long The default setting of the password is null i e empty which means there is no password protection From the Editor type and the BDS5 will ask you for the new password If you do not want password protection enter an empty line Note that the NEW command discussed later also clears the password 4 3 2 4 Insert 1 Entering the Insert I command causes the Editor to enter the Insert
297. ox so you can select the gear ratio you need You must select the gear ratio so that when the master rotates 360 degrees 32 768 counts are generated in the BDS5 think of the 360 degree horizontal axis of Figure 2 as being 32 768 counts long for example suppose the sensor on the drive shaft were a 1000 line encoder Because of quadrature the encoder would generate 4000 counts for every rotation So the 4000 counts should be scaled through the gearbox to generate 32 768 counts The gear ratio would be GEARI 32 768 4096 GEARO 4000 500 or GEARI 4096 and GEARO 500 If you want to test your scaling enable your BDS5 without camming turn GEAR ON and rotate the drive motor 360 degrees The follower motor should rotate 32 768 counts 8 rev s for a 12 bit system or 2 rev s for a 14 bit system 3 Align the Machine Some applications require that the master drive be aligned others assume the drive is O degrees at power up If your application requires drive shaft alignment you must provide the necessary mechanisms as the BDS5 will not have control of the drive shaft Virtually all applications require that you align or home the follower position Depending on your system you may need a home switch In any event the two positions must line up somewhere in the cam table For example in Figure 2 if the drive shaft were at O degrees and the follower were at 3 00 inches either the master drive or the follower would have to move You would
298. ped with a tuning that will work reasonably well with the load inertia between 0 to 4 times the rotor inertia Many applications have approximately matching inertia If your system does you may not have to adjust the tuning of your BDS5 The following section describes how you can re tune your system When tuning a system it may be desirable to disable the BDS5 quickly You can use K the KILL command to disable NOTE with a one letter command The BDS5 provides self tuning This is a feature that senses the inertial load of your system and then attempts to set tuning parameters accordingly Note that self tuning is not fool proof You may need to adjust one or two of the tuning parameters to get exactly the response you need THE MOTOR MAY OSCILLATE Unloaded motors tuned for a large inertia load may become WARNING unstable when the system is activated If the system becomes unstable remove the power immediately 6 3 1 If Your System Is Completely Unstable If your system is completely unstable when you enable it remove power immediately After restoring power but before enabling the BDS5 turn off the switch PL reduce KV to 100 and reduce KVI to 0 This should make the system stable TYPE THESE LINES ONLY IF YOUR BDS5 IS UNSTABLE WHEN YOU CHAPTER 6 COMPENSATION ENABLE IT DON T FORGET TO RESTORE PL WHEN YOU HAVE FINISHED TUNING PL OFF 0 KV 100 If BDSS is still unst
299. peed verify that the AC line voltage is large enough Chapter 1 lists the BDS5 model numbers If the voltage you apply to BDS5 is lower than the specified voltage the motor will not operate properly at high speed If you get overspeed errors ERROR 13 if the error occurs occasionally it may be because you have the limit VOSPD set too low Raise it by 2096 or as high as 12096 of VMAX and see if the problem is corrected if it happens on acceleration it may be because your motor is not tuned properly Is your motor overshooting or ringing Retuning the motor should correct the problem if it happens when the motor is rotating very slowly so that you are sure that the speed is not near VOSPD your resolver or R D converter may have failed This is simple to confirm Disable the BDS5 and write a program that continuously prints PRD Rotate the motor slowly by hand and observe PRD to see if it skips several counts do not be concerned if PRD skips a few counts look for skips of 50 counts or more If PRD skips more than 50 counts when the motor is rotating slowly contact the factory If the system works differently on power up than it does after your program starts running remember that many switches are reset on power up Your program may set a switch that is cleared or clear one that is set during the initial cycle After that the program may operate differently You may also be setting or clearing switches
300. peed will be VDEFAULT For example MA 100000 would move the motor so that PFB is equal to 100000 it would assume a traverse speed of VDEFAULT If you do not specify the speed in MA commands it reduces the execution time This normally means less delay between when the command is entered and when the motor begins turning Appendix F lists the execution times of a few simple moves Not specifying the speed in MA commands reduces NOTE execution time 3 2 CHAPTER 3 PROGRAMMING LANGUAGE 3 8 3 3 Move Incremental MI Command The MI command allows you to command incremental moves by specifying the total distance of the move ACC DEC and SCRV are all in effect for MI moves Like MA if you enter an MI command without specifying a speed the traverse speed will be VDEFAULT For example MI 5000 200 causes the motor to move 5000 counts at a peak speed of 200 RPM The profiles that were shown earlier as SIMPLE PROFILE or S CURVE PROFILE could have been generated from this example As with the MA command MI 25000 causes the motor to move 25000 counts with the peak speed at the speed VDEFAULT For both the MI and MA commands not specifying speed reduces execution time and program size Not specifying the speed in MI commands reduces execution time gt 3 8 3 4 Incremental Move Example SHOCK HAZARD Large voltages from the AC line and the DC bus can cause WARNING
301. pose the master signal in Example 1 came from a 500 line encoder With quadrature encoding a 500 line encoder will generate 2000 counts per revolution If you still wanted 1 3 gearing then GEARI REV4 RESOLUTION GEARO REV RESOLUTION master GEARO L3J 2000 6000 So GEARI would be 4096 and GEARO would be 6000 GEARI 1 299 _ 4096 CHAPTER 3 PROGRAMMING LANGUAGE 3 8 13 4 Profiles and Gearbox Gearboxing can be done in conjunction with incremental moves and Jogs MI and Macro moves based on MCI are summed with the gearbox command to form the profile This can be used for phase adjustment a common function used with electronic gearbox Phase adjustment means that the slave will be locked to the master through the electronic gearbox but occasionally the slave BDS5 adds a short profile on top of the gearbox command For example you may want to increase the slave position phase by 90 while remaining in gear In this case enter the following commands 3 33 CHAPTER 3 PROGRAMMING LANGUAGE BDS5 BDS5 Master Slaving Master Slave or Digital Input _ BDS5 77 Sr or a I I Fog Resolver or i I Feedback I Pulse H Signal or I I E Electronic Gearbox Slave BDS5 Velocity Digital Input X4 ki Decode Analog Input Position Qption Motion Profile Command Generation Profile Regulation Slave BDS5 Position Digital Input i Analog Input Ve
302. programming practices provided in this manual Every effort has been made to make the BDS5 language as simple as possible with BASIC like commands algebraic math and a variety of conditional commands Still some bugs are almost certain to surface in a new program The BDS5 provides two execution modes to help you debug your program Trace and Single Step 5 2 DEBUGGING MODES 5 2 1 Single Step If the error occurs in a section of your program that is not time critical you can use single stepping to help track down the error When you execute your program in the Single Step mode each command is printed out The BDS5 waits for you to press the ENTER key before executing the command Use the nested IF example given previously in this manual Enter the program set X1 and X2 equal to 1 and turn SS on by typing SS ON Then begin execution at label 55 by typing RUN 55 The following line should be displayed 55 S gt Press the ENTER key and the response should be IF 1 0 S gt You can probe the BDS5 variables from the Single Step mode without stopping your program For example type P X1 and the 5 should respond with e In this case the BDS5 executed the print command and displayed the single step prompt indicating it is ready for another command Now press the ENTER key repeatedly to step through the program This example shows several characteristics of the Single Step mode comma
303. r example P 65 C IS THE SAME AS 128 65 C since the BDS5 removes the eighth bit of the expression on the right which has the end effect of reducing the number by 128 If the number is larger than 255 the BDS5 divides the variable or expression into four bytes and prints them out separately For example 2 256 256 256 65 256 256 65 256 65 65 2 prints since the number stored in X2 is equivalent to 4 bytes of 65 The default field width of the character format is 4 and you can change the field width by following the C with the desired format 4 6 1 8 Printing Control Characters The 5 uses the standard ASCII character set as shown in Appendix B There are unprintable characters such as the bell ASCII 7 and carriage return ASCII 0DH These characters have an effect on the terminal but do not print anything on the screen Unprintable characters range from ASCII 1 to The 5 cannot print ASCII 0 As Appendix B shows each unprintable character can be produced with a control sequence For example most terminals will sound a bell when you press lt Control gt G hold down the control key while CHAPTER 4 USER PROGRAMS pressing the G key As Appendix B shows lt Control gt G produces 07 or the ASCII bell You can use the BDS5 to produce unprintable characters by preceding the appropriate character with the carat to signify an unprintable character For example the following BD
304. r program while the BDS5 serial port is connected to the DEP 01 X will be printed on space 0 P A HX MARKS THE FIRST SPACE 4 19 CHAPTER 4 USER PROGRAMS 4 6 1 10 Printing BDS5 Status PS The PRINT STATUS PS command is like the P command except that it appends the BDSS status to the end of the printed line There are five different status words that can be printed with the PS command Each is listed with its meaning Table 4 4 Printing BDS5 Status Explanation OFF BDS5 is OFF READY BDS5 is ready but REMOTE is OFF ACTIVE BDS5 is active but no motion FAULT BDSS has a fault condition JOG BDS5 is jogging PROFILE BDS5 is executing profile GEAR BDS5 is in gear mode You can use all formats and combinations with PS that you did with P These results are identical except that the BDS5 status is appended onto the line 4 6 2 REFRESH R amp RS Commands The REFRESH commands R and RS are identical to P and PS except that R and RS send only a carriage return The P and PS commands print lines that end with linefeed and carriage return pairs R and RS commands display lines that can be overwritten The following example demonstrates how the REFRESH commands work Type in this example from the Editor 7 RS VELOCITY FEEDBACK VFB GOTO 7 Now exit the Editor and type RUN 7 4 20 BDS5 Rotate the motor shaft by hand so that the velocity feedback changes Press the escape key
305. r system s maximum speed to avoid nuisance overspeed faults You can change VOSPD only when the BDS5 is disabled VOSPD is in velocity units 3 7 4 Current 3 7 4 1 Motor Current ICMD amp IMON ICMD is commanded motor current ICMD like PCMD and VCMD is generated internally from motion commands ICMD is in current units IMON is the output of the current monitor circuit and it represents the magnitude of the motor current IMON is always positive and it is in current units IMON is the digital conversion of the analog signal I Monitor on Connector C2 3 7 4 2 Current Limits amp ILIM IMAX is the maximum level of current that the BDS5 can output It is set at the factory its value depends on both the BDS5 rating and on the motor IMAX is in current units ILIM limits the peak of ICMD the commanded current You can set ILIM to any level below IMAX This allows you to limit the current below the maximum level that the BDS5 can output You can set ILIM at any time even during profile moves ILIM is in current units 3 7 5 Enabling the Position Loop with PL PL is a switch that controls the position loop If PL is then the position loop is enabled If PL is off then it is disabled and the BDS5 is running as a velocity loop Most positioning applications run with PL on See later in this chapter for more information about the position loops PL turns on at power up You can change PL at any time 3 16 BDS5
