S3041 user`s manual - Sea
Contents
1. 1 6 PROGRAMMING Configuration and timing channel programming of the 3041 is performed with PLSdev a DOS based programming software package which runs on any IBM PC or compatible Connection of the PC to the S3041 is implemented with an RS 232 cable no other hardware is required PLSdev allows the user to perform the following e Configuration of the S3041 including Scale factor Offset Brake wear compensation enable parameter programming Motion signal enable parameter programming e On and Off line timing channel programming including arbitrary set point programming pulse train channel programming timing channel fine tune e Channel set points download to 3041 e Channel set points upload from S3041 e Configuration and Channel set point printouts e S3041 Hardware Confidence test See section 2 for details on the programming commands and PLSdev features S3041 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION This Page Intentionally Left Blank 53041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING 2 1 INTRODUCTION TO PLSdev PLSdev is a DOS based software package used to configure and program the timing channels of the S3041 PLS module An RS 232 cable connected to COMI of the IBM PC or compatible running PLSdev is used to interface with the S3041 module for on line programming program upload download etc No other additional hardware is required 2 1 1 FEA2. 2 Power up PC and enter PLSdev Enter any user program name to proceed to the PLSdev Main Development Menu 3 Connect Interface cable to COMI on PC and J1 port on S3041 4 Select PLS Hardware Confidence Test A prompt will be displayed verifying to proceed with the test Note Proceeding with the test will clear all set points and configuration data from the S3041 The user channel program will have to be re downloaded to the S3041 once the test is complete Press ESC to abort the test any other key to proceed S3041 User s Manual SYSTEMS Electronics Group 30 SECTION 6 HARDWARE CONFIDENCE TEST 5 Select Perform Test from the Test Functions Menu to start the test Once the test is initiated all tests enabled will be executed repeatedly starting with test thru the last enabled test until any key is depressed If no faults are detected the tests will continue to execute repeatedly displaying test passed messages after the successful completion of each test If a fault does occur the test will stop and display the following Fault Code XX test fault code and description Address of fault memory address or I O address where fault occurred Actual data at fault data actually obtained at address of fault Expected data at fault data that should have been obtained at address of fault Diagnostics test number for factory use only Once a fault occurs exit back to the Main Test
3. PgUp key also performs the same function as the F2 Prev Chan key F3 Select Chan Used to select any channel number for editing When selected the current channel number will be cleared and the cursor will be placed in the CHANNEL field Simply type in the desired channel number in octal and press Enter lt CR gt to accept The set points and data for that channel will then be displayed F4 Doc Chan Used to enter the channel description or name in the DESCRIPTION field This is a user definition of the channel and will be associated with the channel at all times printouts etc Up to 20 printable characters can be entered in this field Once the name is entered press Enter lt CR gt to accept F5 Pulse Train Used to program the channel as a pulse train See section 2 4 for details F6 Fine Tune Used to fine tune increment or decrement the selected set point See section 2 4 for details F7 Clear SetPnt Clears the currently selected set point set point designated with cursor No other set points are affected by this command F8 Clear Chan Clears all the set points in the channel Also used to clear the channel and reset the pulse train mode to no when a channel has been programmed as a pulse train 53041 User s Manual SYSTEMS Electronics Group 14 SECTION 2 PROGRAMMING F9 Set Offset Used primarily in the on line mode to electronically zero the resolver shaft at the machine zero To set the offset lo
4. A dip switch accessible through an access hole on the shield of the module selects the desired resolver reference voltage either 1 45VRMS or 3 70VRMS For Autotech and Gemco resolvers the reference should be set at 1 45VRMS for C amp A at 3 70VRMS For other resolvers refer to the manufacturers specifications to determine which reference should be selected See section 7 2 for details on wiring the resolver to the 53041 and selection of the resolver reference voltage 1 2 TIMING CHANNELS The S3041 contains 16 timing channels which can be programmed with up to 50 arbitrary on off set points or with a pulse train of fixed on and off divisions throughout the entire channel The timing channels are read by the main processor board as two input bytes Channels 00 07 are mapped to the first input byte channels 10 17 are mapped to the second input byte The respective channel is read as a 1 when the channel is on and a 0 when it is off The status of each timing channel is indicated with individual LEDs on the faceplate of the S3041 1 3 RPM POSITION DISPLAY The S3041 has a built in 4 digit display which can display the current angular position or revolutions per minute RPM A switch on the faceplate selects either position or RPM The display is read with the least significant digit on the bottom of the display and the most significant digit at the top of the display S3041 User s Manual SYSTEMS Electronics Group SECTI