306. r the BDS5 to execute the MANUAL program When these conditions are met the BDS5 will begin executing label MANUALS Table 4 10 To Execute MANUALG Multi tasking must be enabled MANUALS must be present in the user program Noroutines can be executing at task level 5 The MANUAL input must be off If these conditions are met the BDS5 will execute the user program at MANUAL You may have noticed that AUTO and MANUAL are very similar The important difference is that while the AUTO program begins when CYCLE START turns on the MANUAL program runs continuously 4 8 8 5 Typical AUTO MANUAL Programs Drawing A 84983 shows typical AUTO and MANUAL programs This flowchart shows the effects of the MANUAL and CYCLE switches The sample AUTO program causes the motor to rotate one revolution each time the CYCLE switch transitions from off to on The sample MANUAL program is written so that and 12 are JOG and JOG switches So when the MANUAL switch is on the BDS5 monitors the jog buttons when MANUAL is off the CYCLE button causes the motor to rotate one revolution Note that both the AUTO and MANUAL programs end with the END command this is the normal way to conclude these programs 4 30 BDS5 4 8 9 Background Task Level 6 The background task is the lowest priority Normally the background task is used for non critical tasks such as refreshing the display and checking low priority inputs The backgr
307. r the follower When you normalize to zero the units do not have any effect However if you want to normalize the master to a non zero position you must A Determine the position of the drive master to which you will normalize B Convert the position to counts where 360 degrees equals 32 768 counts C Temporarily set position units to 1 1 PNUM PDEN 1 D Normalize to the position in counts EN NORM Master Drive Position in Counts CAM E Restore the position units to their original values For example if you knew the follower to be 3 00 inches and you knew the drive to be at 90 degrees A Drive position 90 degrees B Drive position 8192 counts C PNUM 1 PDEN 1 D EN NORM 8192 CAM E Restore PNUM and PDEN 10 Finally you must turn GEAR on This connects drive to follower If you want tot test your system before you connect the master drive you can use VOFF VOFF is the offset speed for the electronic gearbox For example if the master drive is not moving and you turn GEAR ON and set VOFF to 100 RPM the position command will increase at a rate of 100 RPM This has the same effect as the encoder option input running at 100 RPM For a 12 bit system this is equivalent tot the master drive rotating at 409 600 counts per minute as 360 degrees is 32 768 counts this is equivalent to 12 5 409 600 32 768 cycles through the cam table every minute PCAM and PCMD The 5 uses a special variable for c
308. ram NOT w ROTARY You attempted to execute an instruction that is not allowed when the BDS5 is in the rotary mode Type ROTARY OFF to turn the rotary mode off This error breaks execution if the instruction was issued from the program OUTSIDE PROTARY You attempted to make an absolute move either MA or MCA beyond PROTARY For example if PROTARY is 1000 and you typed MA 2000 Use incremental moves MI and MCT if you want to move beyond the rotary limit This error breaks execution if the instruction was issued from the program NORMALIZE FIRST SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 D 7 APPENDIX D ERROR CODES ERROR 62 ERROR 63 ERROR 64 ERROR 65 You attempted to turn on the rotary mode when PFB was less than zero or greater than PROTARY Use the NORM command to normalize the position to between 0 and PROTARY This error breaks execution if the instruction was issued from the program RD ALREADY IN USE You attempted to execute RD when RD was in use from some other task This error occurs when two task levels attempt to simultaneously use the RD command This error breaks program execution NOT AT THIS LEVEL You attempted to execute a command that is not allowed at the present task level For example GOSUB and GOTO are not allowed from within an alarm This error breaks program execution BACKWARD REGULATION The external input count
309. re an alarm TOO MANY POINTS BDS5 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 SEVERITY 2 BDS5 APPENDIX D ERROR CODES You specified too many points in a RECORD command Only 1000 points total can be recorded For example if you are recording four variables they can be recorded no more than 250 times since 4 250 1000 D 4 4 Math Errors ERROR 92 ERROR 93 ERROR 94 ERROR 95 ERROR 96 ERROR 97 ZERO DIVIDE You attempted to divide a number by 0 This error breaks program execution if the instruction is issued from the user program MATH OVERFLOW The final result of a calculation or an intermediate result during the calculation of an expression was greater than 231 or less than 231_ This error breaks program execution 22 PARENTHESES The BDS5 evaluated an expression with more levels of parentheses than the BDS5 supports Up to two levels of parentheses are allowed This error breaks program execution UNEVEN PARENTHESES The BDS5 encountered an expression in which the number of closing parentheses was not equal to the number of opening parentheses This error breaks program execution SCALING OVERFLOW During a conversion to or from user units the result was greater than 231 or less than 231 This error breaks program execution if the instruction is issued from the user program GEAR OVERFLOW The BDS5 encountered an overflow when calculating the velocity from th
310. re enabled and either PMAX or PMIN the software limits have been exceeded If your application does not need software travel limits or if you want to disable software travel limits temporarily type PLIM OFF This error breaks program execution SEVERITY 3 SEVERITY 3 SEVERITY 2 SEVERITY 3 SEVERITY 3 SEVERITY 2 D 3 APPENDIX D ERROR CODES ERROR 24 HARDWARE OVERTRAVEL The BDS5 detected an overtravel condition while it was enabled You can print the state of the overtravel limit switch by typing P LIMIT If LIMIT is 0 then an overtravel condition exists LIMIT should be connected to a limit switch that has contacts that are normally closed but which open where an overtravel condition occurs Hardware overtravel limits cannot be disabled This error breaks program execution and disables the BDS5 ERROR 25 PE OVERFLOW The variable PE the position error exceeded the variable PEMAX This is also called a following error overflow This error breaks program execution and disables the BDSS ERROR 26 PFB ROLLOVER The variable the position feedback exceeded 2 147 483 647 counts If you are using position units then PFB exceeded the position unit equivalent of 2 147 483 647 counts This can occur if the motor rotates indefinitely in one direction If your application requires this consider using the rotary mode ERROR 27 R D JUMPERS Either the jumpers on your BDS5 2 card are
311. re important to Industrial Drives Be sure to follow all instructions carefully and pay special attention to safety How TO USE THIS MANUAL CONVENTIONS To assist you in understanding the material in this manual conventions have been established to enhance reader comprehension Explanations of these conventions are as follows e Safety warnings cautions and notes present material that is important to user safety Be sure to read any safety notices you see as they could prevent equipment damage personal injury or even death to you or a co worker e Bold text highlights other important information that is critical to system operations e CAPITALIZED text stresses attention to the details of the procedure e Underlined text emphasizes crucial words in sentences that could be misunderstood if the word is not recognized x DOUBLE BLOCKED text defines words that are to be typed into the computer by the user to interface with the BDS5 u SINGLE BLOCKED text defines words that are displayed by the BDS5 on the computer terminal to inform the user of system operations or problems How TO USE THIS MANUAL ABBREVIATIONS CCW Counter Clockwise CW Clockwise D L Direction Limit GC Goldline Cable GCS Goldline Cable Set LED Light Emitting Diode NEC National Electrical Code P N Part Number R D Resolver to Digital Regen Regeneration TL Test Limits UL Underwriters Laboratories BDS5 NOTICE This manual is the
312. rial communications with It provides the user with up to 750 user registers It provides a real time trace function It provides an electronic cam function It provides a random number generator It provides for using the run command from within the user program for purposes of restarting a program e It provides up to 5 higher position loop bandwidth EXISTING APPLICATIONS Please be aware that register based operations will run approximately 3 msecs slower see next page This could cause a problem with older time critical applications Should this problem occur with older applications please contact the factory for the older firmware version 2 0 6 UPGRADES When upgrading older systems with 3 0 0 be sure to initialize the three new non volatile flags for proper operation ECHO 1 e MSG I e EXTDX 0 750 USER REGISTERS Be aware that while the extra 500 user registers are enabled the PC SCOPE and PC TRACE commands will be unavailable BDS5 version 3 0 0 Firmware BDS5300 DOC Rev4 June 15 1993 MONITOR 011 This will automatically force entry into the Monitor mode at the start of running program MONITOR is set to 0 on Power up ECHO is remembered on Power up MSG 01 Used to suppress the power up message and the Monitor mode message MSG is remembered on Power up PA lt expr gt lt format gt lt text gt Print Append command This command is like the Print command except there is no term
313. rion sisan Rie T6 1 Tuning the BDS5 Yourself 6 4 Variable Units 3 2 8 VCMD VFB VE amp 3 15 Tuning the Position Loop 6 5 Tuning the Velocity Loop ce 6 4 Velocity ERES 3 15 Tuning the Position Loop 6 5 M ipit NPP MA Ea 2o Tunine the Velocity Loo 6 4 Velocity Limits VMAX amp 3 16 s Velocity Limits VMAX amp VOSPD 3 16 ypes Of Data Files sss 2 9 Velocity Loop 3 38 T 1 AL P SOSOTE 4 sesessososesesosossssssesessssssssossssessssseseeseo zh ypical AUTO y WIN 39 Integrating Velocity Loop 3 38 Proportional Velocity Loop 3 38 Index vii BDS5 INDEX Velocity Loop Bandwidth vs KPMAX T6 5 Velocity Loop Bandwidth vs KVI T6 5 Velocity Offset VOFF 3 35 Version Dump ee entend 4 40 i e entes 4 22 WAIT Ws e eiie uuu 5 5 Whole Word I O see 3 10 Zero Position Error ZPE Command 3 24 BDS Command Receiving from the BDS Sneep patre 4 39 Index viii BDS5 UPGRADE NOTICES VERSION 3 0 x FIRMWARE HISTORY FIRMWARE OBSOLETE MC VERSION CURRENT VERSION S O 10 93 030 3 0 0
314. rives and designed especially for the BDS5 Motion Link makes your IBM PC compatible into a smart terminal Of course you can enter BDS5 commands from your computer as if you were using a terminal For example you can start a program with the RUN command and use the PRINT command to display values of variables Motion Link also provides smart features such as a 2 3 CHAPTER 2 GETTING STARTED full screen editor disk storage and retrieval and the communications capture for debugging 2 4 1 Menus and Windows Motion Link s special features are accessed through a menu bar printed at the top of your PC screen When you select an entry from the menu bar a pull down window appears allowing you to select an item Press the F10 key the right arrow key or the left arrow key to display the menu bar You can leave a window or the menu bar by pressing the escape key There are six choices on the menu bar PROGRAM Edit new old 5 programs retrieve a program from disk or from the BDSS VARIABLE Edit new or old BDS5 variable files retrieve variable files from disk or from the BDS5 Variable files contain static assignments A static assignment is an instruction that sets the value of a variable that does not change throughout the program Of course static assignments can be included in your BDS5 power up routine However moving a static assignment from your program to the variable file saves space in your pro
315. rn to multi tasking MANUAL MI 40960 100 TIL EQ PCMD for motion to stop when MANUAL ON incremental END return to multi tasking ERROR O1 ON D 5000 recovery O1 on wait for 5 seconds to let OK2EN settle wait for OK to Enable O1 off enable motor TIL OK2EN EQ 1 O1 OFF EN END PROGRAM CYCLE AND ERROR RECOVERY USING AUTO WITH THE CYCLE INPUT 1 same as power up POWER UP powerup auto start label PLIM OFF off software limits enable motor return to multi tasking MANUAL 0 CYCLE 1 MI 40960 100 move incremental TIL EQ POMD wait for motion to stop END return to multi tasking ERROR O1 ON D 5000 recovery turn O1 on wait for 5 seconds to let OK2EN settle for OK to Enable turn O1 off enable motor return to multi tasking PROGRAM CYCLE AND ERROR RECOVERY USING RUN WITH INPUT 1 1 POWER UP PLIM OFF EN TIL OK2EN EQ 1 powerup auto start label turn off software limits enable motor 2 211 EQ OFF GOTO 2 if 11 0 then loop MI 40960 100 move incremental TIL EQ POMD for motion to stop GOTO 2 loop to label 2 ERROR O1 ON D 5000 recovery turn O1 on for 5 seconds to let OK2EN settle wait for OK to Enable O1 off program restart at label 1 TIL OK2EN EQ 1 O1 OFF RUN 1 return to multi tasking
316. rogram has been uploaded error free gt gt BDS lt cr gt BDS lt cr gt lt lf gt THE 1 gt PROMPT INDICATES THE BDS5 IS READY TO RECEIVE A PROGRAM on gt lt your first program line gt lt cr gt your first program line gt lt cr gt lt lf gt gt lt gt lt gt gt lt last program line gt lt cr gt lt last program line gt lt cr gt lt lf gt l gt lt esc gt lt cr gt lt lf gt secet Recalculation of this checksum by the host is not possible because this is a special word checksum of the BDS5 s internal program memory with a varying offset As stated earlier the most efficient method of exploiting this checksum is to upload the BDS5 program print out the checksum variable and then use that value for comparison of future uploads gt P CHECKSUM lt cr gt P CHECKSUM cr If lt 7 sp gt 65280 lt cr gt lt lf gt ir d YOU CAN ALSO PRINT THE CHECKSUM IN HEX gt P CHECKSUM H cr P CHECKSUM H lt cr gt lt lf gt lt 4 sp gt FFOOH lt cr gt lt lf gt 26 UPLOADING amp DOWNLOADING SYSTEM VARIABLES The BDS5 can print to the serial port two groups of internal variables The first group is all of the variables The second group is a subset consisting of compensation specific variables DUMP will print to the serial port all variables from the BDS5 DUMP will print to the serial port the compensation specific variabl
317. ror DO NOT TYPE IN THIS EXAMPLE NEW The NEW command also clears the editor password The gt BDS command which is discussed later in this Chapter will also reset the program so that it is no longer corrupt although it will not clear the password 4 4 BUILDING A PROGRAM Programs are sequences of commands most of which can also be executed directly from the keyboard A program stores the sequences of these normal commands Examples of these commands are MI MA and P Print However in order for a program to run properly other commands called program control commands are required Examples of these commands are GOTO and GOSUB 4 9 CHAPTER 4 USER PROGRAMS 4 4 1 Basic Commands 4 4 1 1 Labels Labels are used to mark places in the program where execution begins or continues There are two kinds of labels general purpose labels and dedicated labels General purpose labels are numbers from 0 to 500 followed by a dollar sign You can execute a program that begins at a general purpose label with the RUN command You can jump to a label from within your program with the GOTO and GOSUB commands RUN GOTO and GOSUB are described later in this chapter Dedicated labels each have specific functions Dedicated labels include alarms auto programs and the user error handler These labels are letters or words followed by a dollar sign For example A is the A Alarm label Dedicated labels cannot be used by t
318. ror from a D A converter Here we use it to simplify the test without VOFF testing would require a second motor be connected to the gearbox 4 Loop control Lines 35 37 58 61 5 Calculate which segment this iteration is in it repeats from segment 0 to segment 127 every 128 iterations and store it in X2 Line 38 6 Determine PCMD at the end of the segment Line 40 7T Wait until PCMD reaches the boundary Store the commanded position PCAM Lines 45 53 8 Calculate error between what the command is X4 and what is should be X X2 9 Subroutines to print whether iteration tested good or bad Lines 63 70 15 Q 16 CAM TEST PROGRAM FOR THE BDS5 TEST ghe 7 16 92 use voff set to keep moving at a constant speed Selected that speed to be 20 RPM which is about 1365 counts second The entire cam cycle is 32768 counts Each of the 128 segments is 256 counts So 20 RPM cycles through the cam cycle at one cycle per 32768 1365 seconds or 24 seconds Each of the 128 cycles requires 24 128 or 187 msecs 18 This section loads cam variables with triangular profile where each segment is different from the last by 100 counts First load variables x100 x164 100 starting variable 2 sloop beginning X X1 X1 100 100 load the up side of the triangle X1 XI I increment the loop counter x1 le 164 goto 2 test loop keep going until X164 Now load
319. s 4 38 pplication Flowchart 4 3 Aprlicati 4 38 pplication Specification 4 3 D Multidrop Communications 4 40 Commented Program 4 5 Prot ptSz ose Ut Dt 4 39 Customer Service 4 6 E mesa Serial Watchdog 4 39 xample Application 4 3 Prompts 2 9 System Dump 4 40 ee hee 4 39 SERIAL Switch 421 roportional Velocity Loop 3 38 Serial Watchd 4 39 PROTARX A 4 37 oe 2 PSR4 5 Model Number s 1 6 Master Slave 8 4 33 PSR4 5 Model Number Scheme F1 6 Settine the BDS5 to Autobaud 4 38 PSR4 5 Model Number Scheme T1 6 PAE E 7 Simplified Schematic Diagram and System Diagram sss 1 13 N Q x Single Step yas qasasqa nee ien 5 1 Single Step Mode 2 12 Quick IF Command 4 11 SIZE 4 9 x R Software Installation
320. s enabled 3 8 3 Profiles When a positioner commands the motor to move from one point to another it must control acceleration deceleration and traverse speed The velocity of the motion versus time is called the profile Simple profiles begin and end at zero speed and have three segments acceleration traverse and deceleration You must specify ACC the acceleration rate and DEC the deceleration rate before commanding the move The traverse speed and the distance to move are specified in the move command itself DOCK COUNTS Figure 3 2 A Simple Profile The graph in Figure 3 2 shows a simple profile The move begins at position 0 and ends at position 5000 The traverse speed is 200 RPM ACC and DEC are specified independently before the move is commanded 3 8 3 1 S Curves The BDS5 also allows you to specify the type of acceleration you want You can select S curve accelerations for smoothness or straight line accelerations for quickness The graph in Figure 3 3 shows the profile from Figure 3 2 using S curves instead of straight lines BDS5 Figure 3 3 S Curve Profile Notice that ACC and DEC are still independent Notice also that they specify the average acceleration not the peak Since S curves reduce the acceleration rate at the endpoints of the acceleration the acceleration rate in the middle must increase Typically when you switch to S curves you must reduce ACC and DEC to stay within the ra
321. s 100 program labels 50 user definable variables and 50 user definable switches It also has 15 mathematical logical operations and over 150 system variables e USER UNITS 1 2 BDS5 Quantities such as position velocity and acceleration are automatically scaled into user defined units This feature lets you program the BDS5 in convenient units such as feet inches miles RPM and degrees e SUPERIOR SERVO LOOP CONTROL The 5 offers smooth high resolution control Standard BDS5 position repeatability is better than one arc minute bidirectional The BDS5 has a 32 bit position word The BDS5 position loop completely eliminates the digital dither normally associated with positioning systems Long term speed stability is 0 0196 The standard system converter 12 bit provides a resolution of 0 0005 RPM and a maximum speed of 8000 RPM e SELF TUNING The BDS5 can tune itself You do not have to be a servo expert to set up a system quickly Just specify the desired bandwidth and let the BDS5 do the rest e POWERFUL MICROPROCESSOR The heart of the BDS5 is the 16 bit processor that delivers high performance The result the BDS5 can control a motor and execute its motion program faster than a standard positioner can DIGITAL SERVO LOOPS Both the position and velocity loops are totally digital The digital loops give the BDS5 features not available in standard velocity drives such as self tuning very low velocity
322. s are covered in later chapters 2 13 BDS5 eye 3 PROGRAMMING LANGUAGE 3 1 INTRODUCTION This chapter discusses the basics of the BDS5 and its programming language Your BDS5 system should be mounted and wired as described in the Installation and Setup Manual The AC Line voltage to your PSR4 5 should not be turned on for examples in this chapter Turn on Control Power only and establish communications If the proper connections are not made or the terminal is not communicating then see the Installation and Setup Manual AC LINE SHOULD NOT BE TURNED ON WARNING 3 2 INSTRUCTIONS The BDS5 can respond to instructions entered from the terminal The format of the instructions is usually a command followed by one or more parameters For example the jog instruction is a J followed by one parameter the desired speed J 10 would cause the motor to jog at 10 RPM CHAPTER 3 PROGRAMMING LANGUAGE The command and parameter must be separated by at least one space 3 2 1 Comments Instructions can be followed by comments on the same line A semicolon marks the beginning of a comment The BDS5 ignores everything on the line after the semicolon For example J 10 THIS IS A GOOD COMMENT is a valid instruction The BDS5 ignores everything that follows the semicolon Note that a space must separate the semicolon from the last parameter J 10 BAD COMMENT MUST PRECEDED BY A SPACE GOOD LINE
323. s are special purpose labels A A alarm label B B alarm label C C alarm label VARIABLE variable input label POWER UP power up label AUTO AUTO label MANUAL MANUAL label ERROR error handler label BACKGROUND background label Alarm labels require that you specify the switch that starts the alarm and the state of the switch ON or OFF that should trigger the alarm If the switch is in the specified state when execution is enabled the alarm will be fired Otherwise the alarm is edge sensitive Specifying ON is actually specifying the positive edge Format lt Label gt lt Alarm Label gt lt Switch gt lt On Off gt Example 55 BACKGROUND A 11 ON C 3 4 BDS5 CONTINUE DUMP APPENDIX C SOFTWARE COMMANDS Quick If Conditionally executes one instruction if the condition is true and another instruction if the condition is false Allowed from the interactive and monitor modes and the user program Format Condition Instruction Instruction Example PFB GT 100 P PFB EQ 1 P X1z 1 P lt gt 1 X1 X2 NE X4 X5 5 LIMIT EQ ON P LIMIT IS OFF Condition is the same as Expr Logical lt gt Instruction is any instruction except TIL Break program execution Allowed from the user program or the monitor mode Format B Continue motion at the present speed Turn REG and GEAR off Optionally you can specify the
324. s case the decimal point following the is incorrect Pay careful attention to the rules for formats in Chapter 4 This error breaks program execution if the instruction is issued from the user program INVALID INSTRUCTION SEVERITY 2 You attempted to execute an instruction or change a variable that the BDS5 does not recognize This error breaks program execution if the instruction is issued from the user program NOT PROGRAMMABLE SEVERITY 2 You attempted to change a variable that is not programmable This error will break program execution if the instruction is issued from the user program BAD NUMBER ENTRIES SEVERITY 2 The instruction that is executing has too many or too few parameters Look up the instruction in Appendix B to determine the correct number of entries This error breaks program execution if the instruction is issued from the user program BAD OR OUT OF RANGE SEVERITY 2 You entered a parameter to an instruction that was too large or too small Check Appendix C for limits on variables This error can also occur when a parameter is in the wrong format such as a character string where a number is expected This error breaks program execution if the instruction is issued from the user program OUT OF BOUNDS SEVERITY 2 The variable listed is out of bounds If the variable is protected that is set by the factory as defined in Appendix C contact the factory If the variable is not protected
325. s makes the line a comment so that when the line is re transmitted it has no effect If the were not there re transmitting the dump information would generate an error when a protected variable was changed Every line of the user program is preceded with a semicolon for the same reason 4 10 5 1 Version Dump Your BDS5 will print out its firmware version at any time with the DUMP VERSION command DUMP VERSION 4 10 6 Multidrop Communications This function is not available for the RS 232 option NOTE Multidrop communication allows you to have many up to 32 axes on one serial line This is only supported with RS 485 When the BDS5 is in Multidrop mode each axis must have a unique address This address is a prefix on all communications to and from the BDS5 The address is stored in variable ADDR ADDR is set to 0 for standard single drop communications Valid addresses are 48 ASCII 0 through 57 ASCII 97 and 65 ASCII A through 90 ASCII 77 see BDS5 Appendix B Note that the address must be set before multiple units are connected to the same serial line When the BDS5 powers up in Multidrop mode it is asleep When asleep the 5 continues to execute programs and control the motor properly but it does not communicate over the serial line The BDS5 executes commands which normally print to the serial port P PS R RS INPUT and errors except that the output is not sent to the serial transmitt