5. A shielded twisted pair cable should be used to wire the resolver to the S3041 making sure the cable is routed free of other high voltage wiring The shield connection SH should be tied to either the resolver reference ground R2 or to earth ground S3041 User s Manual 34 SYSTEMS Electronics Group SECTION 7 INSTALLATION 7 2 2 RESOLVER REFERENCE VOLTAGE SELECTION The resolver reference voltage of the S3041 PLS module can be selected for either 1 45VRMS or 3 70VRMS depending on the requirements of the resolver For Autotech and Gemco resolvers the reference should be set for 1 45VRMS For C amp A resolvers the reference should be set for 3 70VRMS For other resolvers refer to the manufacturers specifications to determine which reference should be selected The reference is selected via dip switches accessible through an access hole in the upper middle section of the 53041 shield The S3041 must be removed from the rack to set the reference To select the 1 45VRMS reference set both switches down on the side that reads 1 45VRMS To select the 3 70VRMS reference set both switches up on the side that reads 3 70VRMS Note The proper reference voltage level must be selected for the specific resolver used otherwise erroneous operation may result 7 3 WIRING TIMING CHANNEL OUTPUTS CH00 CH03 are available as outputs and are implemented with 15 VDC MM88C30 differential line drivers The devices these out
6. invalid set point operations in process 1 loading file etc OFFSET The current resolver offset of the selected program This is entered using the F10 Set Offset command PULSE TRAIN Defines whether the channel is programmed as a pulse train YES or not NO The channel defaults to NO until the F5 Pulse Train command is executed Once programmed as a pulse train the channel must be cleared using the F8 Clear Chan command to reset PULSE TRAIN to NO See section 2 4 for details of the pulse train command ON On duration in degrees of the pulse train OFF Off duration in degrees of the pulse train START Starting location of the pulse train The Channel will be programmed throughout with the on and off durations starting at the Start location S3041 User s Manual SYSTEMS Electronics Group 13 SECTION 2 PROGRAMMING The function key commands of the channel edit menu are defined as follows F1 Next Chan Selects the next highest numbered channel for editing When selected the channel number will increment by one and the set points and data for that channel will be displayed The PgDn key also performs the same function as the F1 Next Chan key F2 Prev Chan Selects the next lowest numbered channel for editing When selected the channel number will decrement by one and the set points and data for that channel will be displayed The
7. the large cursor will always be located in the on parameter of the set point Enter the set point as follows 1 Type in on parameter in degrees cursor will change to the small data entry cursor 2 Press Enter lt CR gt or to enter the on parameter 3 Type in off parameter in degrees 4 Press Enter lt CR gt to enter the off parameter 5 The cursor will change back to the large set point cursor and automatically advance to the on parameter of the next set point The set point has now been entered 6 If an invalid set point number is entered a message stating this will be displayed in the message field of the channel edit menu Re enter a proper set point value or press ESC to abort the set point entry Note The set point values entered must be less than the scale factor Set points are also not allowed to overlap any existing set points already entered in the channel S3041 User s Manual SYSTEMS Electronics Group 17 SECTION 2 PROGRAMMING Example 1 The following key sequence enters the set point 020 040 at set point number 1 Key Depressed 2 0 4 0 Enter lt CR gt Example 2 The following example programs the entire channel on by specifying both the Set Point Field 2o 20 020 020 4 020 40 020 040 on and off parameters to 000 Key Depressed 0 Enter lt CR gt 0 Enter lt CR gt Set Point Field 00
8. 1 16 50 Scale factor 2 12 bits 10 arc mins 1LSB 10 000 RPM 6 000 RPM 2 Vrms 8 volts 100K ohms 1 45 Vrms or 3 70 Vrms selectable 2 500 HZ Output Section Timing Signal and Pulses Rev Number of Outputs Timing Signals 128 pulses rev 1024 pulses rev Output Type Output Voltage Vout on min Vout on max Output Current max Short Circuit Protection S3041 User s Manual 37 4 CH00 03 1 1 Differential line driver MM88C30 13 00 volts 15 75 volts 50 milliamps No SYSTEMS Electronics Group SECTION 8 SPECIFICATIONS Digital Input Section Number of Inputs Input Type Input Voltage Vin on min Vin on max Vin off max Input Current max Power Requirements S3000 bus Icc 5VDC max Icc 15VDC max Icc 15VDC max Temperature Ranges Storage Operating Relative Humidity 53041 User s Manual 38 1 INPUTI Differential 12 volts 30 volts 5 volts 10 milliamps at Vin 30 volts 900 milliamps 100 milliamps 100 milliamps 0 to 70 degrees C 0 to 60 degrees C 5 to 95 non condensing SYSTEMS Electronics Group APPENDIX A RS 232 PIN OUTS CABLES USED RXD RECEIVE DATA IN TXD TRANSMIT DATA OUT NOT USED SIGNAL GROUND USED NOT USED NOT USED NOT USED PROG CHAN Port Pin Out 0 0 ALUNA oO d OU E OM o O DB9 FEMALE DB9 FEMALE COMPUTER INTERFACE PROG PORT RXD 2 2 ol TXD 3 3 TXD SG 5 5 sc
9. 3041 User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 02 2004 3041 User s Manual Copyright 1992 Systems Engineering Associates Inc All Rights Reserved WARNING To ensure the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electric Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study this User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The contents of the User Manual are believed to be correct at the time of printing however no responsibility is assumed for inaccuracies In the interests of a commitment to a policy of continuous development and impr
10. Menu and re initiate the test to reset the fault code Once testing is complete exit back to the Main Development Menu The user channel program will now have to be re downloaded to the S3041 6 3 INTERACTIVE INTERFACE The interactive interface menu contains selections to read the fault code same as displayed when a fault is detected perform diagnostics routines for use by the factory only and to read and write via the RS 232 ports to any address in the S3041 In general all these selections are for factory use and are of little significance to the user 53041 User s Manual SYSTEMS Electronics Group 31 SECTION 6 HARDWARE CONFIDENCE TEST This Page Intentionally Left Blank 53041 User s Manual SYSTEMS Electronics Group 32 SECTION 7 INSTALLATION 7 1 INSTALLING THE 3041 Prior to installing the S3041 the resolver select dip switches must be set for the resolver that the 3041 will interface to For C amp A resolvers set both switches down on the side that reads 3 7 C amp A For Autotech and Gemco resolvers set both switches down on the side that reads 1 45 RL100 For other resolvers refer to the manufacturer s data sheet for the appropriate reference voltage required The dip switches are accessible through a hole in the S3041 shield The 3041 occupies two slots and may be installed in any I O slot between 0 and 14 Install the S3041 by aligning the board with the card guides and sliding in until fi
11. Where input variable type X aa two digit left slot address 00 14 b channel group 0 channels 00 07 1 channels 10 17 c channel address 0 7 In addition to the timing channels that are read as inputs the current position and RPM can also be read from the 53041 during normal operation using the sfunc05 system function in the main processor board The position and RPM is read as four consecutive bytes from the S3041 with the bytes mapped as follows bytel position low byte byte2 position high byte byte3 RPM low byte byte4 RPM high byte The form of the sfuncOS as used in the main program of the main processor board should be sfunc05 slot 0 Byyy 4 Byyy where Byyy is the first byte of the four consecutive byte locations where the position and RPM will be stored in the main processor when the sfunc05 is performed Refer to the appropriate main processor user s manual for more details on the use of sfuncOS 53041 User s Manual SYSTEMS Electronics Group 25 SECTION 4 MAIN PROCESSOR INTERFACE This Page Intentionally Left Blank 53041 User s Manual SYSTEMS Electronics Group 26 SECTION 5 FAULT CODES The 3041 module detects two fault states These are invalid scale factor code 07 and invalid offset code 08 When the 53041 detects any one of these faults the respective fault code is displayed on the RPM POSITION display of the module in the form 88XX where XX is the fault code The
12. file on disk for the selected program when existing the on line mode 3 Edit PLS Configuration This activates the PLS configuration menu See section 2 3 When PLSdev is initially invoked and the program name entered does not exist the PLS configuration menu is automatically activated This selection allows the user to modify the system configuration at any time 4 Download Channels to PLS This selection downloads both the PLS configuration and channel data files for the selected program to the 53041 module To download the data to the 3041 perform the following Note Each channel is cleared prior to downloading the set points for that channel thus machine operation should be ceased prior to initiating the download 1 With both the PC running PLSdev and the S3041 powered up connect COMI on the PC to the J1 port on the S3041 using the appropriate RS 232 cable 2 Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the download press ESC otherwise press any key to start the download 3 While the download is in progress the channel number which is currently being downloaded will be displayed Once all channels are downloaded a dump complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu 4 Ifthe computer was unable to initiate the download to the S3041 a message stating this will b