326. s normally entered from either the Interactive mode the RUN command or from multi tasking If the power up label POWER UP is present the BDS5 will start running your program at that label on power up Also the BDS5 will exit the Run mode to the Monitor mode if the escape key is pressed Errors can also cause the BDS5 to change modes Some errors are serious enough to cause the BDS5 to break program execution Usually this has the identical effect of issuing BREAK B command As an option you can write an error handling routine beginning at label ERRORS This routine should be short and should end with a BREAK B command The error handler is intended for graceful error recovery For example you can set outputs or print a message It is not intended to continue the program as if the error never occurred 2 6 2 3 Monitor Mode The BDS5 Monitor mode is a unique mode for positioners In this mode the user program is running but commands are accepted from the terminal for immediate execution The Monitor mode allows you to display and change variables during program execution including tuning variables You can print any variable and change any programmable variable from the Monitor mode The commands that are allowed from the Monitor mode are a subset of the commands allowed from the user program and Interactive modes and include the following commands Table 2 4 Monitor Mode Commands In the Monitor mode all print
327. s parent Kollmorgen Corporation continue to rank first in servo technology Other achievements Yes too many in fact to mention Each achievement stands as a testimony to the committed quality and excellence in design technology This constancy of purpose is unyielding in an era of rapidly changing technology BDS5 How To USE THIS MANUAL INTRODUCTION This User s Manual is designed to help you properly operate a BDS5 Servo System You do not have to be an expert in motion control to utilize the system however this manual does assume you have the fundamental understanding of basic electronics and motion control concepts Many of these are explained in the glossary of this manual The BDS5 is a programmable motion control device An understanding of computer programming techniques will be beneficial to all users For applications that require complex programs a professional programmer should be consulted RECOMMENDATIONS It is recommended that you read this entire manual before you attempt to operate the BDS5 so you promptly find any information you need This will also familiarize you with system components and their relationship to one another After installation and before you apply your own application check all system functions and features to insure you have installed your BDS5 properly These instructions are intended to aid you to administer the BDS5 to your own applications Your safety and satisfaction a
328. s the command is entered Usually you will want the traverse to begin at the end last specified acceleration segment For example consider the Macro Move Example 1 in Chapter 3 It could have been done with one JOG and two JOG TO commands START MOTION WAIT TIL JOG ACCEL IS DONE ENTER JT FOR FIRST DECEL JT 10000 200 W 3 WAIT TIL JT DECEL 15 DONE ENTER FINAL SEGMENT OF MOVE JT 11000 0 5 5 5 Gating Motion with GATE The GATEMODE variable allows you to pre calculate a profile and begin motion within 1 5 milliseconds of a switch closure To enable GATE turn on GATEMODE and follow it with either 1 One or two MA or MI commands 2 Oneortwo Macro Go MCGO commands or 3 Jog or MRD command When the hardware input GATE transitions from low to high motion begins GATE is on Connector C7 Pin 17 After motion is begun GATEMODE is turned off You must re enable GATEMODE for each move that you want gated Also you cannot turn GATEMODE on when motion is commanded from Jogs MA MI or MCGO commands If you turn GATEMODE on and command motion but turn GATEMODE off before the GATE input turns on 5 6 BDS5 thus allowing motion to begin the commanded motion will be forgotten by the BDS5 In the following example two MI commands are entered and precalculated with GATEMODE on GATEMODE ON MI 1000 100 ENABLE GATING PRECALC MOVES MOTION MI 1000 DELAYED TIL GATE IS HIGH W 0 WA
329. se angle of a system at the frequency where the open loop gain is unity PID Proportional Integral Derivative An acronym that describes the compensation structure that can be used in a closed loop system PLC Programmable Logic Controller An industrial control device that turns on and off outputs based upon responses to inputs PMDC Motor A motor consisting of a permanent magnet stator and a wound iron core rotor These are brush type motors and are operated by application of DC current Point to Point Move A multi axis move from one point to another where each axis is controlled independently No coordination between axes is required Pole A frequency at which the transfer function of a system goes to infinity Pole Pair Electromechanical The number of cycles of magnetic flux distribution in the air gap of a rotary electromechanical device Position Error The difference between the present actuator feedback value and the desired position command for a position loop Position Feedback Present actuator position as measured by a position transducer BDS5 GLOSSARY Power The rate at which work is done In motion control Power Torque x Speed Process Control A term used to describe the control of machine or manufacturing processes especially in continuous production environments Pull In Torque The maximum torque at which an energized stepping motor or synchronous motor will st
330. second of a two part manual structure The Installation and Setup Manual is intended to instruct the user on the installation procedures and practices to be used with the BDS5 TABLE OF CONTENTS TABLE OF CONTENTS CHAPTER 1 SYSTEM DESCRIPTION 1 1 Introductions 1 1 1 2 Product Description 1 1 1 3 Features DERI 1 1 1 4 Part Number Description 1 3 1 4 1 BDS5 Model Number 1 4 1 4 2 Compensation Module Model Number 1 5 1 4 3 5 4 5 Model Number 1 6 1 4 4 ER External Resistor Kit Model Number 1 7 1 4 5 Molex Assembly Tools 1 7 1 5 Specifications and Ratings 1 8 1 6 Theory of Operation 1 12 1 7 Simplified Schematic Diagram and System Diagram 1 13 CHAPTER 2 GETTING STARTED 2 1 Introductions 2 1 2 2 Computer Requirements 2 1 2 3 Software Installation sees 2 1 2 3 1 Backing Up the 015 5 2 1 2 3 2 Software Installation 2 2 2 3 2 1 Install on a Hard Disk 2 2 2 3 2 2 Install on a Floppy Disk 2 2 2 3 3 Establishing Communications
331. sed to equate any system variable to any valid math expression Valid math expressions include user variables indirect references to user variables constants algebraic and logical math operators parentheses Parentheses can be nested up to two levels deep Spaces are not allowed in expressions P lt expr gt lt format gt lt text gt Print command Used to print strings and variables specified with the optional format terminated by a lt cr gt lt If gt sequence Also see the RS and PAS print commands PS lt expr gt lt format gt lt text gt 1 Print Status command Used to print strings and variables specified with the optional format terminated by the drive status and a lt cr gt lt lf gt sequence R lt expr gt lt format gt lt text gt Refresh command Used to print strings and variables specified with the optional format terminated by a lt cr gt This command identical to the P command except there is only a terminating cr Also see the PS and PAS print commands RS lt expr gt lt format gt lt text gt Refresh Status Used to print strings and variables specified with the optional format terminated by the drive status and a cr 30 BDS5 COMMUNICATIONS The BDS5 will communicate over an RS 232 serial bus with simple ASCII commands Each ASCII character transmitted to the BDS
332. shown here These commands are not meant to represent the worst case but are only provided as an estimate of the execution times times are based on tests run at Industrial Drives Electronic Lab Reference Test 67 of May 21 1990 F 1 BDS5 GOSUB 10 GOTO 10 JT 50000 1000 JF 50000 1000 4096 100 MA 4096 4096 100 4096 MCI 10000 1000 200 MCI 1000 0 MCGO MRD 1000 100 CW O1 ON O1 OFF OUTZOUT 0C8H NORM 0 P P X1 8 P 1 RET TIL 1 EQ 0 X1 X2 X1 X2 1 X1 X2 1 X1zX2 100 X1zX2 100 ZPE 1 EQ 1 O1 ON IF 1 EQ 0 X1z1 ELIF 1 EQ 0 X122 ELSE X1 3 ENDIF 10 F 2 31 6 MSEC 31 6 MSEC APPENDIX F COMMAND TIMINGS 35 8 MSEC CALCULATION TIME ONLY 35 8 MSEC CALCULATION TIME ONLY 35 5 MSEC CALCULATION TIME ONLY 35 0 MSEC CALCULATION TIME ONLY 35 8 MSEC CALCULATION TIME ONLY 35 0 MSEC CALCULATION TIME ONLY 311 0 MSEC FOR ALL 3 COMMANDS CALCULATION TIME ONLY 33 5 MSEC 31 9 MSEC 31 9 MSEC 32 8 MSEC 32 0 MSEC 33 5 MSEC 33 5 MSEC 33 8 MSEC 30 8 MSEC 32 6 MSEC 31 7 MSEC 32 2 MSEC 32 2 MSEC 32 3 MSEC 32 3 MSEC 31 0 MSEC 34 0 MSEC 19 0 MSEC ALL 7 LINES 1 0 MSEC BDS5 GLOSSARY LOSSARY Absolute Position Position referenced to a fixed zero position Absolute Positioning Refers to a motion control system employing position feedback devices absolute encoders to maintain a given mechanical loc
333. sired operation Table 4 3 Desired Operation of Program Example PFB RANGE MESSAGE TO PRINT PFB 50 PFB TOO LARGE PFB TOO SMALL PFB WITHIN RANGE PFB 50 50 lt PFB lt 50 The IF ELIF ELSE and ENDIF commands implement the desired functions 4 14 BDS5 IF PFB GT 50 O1 OFF BEGIN BLOCK IF O1 MEANS WITHIN RANGE P PFB EXCEEDED MAXIMUM PRINT ERROR MESSAGE ELIF PCMD LT 50 CHECK THE NEGATIVE LIMIT P PFB EXCEEDED MINIMUM PRINT ERROR MESSAGE O1 MEANS WITHIN RANGE HERE WITHIN O1 OFF TURN ON O1 P PFB WITHIN RANGE PRINT MESSAGE ENDIF END OF BLOCK IF This example could have been written with commands as the following program shows Notice that the program requires more lines uses 3 labels and is harder to read that is less intuitive PFB LE 50 GOTO 10 START OF BLOCK EXECUTE BLOCK gt 50 EXCEEDED MAXIMUM DONE GO TO END O1 OFF PFB GE 50 GOTO 11 sEXECUTE BLOCK PFB 50 P PFB EXCEEDED MINIMUM O1 OFF GOTO 20 DONE GO TO END 11 GET HERE IF WITHIN RANGE O1 ON P PFB WITHIN RANGE 20 END OF BLOCK You can choose whether to use or the IF command when you are writing your program You should choose the command that results in the most readable form For example if multiple commands are to be executed the IF command s block structure sets off the commands and avoids the use of a GOT
334. sitions printing PRD each time Notice that PRD changes for each position 3 7 2 4 Sampling PFB PCMD and PEXT When PFB and PCMD are used on the same line they are always sampled during the same sampling interval millisecond This allows you to use PCMD PFB and a third variable called PEXT which is discussed later in this chapter without concern that the variables might be sampled at different times For example P PCMD PCMD PFB CHAPTER 3 PROGRAMMING LANGUAGE This command would print the expected results This is because the BDS5 stores PCMD and at the beginning of every command then uses those stored values when the command is executed On the other hand if you type P PCMD PRD PCMD PRD the results may not be as expected This is because PRD is not stored at the beginning of the command If the motor is turning the two references to PRD will produce different results This command takes up to 6 milliseconds to execute and PRD can change several times while this command is executing 3 7 3 Velocity 3 7 3 1 VCMD VFB VE amp VAVG VCMD is the commanded velocity Like PCMD VCMD is generated internally from motion commands VCMD is zero when the BDSS is disabled VCMD is in velocity units VFB is the feedback velocity It is updated every millisecond VFB is always active even when the BDSS is disabled if you turn the motor shaft by hand and print VFB on the terminal you
335. specially at low speeds Command Position The desired angular or linear position of an actuator BDS5 GLOSSARY Commutation A term which refers to the action of steering currents or voltage to the proper motor phases so as to produce optimum motor torque In brush type motors commutation is done electromechanically via the brushes and commutator In brushless motors commutation is done by the switching electronics using rotor position information typically obtained by hall sensors a tachsyn a resolver or an encoder Commutator A mechanical cylinder consisting of alternating segments of conductive and insulating material This cylinder used in DC motors passes currents from the brushes into the rotor windings and performs motor commutation as the motor rotates Compensation The corrective or control action in a feedback loop system which is used to improve system performance characteristics such as accuracy and response time Compensation Feedforward A control action which depends on the command only and not the error to improve system response time Compensation Integral A control action which is proportional to the integral or accumulative time error value product of the feedback loop error signal It is usually used to reduce static error Compensation Lag A control action which causes the lag at low frequencies and tends to increase the delay between the input and output of a system while decreasin
336. st one hundred generally they are above one thousand make sure ILIM is not too small If ILIM is below 10 the motor may not be able to overcome frictional load make sure you are commanding a speed that you can see The BDS5 can command speeds as low as 0004 RPM or about one revolution every three days depending on how you program velocity units If you have changed VNUM or VDEN from the factory setting temporarily restore them to see if the problem goes away If the motor moves and you get PE OVERFLOW error ERROR 25 the error occurs occasionally it may be because you have the limit PEMAX set too low Raise it by 2096 and see if the problem is corrected use the BDS5 RECORD function to record ICMD when a PE overflow occurs If ICMD is saturating that is equal to ILIM for more than a few milliseconds you are commanding motion that your motor cannot perform See hints on motor loading ILIM ACC DEC and PEMAX below If the overflow occurs at high speeds and with low ICMD below ILIM see the hint about speed problem make sure that the load does not exceed the capability of the motor make sure that ILIM is set high enough if you get the error during acceleration or deceleration make sure ACC and DEC are not set too high If they are too high the commanded profile will exceed the capability of the motor CHAPTER 5 DEBUGGING you get the error during constant s
337. statement prints both X1 and PFB on one line and should show them to have approximately the same value Note that when the motor is disabled the position feedback can change slightly so there may be a small difference in the values Turn the motor about one half of a revolution and repeat the print statement from above Notice that X1 has remembered the old position feedback while PFB has changed X1 will not change unless you assign it a new value 3 3 10 1 Indirect User Variables An advanced method of accessing the values stored in user variables is called indirect With indirect user variables the specified user variable points at another user variable Indirect references to variables have the format X Xn where n is between 1 and 250 The value stored in the variable Xn specifies the variable that X Xn refers to This is best illustrated with an example Suppose you want to look at either X1 or X2 when X10 is either 1 or 2 Type this example 1 100 2 1000 10 1 USE X10 TO POINT TO X1 P X X10 PRINT WHAT X10 POINTS The 5 responds 3 7 CHAPTER 3 PROGRAMMING LANGUAGE since X X10 X1 100 Now type X10 2 TO X2 USE X10 TO POINT P X X10 PRINT WHAT X10 POINTS The 5 responds since X X10 is now X2 which equals 1000 So printing X10 indirect X X10 prints the user variable to which X10 points not X10 itself Indirect user variables are often used
338. sum gt is an eight bit checksum of the command string represented by two ASCII hex characters example P PFB48 lt cr gt sprint the feedback position P PFB48 lt cr gt lt lf gt lt ack gt gt string received echoed acknowledged and prompt returned Command P F Checksum Hex 5 20b 50h 46h 4h Decimal 80 32 so 70 66 328 148h To calculate the checksum each ASCII byte in the command should be summed excluding the cr then drop all but the least significant byte this is the serial checksum So the checksum of is 48 The only difference between this convention and that of the normal BDS5 is the addition of a checksum The checksum will consist of a hex byte represented by two ASCII characters 0 9 A F or a f If the command is valid and checksums the BDS5 will execute the command and will respond with lt command string gt lt checksum gt lt cr gt lt lf gt lt ack gt gt where lt ack gt 4F 06h 06d If a checksum error is detected then the BDS5 will ignore the command and will respond with lt command string gt lt checksum gt lt cr gt lt lf gt lt nak gt gt where lt gt 0 15 214 A 16 bit checksum of the contents of the BDS5 program memory can also be printed to the serial port This checksum is contained in the variable PGMCKSUM It can be displayed by entering
339. t label ERRORS This routine should be short and should end with a Break B command ERRORS is provided as a graceful end to program execution and not as a means of automatically restarting the program The program can be restarted using the AUTO and the CYCLE input For example you can set outputs or print a message It is not intended to continue the program as if the error never occurred ERRORS The BDS5 responds to a variety of conditions both internal and external hardware and software which are grouped in a single broad category errors An error indicates that there is a problem somewhere More serious errors are grouped as faults The BDS5 s response to an error depends on the severity There are four levels of severity listed below in increasing order ERROR SEVERITY LEVELS AND ACTIONS Errors which cause warnings Errors which cause a program break and stop motion in addition to Level 1 Actions Errors which disable the system and set the FAULT LED in addition to Level 2 Actions 4 Errors which disable almost all BDS5 functions including communications and flash the CPU LED to indicate the error number These are called firmware errors ERROR MESSAGES When any error except a firmware error occurs a message is displayed to the screen The following items are printed the error number the offending entry and an abbreviated error message For example disable the drive and type in a jog
340. t confuse these faults with autobauding on power up When autobauding the CPU LED blinks at a constant rate about three times per second 3 6 2 Fault Logic Area 2 The large OR gate in Area 2 combines three types of faults hardware software and firmware The circuits that generate these faults are typical of motor controllers and are listed on the drawing These faults are errors that are serious enough to disable the BDSS as described in Appendix D 3 6 3 Fault Latch Area 3 The latch in Area 3 turns on the FAULT LED the FAULT software switch and the FAULT output on Connector C8 Any fault sets this latch you can also write your program to turn it on if you detect a fault condition The fault latch can be reset by 1 Turning FAULT off 2 Typing the enable command EN or 3 Powering down the BDS5 CHAPTER 3 PROGRAMMING LANGUAGE 3 6 4 Ready Latch Area 4 Area 4 shows the logic required to make the drive ready If there are no faults the EN command sets the ready latch This turns the READY software switch on This latch is reset with the KILL K command the DISABLE DIS command or a fault These turn READY off 3 6 5 ACTIVE Area 5 Area 5 shows that ACTIVE will be on if both READY and REMOTE are on This turns on the ACTIVE LED It also allows the BDS5 to actively control the motor REMOTE Remote Enable is an isolated input that is accessed from Connector C2 on the front of the drive You can print
341. t is releasing new beta level proms that fix some operational problems with error recovery These proms are replacements for the current factory default prom version 3 0 1 The new prom is labeled 3 02b The b indicates this prom is still in beta release until the BDS5 firmware qualification tests are finished This prom has passed our initial qualification tests This prom is being released early in an attempt to help our customers Please immediately forward any feedback from testing this prom to our field service group your success is very important to us The following changes have been made to the firmware e The user flag MSG when cut off will suppress any printing of error messages This is in addition to its suppressing the power up message the running program message and the Entering and Exiting Monitor mode message The Monitor mode will now be properly canceled by any error that is not directly caused by the Monitor mode This fixes the problem with the error handler hanging until control of the serial port is returned from the Monitor mode thus allowing the error message to print to the serial port Now the printing will be allowed and the error handler as a final step can pass execution to the ERROR label This modification also prevents a print command from within the ERROR from hanging the error handler NOTE Since an error will cancel the Monitor mode multiple errors in fast succession could cause problems with enter
342. t lost when the 5 is powered down User programs are composed mostly of the commands that have been described in earlier chapters In addition there are commands necessary for controlling the way the program executes these commands are covered in this chapter The first section describes the BDS5 Editor which allows you to enter and modify programs from the terminal If you have not already done so read Chapter 3 before proceeding This manual is written to be read sequentially Do not attempt to save time by skipping ahead to this chapter READ THIS ENTIRE SECTION CAREFULLY This section discusses programming practices The BDS5 has a flexible language You must follow proper programming principles to insure that the flexibility does not lead to overly complex programs If you follow good programming practices you will be able to modify programs when the application changes have fewer programming errors have an easier time fixing the programming errors that do occur and be able to get help with errors you cannot fix People who are new to programming often disregard good programming practices because they have not experienced the problems that result from poor programming practices Save yourself the misery of having to re write your entire program Follow these steps 1 DO NOT PROGRAM SAFETY FUNCTIONS Always hardwire personal safety functions Never WARNING program these functions
343. t refresh the display BDS5 TIL PFB GT 10000 TIL can be used to delay program execution NOTE More examples of the command are TIL 11 EQ ON DELAY EXECUTION TIL 11 EQ ON P PRESS INPUT 1 TIL SEG EQ 0 DELAY UNTIL MOTION STOPS TIL SEG EQ 0 P PFB PRINT UNTIL MOTION STOPS 4 4 2 4 IF ELIF ELSE and ENDIF Commands The IF command together with ELIF ELSE and ENDIF will allow you to conditionally execute large blocks of commands These commands are provided because the command which is limited to a single line does not provide the most efficient means to control blocks of commands You can use the IF command to write more readable and thus less error prone programs The format of the IF ELIF ELSE and ENDIF commands follows Note that the conditions have the same format as the conditions for the TIL and commands Note also that block can indicate any number of commands IF IF condition Block IF ELIF ELIF condition 1 ELIF block 1 ELIF ELIF condition 2 ELIF block 2 ELSE ELSE block ENDIF The above example shows two ELIF commands You can have any number of ELIF commands The operation of this example IF command is as follows If IF condition is TRUE commands in the Block IF are executed No other blocks are executed even if some or all of the other conditions are true CHAPTER 4 USER PROGRAMS Program execution continues after the ENDIF comm
344. t terminated by no characters 31 Additionally for more communications capabilities following commands have been added to firmware version 3 0 0 NEW BDS5 SERIAL COMMANDS Firmware Version 3 0 0 and Later MONITOR 011 This will automatically force entry into the Monitor mode at the start of running a program MONITOR is set to 0 on Power up ECHO is remembered on Power up MSG 011 Used to suppress the serial Power up message and the Monitor mode message MSG is remembered on Power up PA lt expr gt lt format gt lt text gt Print Append command Used to print strings and variables specified with the optional format This command identical to the P command except there is no terminating lt cr gt lt If gt sequence Also see the PS and RS print commands PAS lt expr gt lt format gt lt text gt Print Append Status command Used to print strings and variables specified with the optional format terminated by the drive status This command is identical to the PS command except there is no terminating lt cr lt lf gt sequence Note the BDS5 now has a full set of Print commands These commands are P PS R RS PA and PAS The only differences being the P and PS commands terminate the output string with a lt cr gt lt lf gt the R and RS commands terminate the output string with just a cr and the PA and PAS commands do not terminate the output stri
345. te with the BDSS Similarly the 5 will not accept input unless gt has been issued by the BDS5 The INPUT command is the only exception to this rule This rule can be awkward if you are using the BDS5 from a terminal if an error occurs during the interactive or monitor modes after the gt has been displayed the BDS5 will not print the error message until a carriage return or escape has been entered The prompt for each mode is listed below The only exception is the Run mode This mode does not have a prompt since input is not accepted from the serial port Notice that the trace prompt does not end with the gt This is because the trace prompt does not indicate that the 5 is waiting for input If the BDS5 is communicating within a multidrop communication line then the prompt is modified to include a prefix which indicates the axis address The table below shows the prompts in both the normal non multidrop and multidrop configurations Note that the multidrop address is 65 or ASCII A Table 2 3 BDS5 Prompts Mode Non multidrop Multidrop ADDR 0 ADDR 65 Interactive Monitor Single step Trace Edit Load Edit Insert Edit Find Edit Change 2 6 2 Descriptions of Modes The following section describes each of the modes of operation Refer Figure 2 2 which is a diagram 2 10 BDS5 showing each mode and how it interacts with the other modes 2 6 2 1 Interactive Mode The BDS5 normally po
346. ter The low pass filter is often required to reduce noise or torsional resonance Leave at initial setting for preliminary operation Set to 1 if system is too noisy The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Low pass filter break frequency The low pass filter is often required to reduce noise or torsional resonance Leave at initial setting for preliminary operation Reduce value if system is too noisy The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Enable multi tasking General purpose outputs Reset to 0 on power up These variables are discussed later in this chapter Position units denominator Initially set to 1 Position error limit for clamping Initially set to 100 Value of this variable does not matter if CLAMP is 0 during preliminary operation Position error limit for system This variable is initially set to 32767 its upper limit for preliminary operation and can be reduced later 3 5 CHAPTER 3 PROGRAMMING LANGUAGE PEXT PL PLIM PMAX PMIN PROMPT PNUM PROP PXDEN PXNUM 3 6 PEXT monitors the position of the external master axis Initially this variable is undefined Value of this variable does not matter during initial operation Enable position loop This variable is set to 1 on power up and left at 1 for preliminary operation Enable software
347. testing most BDS5 functions 2 6 PROCESSOR MODES 2 6 1 Prompts The BDS5 provides several modes of operation Each mode is distinguished by a unique prompt A prompt is the short series of characters that the BDS5 writes to the screen asking you for input For example the interactive prompt is gt This prompt is unique and tells you that the BDS5 is in the Interactive mode The BDS5 is designed to receive commands from a terminal or a computer through a serial port In order to support computer communications the BDS5 observes the following conventions Table 2 2 BDS5 Rules For Prompts Prompts are 3 characters long except single step and trace Prompts end with a greater than gt Each mode has a unique prompt Once the BDS5 displays a prompt it stops transmitting until a new instruction and or a carriage return is received These conventions are designed to allow efficient communications between the BDS5 and a computer The last rule ensures that there is never a question about which device is transmitting If a gt has been issued from the BDS5 then the BDS5 will not transmit anything until a carriage return or escape has 2 9 CHAPTER 2 GETTING STARTED been entered The only exception is if you program the BDS5 to print a gt from a PRINT or INPUT command The BDS5 will allow gt in print statements though this is considered a poor practice if you are using a computer to communica
348. th 15 25 current so you can set ILIM as low as 15 or 25 during preliminary operation Current units numerator Initially set LPFHZ to 4095 for percent Low speed graininess compensation Almost always set to 200 See discussion in the Installation and Setup Manual where a procedure for fine tuning this variable is given Tuning gain for velocity feed forward Set to 0 for preliminary operation Tuning gain for position loop Leave at initial setting for preliminary operation The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Use TUNE command to change if necessary Tuning gain for proportional velocity loop Leave at initial setting for preliminary operation The initial value is listed on the Test and Limits TL sheet which should be enclosed PDEN PECLAMP PEMAX PROGRAMMING LANGUAGE with your system Use TUNE command to change if necessary Tuning gain 1 for integrating velocity loop Leave at initial setting for preliminary operation The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Use TUNE command to change if necessary Tuning gain 2 for integrating velocity loop Leave at initial setting for preliminary operation The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Use TUNE command to change if necessary Enables low pass fil
349. that were captured select EDIT in this menu 241 4 Scope VIEW AGAIN This selection lets you view playback data that was previously retrieved from the BDS5 FROM DISK This selection retrieves recorded data from your computer disk Motion Link will display all of the playback files currently on your disk and allow you to choose the file you want Playback files have the file type CSV for comma separated variables This format is compatible with most spreadsheets FROM BDS5 This selection retrieves playback data stored in the BDS5 After the playback data is retrieved the data is plotted and stored on disk VIEW DATA View the data in numerical rather than graphical format PRINT PLOT Print the plot on a line printer 2 4 1 5 Options SELECT AXIS This selection allows you to select options that are available to systems using RS 485 communications BDS5 PASSWORD This selection allows you to enter the password that you set in the BDS5 editor If you set such a password in the BDS5 Motion Link needs the password to transmit new programs to BDS5 If you use this selection to change the password then you should use the UPDATE CONFIGURATION function below to write a new configuration file COMMUNICATIONS This selection allows you to set up your communications port After you have set up this port Motion Link will initiate an autobaud sequence to 2 5 CHAPTER 2 GETTING STARTED N N
350. the A drive The DOS Disk must have the DOS file FORMAT COM 2 Insert a blank disk into the B drive 3 Type 4 Type FORMAT B S 5 The Format program will ask you to hit a key to continue 6 After the format is completed your computer will prompt you to format more disks answer N to exit the Format command 7 Remove the DOS disk from the your computer Leave the formatted disk in the B drive 8 Insert the Motion Link disk into the A drive This disk should be in the disk holder in the front of this manual 9 Copy all the files from the original Motion Link disk onto your disk by typing COPY A B 10 Label your disk as Motion Link Include today s date on the label 11 Store the original Motion Link disk in a safe place Do not use this disk except to make other copies 2 3 3 Establishing Communications This procedure will get you started using Motion Link after you have installed it 1 Connect and turn on your 5 as described in the Installation and Setup Manual BDS5 CHAPTER 2 GETTING STARTED MOUSE INSTALLED VGA w COLOR MONITOR ML CNF CONFIGURATION FILE FOUND CONFIGURATION FILE E gt BAUD COM PORT AUTOBAU ML CNF FOUND EEN COLORS FOREGROUND gt 9 BACKGROUND gt 1 E FOREGROUND gt 2 E BACKGROUND gt 5 0 80195 AUTOBAUD PER ML CNF BDS5 OFFLINE INTRO
351. the motor being undersized ACC or DEC being set too high or ILIM being set too low When a motor is overloaded it has the following characteristics The system overshoots sometimes excessively but does not ring or oscillate Reducing ACC and DEC eliminates the problem Turning off PL eliminates the problem The motor current is near or at saturation during a large part of the move Use the BDS5 RECORD function to record ICMD If ICMD is equal to ILIM for more than a few milliseconds then your system is saturated Overloading the motor can be corrected by the following actions Reducing ACC and DEC Reducing the load on the motor Increasing ILIM if it is less than IMAX Using a BDS5 with a higher current rating Using a motor with more peak stall torque 6 7 2 Compliance In compliant systems the load is not tightly coupled to the motor shaft If you move the load by hand you can feel springiness Compliant systems often are very stable when you tune with lower target bandwidths However they oscillate vigorously at low frequencies when you try to tune them for higher bandwidths BDS5 When a system is compliant it has the following characteristics There 15 springiness between the motor and the load or at the motor mounting plate The TUNE command calculates tuning variables that cause the system to oscillate The frequency of oscillation is less than 100 Hz
352. the specified distance at the specified traverse and ending speed See Chapter 5 for descriptions of defaults Allowed from the interactive mode and the user program Format MCI Position Traverse End Example MCI 100000 500 5000 MCI 3000 10 MCI 56000 MCI 8000 0 LAST SECTION Incrementally move the specified distance at the specified speed If the speed is not specified it is assumed to be VDEFAULT Allowed from the interactive mode and the user program Format MI Position Velocity Example MI 10000 1000 MOVE AT 1000 MI 1000 MOVE BACK 1000 Display the present motor drive combination This command is used to determine the motor for which your BDS5 was configured when it was shipped This command is not normally used by the customer Format MOTOR APPENDIX SOFTWARE COMMANDS BDS5 MRD NORM Make an absolute move so that the output of the Resolver to Digital converter output PRD will equal the specified value A direction option indicates whether the motion should be clockwise CW counter clockwise CCW or whichever way is shortest no option specified Allowed from the interactive mode and the user program Format MRD lt R D Position gt Velocity Option Where R D Position is greater than 0 and less than the resolution of the Resolver to Digital R D converter For the standard 12 bit resolution R D converter the upper limit is 4095 Option is either CCW or CW Example M
353. ther the DOS disk or directory where DISKCOPY COM is located and type 2 1 CHAPTER 2 GETTING STARTED DISKCOPY A A Press enter and follow the DOS prompts on screen concerning source Motion Link and destination blank disk disks n After DOS finishes copying the disk s place the Motion Link original disk s in a safe place for storage Use it only to make extra copies Never use the original disk s in day to day operation 2 3 2 Software Installation Motion Link can be installed on either a hard disk 5 1 4 floppy disks or 3 1 2 floppy disks Follow the corresponding instructions below for the installation that your system requires 2 3 2 1 Install on a Hard Disk Use this procedure to install Motion Link on a hard disk nm Make a subdirectory named ML on your hard disk Type MD WL5 Change to subdirectory ML5 Type CD ML5 4 Insert the Motion Link disk into the A drive This disk should be in the disk holder in the front of this manual 5 Copy all the files from the Motion Link disk onto the hard disk by typing COPY A a Store the original Motion Link disk in a safe place Do not use this disk except to make other copies N 2 BDS5 2 3 2 2 Install on a Floppy Disk Use this procedure to install Motion Link on a floppy disk Use the procedure for both Motion Link disks if you are using a 5 1 4 floppy 1 Insert your DOS disk into
354. tings of the motor However since S curves reduce overshoot you may find that you increase the overall acceleration rate when you use them You may need to reduce ACC and DEC when using NOTE S curves For some applications S curves can reduce the average acceleration too much in others straight line acceleration produces motion that jerks the motor excessively The BDS5 provides different levels of S curves allowing you to make the trade off There are five levels that are selected by setting the variable to either 1 2 3 4 or 5 For more information on S curves see Industrial Drives application note B101 Acceleration Profiles CHAPTER 3 PROGRAMMING LANGUAGE Table 3 7 S Curve Acceleration Chart Straight Line Modified Polynomial Polynomial Modified Sinusoid Sinusoid 3 8 3 2 Move Absolute MA Command There are two kinds of simple moves absolute and incremental With absolute moves you specify the end position with incremental moves you specify the total distance of the move The MA command allows you to command absolute moves by specifying the end position ACC DEC and SCRV are all in effect for MA moves option you can specify the traverse speed For example MA 50000 1000 moves to position 50000 at a peak speed of 1000 RPM The variable VDEFAULT is the default velocity for MA and MI commands If you enter an MA command without specifying a speed the traverse s
355. tion sese 1 12 Restrictions of Variable Input 4 28 Three Types of Variables 3 2 E Using Variable Input with Profiles 4 28 TII COmmand eee eris 4 12 Variable Limi 3 2 To Execute AUTOS T4 30 2 4 2 ARI M 20 To Execute MANUALS s T4 30 ariable Varables 2 4 Torque eee 3 39 Variables xe 3 1 Traces de rere des 5 2 Chane Variabl 3 3 Motion Link and Trace 5 2 ua AM IPC EM I Initial Settings of Control Trace Mod aa 2 12 and User 3 4 Transmit Receive Programs 4 39 xs Power up and Control Variables 3 3 lt BDS Command Receiving from ie Printing Variables sess 3 2 the BDS5 4 39 P ine Conditi 3 3 The gt BDS Command Transmitting 77 ONGIODS tthe BDST 4 39 cuu c 25 an Command oni And 6 4 Three OF eter 3 2 nnnc p 6 3 User Switch 3 8 iE Your SystenTs Conipletely es 6 3 ser Switches sse 3 User Variables esee 3 7 Reducing ILIM 6 3 RE Se Variable Limits see 3 2 Tuning Crite
356. tion twice once with the instruction and once without the instruction Subtract the amount of time it takes to run this program with the instruction from the time to run without the instruction The result is the amount of time it takes to execute the instruction instruction TMR1 GT 0 GOTO 5 B With an oscilloscope measure the amount of time that Output 1 is ON while running the program with the lt instruction gt and subtract from this the amount of time the Output 1 is ON while running the program without the lt instruction gt The result is the amount of time it takes to execute the instruction 5 PLIM 0 EN O1 ON lt instruction gt CAMMING with the BDS5 BDS5 CAM DOC Rev3 June 02 1993 ROTATIONAL MOTION LINEAR MOTION Figure 1 A Conventional Cam Conventional Cams Conventional cams convert rotational motion to linear motion As Figure 1 shows the command signal comes from a master drive shaft which is fitted with a cam The cam generates linear motion on a follower Cams are used when a specific profile must be generated each time a drive shaft turns The cam itself can have a wide variety of shapes This leads to tone of the most important features of cams you can generate a wide range of linear motion profiles using only constant rotational motion Electronic cams offer many advantages over conventional mechanical cams For example the profile of an electronic cam is mu
357. to detune your system in these regions 6 7 4 Resonance Resonance is a high frequency gt 500 Hz where the system mechanics oscillate Normally systems with resonance will be very stable when you tune with lower target bandwidths As you increase the target bandwidth you will begin to hear a fairly pure high pitch If you want to decrease resonance use shorter larger diameter driving shafts Often the low pass filter can help you raise the bandwidth 2096 or 30 but this can be a difficult trial and error process you slowly lower the low pass filter frequency LPFHZ and attempt to raise the target bandwidth for tuning When your system has a resonance it will have the following characteristics The system will make a clear high pitch gt 500 Hz Do not confuse this problem with compliance which has a low pitch If the system performance is poor because of changing inertia you can make the following corrections Enable the low pass filter LPF and reduce LPFHZ if necessary Reduce the bandwidth of the system Shorten the length and increase the diameter of shafts and lead screws 6 7 5 Low Pass Filters The LPF switch enables the low pass filter It can be turned on and off when the drive is operating The frequency of the low pass filter is stored in LPFHZ in Hz It can also be changed when the drive is operating For example if LPFHZ is 200 and LPF is on then a 200 Hz low pass filter is run
358. to look up data in tables For example they are often used in teach programs programs that remember a large number of positions taught by the operator In this case many user variables are used to remember positions and one variable is used to point at the group Use indirect references with caution since it is easy to make mistakes with them 3 3 11 User Switches User switches are similar to user variables except that they can only take on values of 0 or 1 A user switch can be used in place of a user variable if you only need to store 0 or 1 An example of a good place for a user switch would be to store information for go no go decisions This saves user variables for other places There are 50 user switches ranging from XS1 to XS50 For example type XS33 1 P XS33 and the BDS5 should respond by printing 1 3 3 12 Special Constants The examples above have used decimal numbers in most of the assignments There are four special constants that make the BDS5 easier to use ON 3 8 BDS5 OFF Y and N ON is the same as and OFF is the same as 0 Similarly Y is 1 and N is 0 These constants are normally used for switches Compare the two statements O1 1 O1 ON Although both statements have the same effect the second is easier to read that is more intuitive When you write programs the use of ON and OFF and Y and N can make the program easier to understand Note however that the P command normally prin
359. tobaud make sure ABAUD is on before powering down Start with 1200 baud and see if the problem is cured 5 3 DEBUGGING AND MULTI TASKING If your program uses multi tasking the Trace and Single Step modes show you which level is currently being executed For example enter the program given in Section 4 8 5 2 Turn on the Trace mode and type RUN 1 The result should be something like this 1 MAIN PROGRAM T EN BDS5 T MI 10000 10 START MOVE T P MOVE PROCESSED MOVE PROCESSED T W 0 WAIT FOR MOVE T BACKGROUND T P UPPER TASK IDLED UPPER TASK IDLED T D 250 DWELL 0 25 SEC T END T BACKGROUND T P UPPER TASK IDLED UPPER TASK IDLED T D 250 DWELL 0 25 SEC T END AT THIS POINT ASSUME MOTION STOPS AND TASK 5 IS NOT IDLED T P ALL MOTION STOPPED ALL MOTION STOPPED T B Notice that when the example is executing the background level task an asterisk is printed Each task level prints out a slightly different prompt in the Trace and Single Step modes as the following table shows Table 5 1 Multi Tasking Debug Prompts TASK LEVEL SINGLE STEP TRACE PROMPT PROMPT PROMPT Alarm A Alarm B Alarm C Variable Input Main Program Background 5 4 REMOVING CODE If you cannot find the bug in your program with single step or trace then you must begin removing sections of your code that you do not think are causing the problem The procedure is to remove
360. ts numbers not ON OFF Y or N For example O1 ON P OUT will result in 1 being printed not ON Another point to recognize is that the equal sign is optional The two statements O1 ON O1 ON produce identical results The program can be more readable if the is not used with Y N ON and OFF 3 4 MATH 3 4 1 Hexadecimal The BDSS5 allows constants to be entered in hexadecimal or hex Hex is base 16 representation which is often used when programming computers BDS5 hex constants begin with a number and are followed by an h For example 16h OFh and OFFh are all hex numbers Appendix H shows the hex conversion of 0 through 255 From the appendix you can see that hex 25 is equal to decimal 37 The two instructions 9 37 9 25 have identical effects because 25 equals 37 decimal Sometimes the first digit of a hex number BDS5 can be a letter In this case the number must be preceded with a zero For example X9 FFH ERROR HEX NUMBER MUST BEGIN WITH NUMBER X9 0FFH VALID STATEMENT Hex is useful when trying to use general purpose inputs to control the user program See later in this chapter for more information about applying these inputs 3 4 2 Algebraic Functions The BDS5 provides four standard algebraic functions multiplication division addition and subtraction The usual algebraic operators are used Standard algebraic hierarchy is observed
361. ty units numerator Initially set to VNUM Value of this variable does not matter during preliminary operation WATCH Enable the serial watchdog timer This function disables the BDS5 if a command is not received from the serial port every WTIME milliseconds Set to 0 on power up WTIME See WATCH above Initially set to 1000 X1 X250 User variables Initially set to O XS1 XS50 User switches Initially set to 0 ZERO Puts the BDS5 in Resolver Zeroing mode This is set to 0 on power up Zeroing mode is used only during installation If 1 BDS5 rotates the motor to the zero position If 0 the BDS5 controls the motor normally 3 3 10 User Variables User variables are like memory on a hand held calculator They can be used as application specific variables or for storing intermediate results of complex calculations There are 250 user variables X1 X2 X250 Extended to 750 with Varaable EXTDX 1 PC Scope is not available with EXTDX 1 They can be displayed and assigned new values like other variables They can store CHAPTER 3 PROGRAMMING LANGUAGE numbers that range from 231 2 147 473 648 to 231 1 2 147 473 647 For example if you want to store PFB the position feedback at a particular time and use it later in a calculation you can assign PFB to a user variable Type the following line on the terminal 1 Now without moving the motor print X1 and by typing P X1 PFB This print
362. u where your program stopped For example NORM 0 ERROR OCCURS here PFNL 0 MA 1000 100 if ERROR OCCURS here PFNL 1000 MA 2000 1000 ERROR OCCURS here PFNL 2000 even if the first move is still in progress You can use PFNL to tell which moves were calculated before the error occurred You can use PFB to tell which moves were actually processed FIRMWARE ERRORS Firmware errors are an indication of a serious problem with the BDS5 These errors stop communications disable the drive and flash the CPU LED The CPU LED flashes several times then turns off and pauses The number of flashes represents the error number These error numbers range from 2 to 5 Contact the factory should one of these errors occur PROGRAMI CYCLE AND ERROR RECOVERY USING AN ALARM WITH INPUT 1 1 same as power up POWER UP auto start label PLIM OFF off software limits enable motor return to multi tasking A 11 ON when input 1 1 MI 40960 100 move incremental TIL PFB EQ PCMD for motion to stop END return to multi tasking ERROR O1 ON D 5000 error recovery O1 on wait for 5 seconds to let OK2EN settle wait for OK to Enable O1 off enable motor return to multi tasking TIL OK2EN EQ 1 PROGRAM CYCLE AND ERROR RECOVERY USING MANUAL WITH THE MANUAL INPUT 1 POWER UP PLIM OFF powerup auto start label turn off software limits enable motor retu
363. use it causes overshoot 3 8 14 1 REG amp REGKHZ REG enables the Profile Regulate mode If REG is on then profile regulation is enabled REG and GEAR cannot be on at the same time To use profile regulation you must determine 1 The maximum frequency of external input Set REGKHZ to this value 2 desired speed of the move when external input frequency is REGKHZ Use this value as the commanded velocity of the profile The maximum frequency of the external input is stored in the variable REGKHZ in kHz The profile will execute normally that is at the specified velocity and acceleration when the external input frequency is equal to REGKHZ If the input frequency is less than REGKHZ then the profile will move the specified distance but the acceleration and velocity will be less than and in proportion to the input frequency The move will never go faster than specified in the original move command even if the 3 35 CHAPTER 3 PROGRAMMING LANGUAGE input frequency goes above REGKHZ However the input frequency should always be less than REGKHZ REGKHZ is only resolved to 1 kHz for example 499 5 kHz is converted to 500 kHz REGKHZ is somewhat arbitrary it must be greater than the maximum frequency of the external input and less than 2 MHz Beyond those limits you can set it to any frequency that is convenient and adjust the commanded motion by changing the speed of the profile NOTE The
364. ust be entered SCKSUM 043 SCKSUM is set to 0 on Power up PGMCKSUM This is a 16 bit checksum of the BDS5 User Program RS 485 Communications with Serial Checksum RS 485 be used in conjunction with the new serial checksum feature for enhanced communications Example with MultiDrop enabled SCKSUM I cr SCKSUME 1 lt cr gt lt lf gt gt PLIM 09F lt cr gt PLIM 09F lt cr gt lt lf gt lt ack gt gt EN93 lt cr gt EN93 lt cr gt lt lf gt lt ack gt gt ADDR 65C3 ADDR 65C3 lt cr gt lt lf gt lt ack gt A gt A lt cr gt lt cr gt lt lf gt lt ack gt A gt MI 4096 1000 lt cr gt MI 4096 1000 lt cr gt lt lf gt lt nak gt A gt MI 4096 10006A lt cr gt MI 4096 10006A lt cr gt lt lf gt lt ack gt A gt SCKSUM 043 lt cr gt SCKSUM 043 lt cr gt lt lf gt lt ack gt A gt ADDR 0 lt cr gt lt cr gt lt lf gt PROMPT 1 lt cr gt gt ECHO 1 lt cr gt gt P PFB lt cr gt P PFB lt cr gt lt lf gt 1212 gt enable Serial Checksum protocol echo prompt turn off software travel limits echo acknowledge and echo enable the motor echo acknowledge and echo enable RS 485 and enable address A ASCII 65 decimal echo Axis ID set axis then disconnects until addressed select axis A echo acknowledge and echo move incremental 4096 counts 1000 rpm checksum negative acknowledge bad checksum
365. ut a value between the specified low limit 10 and high limit 100 If the input is invalid or outside the range an error message is sent and the operator is prompted again The limits can be constants as shown above as well as any valid numerical expression If the limits are outside the variable s normal range they are ignored If they are not specified at all the variable s normal range is used as the limit For example the limits on ACC are 0 and AMAX Type in this command 1 STORE ACC INPUT ENTER NEW ACC ACC 1000 1000 The BDS5 knows that the lower limit on ACC is 0 so that no negative numbers will be accepted If AMAX is less than 1000 AMAX will be the upper limit Otherwise 1000 will be the upper limit If you specify limits that are outside the variable s program limits the BDS5 uses the program limits Appendix E lists all variables and their program limits 4 6 3 2 INPUT and Decimal Point You can use the INPUT to prompt the operator for values that include a decimal point You must specify the number of characters after the decimal point This is the only way you can enter numbers having a fractional part into the BDS5 For example suppose your user position units are mils 0 001 inches You can prompt the operator for any position in inches with the INPUT The following example stores the results of the INPUT command in X1 Enter this short program in your BDS5 then type RUN 44 44
366. ut the other tasks continue running 4 8 4 Enabling and Disabling Multi tasking Multi tasking is always enabled when a program is running For example if you have a program that starts at 55 and has 2 alarms then the alarms will be active if you type RUN 55 If your program ends with a Break command then the program will stop executing and multi tasking will be disabled that is the BDS5 will return to the Interactive mode If your program ends with an END command then only the task level that executed the END will stop executing other tasks will continue executing If there are no other tasks that are executing then the BDS5 does not return to the Interactive mode but instead becomes dormant In this case multi tasking remains enabled For example alarms will continue to be serviced If you want to enable multi tasking without running a particular program type RUN without entering a label 4 23 CHAPTER 4 USER PROGRAMS Table 4 5 Multi Tasking Overveiw Task Labels A How to Task Level Start Task Task Name Hardware or Software Switch 1 ALARM A Highest Priority VARIABLES POWER UP Hardware or Software Switch Hardware or Software Switch ATTN from DEP 01 or V from a PC ora Terminal VARIABLE INPUT POWER UP PROGRAM Power up BDS5 and Establixh Comminication Manual Switch Off and Positive Transition Of Cycle Input AUTO AUTOS PROGRAM MANUAL PROGRAM MANUA
367. variable file FROM BDSS This selection retrieves all of the variables currently stored in the 5 After the variables are retrieved the Motion Link Editor is called allowing you to examine and change the variable file NEW VARIABLES This selection calls the Motion Link Editor allowing you to enter a new set of variables Upon exiting the Motion Link Editor you can store the variable settings to your computer disk and or transmit them to the BDS5 2 4 1 3 Capture This is a communications capture and is unrelated to the BDS5 variables CAP and CAPDIR which are for position NOTE capture EDIT This selection allows you to examine the communications that have been captured Upon exiting the Motion Link Editor you can store the captured data on your computer disk Note that if you selected an item from either the PROGRAM or VARIABLES menu since you last captured communications or loaded a communications capture file this selection is invalid FROM DISK This selection allows you to retrieve a capture file from disk and examine it with the Motion Link Editor START CAPTURE This selection starts or re starts capturing communications from the BDS5 This selection always clears the CHAPTER 2 GETTING STARTED capture storage area before beginning to capture new communications STOP CAPTURE This selection terminates the communications capture If you want to examine the communications
368. ve use the Macro Dwell MCD command In this command you specify the time of the dwell in milliseconds For example MCD 100 3100 MSEC DWELL This example specifies a 100 millisecond dwell Macro dwells are only allowed at the beginning of a Macro move and when the previous section has ended at zero speed After all motion sections have been specified with the final motion ending at zero speed use the Macro Go MCGO command to begin the motion MCGO is only allowed when the speed at the end of the last Macro move is 0 MCGO also ends calculations for Macro moves Subsequent MCI MCA or MCD commands reset the Macro move sequence Subsequent executions of MCGO will execute the move again The effect of multiple MCGO s on Incremental Macro moves is that the Incremental move is executed again The effect of multiple MCGO s on Absolute Macro moves is more difficult to understand This is because all Macro moves are converted to Incremental before being executed whether they are MCI or MCA based This can cause undesirable effects if the position does not return to the starting point at the end of the Macro move Absolute Macro moves that are to be executed more than once should return to the starting position Enabling the BDS5 resets the Macro move memory If you are typing in a Macro move and you make an error you should disable then enable the BDSS and retype the entire move Jog MA and MI commands do not reset the Macro move
369. ved the computer can transmit at the full baud rate without inserting delays 4 10 3 Serial Watchdog The BDS5 provides a serial watchdog timer for applications where a command should be received from a computer on a regular basis If a complete command is not received from the serial port in the specified time an error will be generated that will disable the BDS5 and break the user program The serial watchdog is a safety feature that disables the BDS5 if the communications line breaks The serial watchdog waits for a carriage return to signify a completed command It does not test the validity of the command For example if your computer fails and begins sending random carriage returns the serial watchdog will not generate an error CHAPTER 4 USER PROGRAMS The BDS5 serial watchdog is intended to detect a broken serial communications line It does not test the validity of WARNING data received from your computer Set WTIME in milliseconds to the time that you want the serial watchdog to timeout To enable the serial watchdog type WATCH ON 4 10 4 Transmit Receive Programs The BDS5 provides commands that allow programs to be transmitted and received without using the Editor These commands are intended for applications which require that a computer directly transmit and receive programs This does not include Motion Link the software communications package that is run from an IBM PC or compatible Refer
370. velocity response of the BDS5 to a JOG command After data is recorded you can use the PLAY command to print each point on the screen However Motion Link provides all the routines to retrieve plot print and store recorded data on your computer and line printer The RECORD command is useful when tuning a system because you can display the BDS5 response to commands without an oscilloscope However it is not limited to tuning For example you can record VCMD to plot a motion profile or you can plot VEXT to watch the external encoder analog input You can also plot user variables to watch the performance of your program 6 7 PROBLEMS Some times there are problems tuning Usually the TUNE command will provide you with a tuning that is either acceptable or close to acceptable If not you can tune the system yourself Sometimes there are physical factors that prevent you from attaining the performance you need These problems fall into four categories 1 Overloading the Motor 2 Compliance 3 Resonance 4 Changing Load Inertia or Reflected Inertia 6 6 BDS5 6 7 1 Overloading the Motor Overloading the motor is the most common problem for positioning systems that is systems with PL on If you overload the system the position error can grow to very large values When the command stops the motor reels in the following error and can overshoot excessively It looks like a tuning problem but it is actually caused by
371. veyor continues at full speed and stops the item where the operation will take place The high speed position capture works at all velocities and during accelerations It is accurate to 25 microseconds if Connector C2 Pin 19 is used and therefore will work properly on demanding index to registration applications If the OPTO 22 Connector C7 is used with standard industrial OPTO 22 style modules the optical module may add as much as 25 milliseconds of delay so be careful to properly specify the optical coupling to the registration switch To implement index to registration you usually jog the motor at a constant speed capture the position with the registration device connected to the HOME input then use the Jog To command to stop the motor at an endpoint normally a specified distance beyond the registration input CHAPTER 3 PROGRAMMING LANGUAGE 3 8 11 2 Registration Example The following example shows how to program the BDSS for registration The desired operation of the program is as follows 1 Set CAPDIR 1 for low to high transition 0 for high to low transition 2 Enable capturing 3 Begin move 4 Wait for the BDS5 to capture 5 Use the captured position to set the endpoint of the move For example the following code segment jogs at 2000 RPM and stops 4000 counts after the registration input transitions from low to high CAPDIR 1 SET CAPDIR FOR LOW TO HIGH CAP ON ENABLE CAPTURE J 2000
372. wers up in the Interactive mode This mode allows you to start programs display and change variables and enter motion commands for immediate execution The prompt gt is written to the screen and the BDS5 awaits a new command Your program is not running if the BDSS is in the Interactive mode Refer to Figure 2 2 There are many ways to enter the Interactive mode First if the power up label POWER UP is not present the BDS5 will power up in the Interactive mode The BREAK B command and errors that break program execution cause the BDS5 to exit the Run mode and enter the Interactive mode BDS5 CHAPTER 2 GETTING STARTED PROGRAMMING MODES lt Esc gt or lt CR gt lt CR gt PROGRAM DUMP RUNNING MODES POWER UP NOT PRESENT POWER UP PRESENT TASK ou LEVELS isse ALARM A ALARM B g Or x RUN or RUN lt label gt VARIABLE C POWERUP v MAIN PROGRAM ERROR PRESENT BACKGROUND Esc TRC OFF text Operator Entered italic Program Executed text Equivalent Command Figure 2 2 BDS5 State Table 2 11 CHAPTER 2 GETTING STARTED 2 6 2 2 Run Mode The 5 is normally in the Run mode when program is executing There is no prompt because input is not accepted from the terminal The program is running it can display errors and print to the terminal Refer to Figure 2 2 After autobauding the Run mode i
373. y the BDS5 Gain and offset adjustments are made digitally inside the BDS5 not with potentiometers e PULSE INPUT OPT2 CARD The BDS5 can accept special pulse inputs The standard BDS5 can accept signals directly from encoders or encoder like devices As an option the BDS5 can accept other pulse formats such as count direction or up down e LED S The 5 provides LED s for diagnostics These LED s are on the front panel of the BDS5 The LED s are listed below ACTIVE SYS OK CPU FAULT RELAY CHAPTER 1 SYSTEM DESCRIPTION e CURRENT LOOP COMPENSATION The 5 has analog current loops The current loop compensation components are all contained in the compensation module located on the front of the BDS5 The current loop compensation changes when you change the motor model You must install the correct compensation module when changing motor models YOU MUST HAVE THE PROPER COMPENSATION MODULE INSTALLED FOR YOUR MOTOR CAUTION Failure to install the proper compensation module can cause damage to the BDS5 the motor or both 1 7 SIMPLIFIED SCHEMATIC DIAGRAM AND SYSTEM DIAGRAM Drawings D 93030 and A 84847 illustrate a BDS5 servo system with all of the major components CHAPTER 1 SYSTEM DESCRIPTION BDS5 TXD RS 232 RXD TD TD RS 485 RD RD C5 PIN 3
374. ystem The procedure to determine ANUM and ADEN is as follows A Select Table 4 14 RPM sec or 4 15 radians second second B Select a convenient amount of motor acceleration C Calculate the corresponding machine acceleration 4 35 CHAPTER 4 USER PROGRAMS D Perform the operation indicated in the table under ACCELERATION UNITS and set ANUM ADEN equal to this value E If your R D converter resolution is 14 bits multiply ANUM by 4 Multiply ANUM by 16 for a 16 bit system For external inputs PEXT and VEXT the procedure for calculating the conversion constants PXNUM PXDEN VXNUM and VXDEN is similar It differs in that the external inputs are not functions of the motor position or R D resolution Table 4 16 has been provided to assist in calculating the conversion constants Table 4 16 External Units Conversion EXTERNAL POSITION UNITS PXNUM _ External Input In Counts PXDEN Machine Movement In Your Units EXTERNAL VELOCITY UNITS VXNUM VXDEN External Input In Counts Sec Machine Velocity In Your Units 65 535 x The procedure to determine PXNUM and PXDEN 15 as follows A Select a convenient number of counts on the external input B Calculate the corresponding machine movement in your user units C Perform the operation indicated in Table 4 16 under EXTERNAL POSITION UNITS and set PXNUM PXNUM equal to this value The procedure to determine VXNUM and VXDEN is as

USER`S MANUAL - Motorsystems Repair

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