13. individual faults are discussed below 8807 INVALID SCALE FACTOR This fault is displayed when the scale factor is greater than 512 or less than 2 To reset the fault download the user channel program through PLSdev This downloads the configuration file which contains the scale factor as specified by the user 8808 INVALID OFFSET This fault is displayed any time the offset is greater than or equal to the scale factor To reset the fault set the offset to less than the scale factor by downloading the user channel program or by setting the offset in the on line mode of PLSdev 53041 User s Manual SYSTEMS Electronics Group no SECTION 5 FAULT CODES This Page Intentionally Left Blank 53041 User s Manual SYSTEMS Electronics Group 28 SECTION 6 HARDWARE CONFIDENCE TEST The hardware confidence test allows the entire S3041 hardware to be verified for proper operation The test is resident in all S3041s and is initiated through PLSdev The hardware confidence test is the same test used at the factory to initially test the production S3041s and therefore provides the same 100 hardware test as provided at the factory The test is provided to the user to verify whether the S3041 hardware is functional or not Not as a tool to repair S3041s If a fault is detected the S3041 should be returned to the factory for repair Any attempt to repair an S3041 will void the warranty 6 1 TESTS PERFORMED The following is a list of the
14. no longer stop at TDC but will instead overshoot When enabled the brake wear algorithm of the S3041 will automatically adjust the TDC timing signal such that the press always stops at the desired stopping location regardless of brake wear 3 1 BRAKE WEAR COMPENSATION PARAMETERS The brake wear algorithm is implemented in and can be enabled or disabled in the PLS configuration see section 2 3 3 When disabled CHOO functions as a standard timing channel When enabled the following parameters set by the user are used to implement the algorithm Desired Stop Location This is the location in degrees that the press is desired to stop at i e 0 degrees TDC Allowed Stopping Error This is the plus or minus allowed deviation in degrees from the desired stopping location that the press will be allowed to stop before the algorithm adjusts the timing signal to compensate for brake wear Timing Signal Width This is the width in degrees that the algorithm will program the timing signal Note The algorithm assumes the leading off to on transition of the timing signal is used to declutch the press for a TDC stop Compensation Enable Window This is a window in degrees in which is allowed to move in order to compensate for brake wear This allows the user to place a limit on the amount of compensation the 3041 will perform If no limit is to be placed on the compensation of e
15. 0 0 _ 000 000 2 4 2 FINE TUNE SET POINT COMMAND The fine tune set point command allows the user to increment or decrement by one the on or off parameter of an already existing set point The fine tune command is executed by selecting F6 Fine Tune from the channel edit menu When this is done the fine tune menu is displayed This menu contains the following commands F1 On Setpnt This is used to select the on parameter of the set point When selected the cursor will move to the least significant digit of the on parameter F2 Off Setpnt This is used to select the off parameter of the set point When selected the cursor will move to the least significant digit of the off parameter Inc This command increments the selected parameter either on or off whichever was selected with the On Setpnt or Off Setpnt commands by one 53041 User s Manual 18 SYSTEMS Electronics Group SECTION 2 PROGRAMMING F4 Dec This command decrements the selected parameter either on or off whichever was selected with the On Setpnt or Off Setpnt commands by one The fine tune command is primarily used in on line mode to fine tune set points while the machine is in operation 2 4 3 PULSE TRAIN COMMAND The pulse train command is used to program a channel with a fixed on and off duration throughout the entire channel in one simple comman
16. Executing the Test Interactive Interface 7 Installation 7 1 7 2 7 3 74 Installing the S3041 Resolver Interface 7 2 1 Resolver Wiring 7 2 2 Resolver Reference Voltage Selection Wiring Timing Channel Outputs Wiring the 128ppr and 1Kppr Outputs 8 Specifications CONTENTS LIST OF FIGURES Figure 7 1 S3041 Resolver Interface 34 Figure 7 2 Typical Channel Output 128ppr or 1Kppr Output 36 APPENDICES RS 232 Pinouts Cables Appendix A Field Wiring Connector Pinouts Appendix B SYSTEMS Electronics Group LATE SECTION 1 GENERAL DESCRIPTION The S3041 PLS module is a high speed programmable limit or cam switch which accepts angular position information in the form of resolver format signals and converts these to digital The module contains 16 timing channels which can be programmed on and off at user defined position set points The scale factor of the S3041 is programmable from 2 to 512 divisions per revolution while the offset is programmable from 0 to one minus the scale factor High speed operation is attained with a resolver tracking rate greater than 6 000 RPM and a timing channel output update uncertainty of less than one microsecond to a change in angular position 1 1 RESOLVER INTERFACE The S3041 can be used with virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals These include resolvers manufactured by C amp A Autotech Gemco etc
17. ON 1 GENERAL DESCRIPTION 1 4 BRAKE WEAR COMPENSATION The brake wear compensation algorithm can be used in conjunction with presses which incorporate a top dead center TDC or back dead center BDC stop feature With these presses a timing signal is used to declutch the press for TDC or BDC stops However as the brake wears the press will no longer stop at TDC but will instead overshoot When enabled the brake wear algorithm of the 3041 will automatically adjust the TDC timing signal such that the press always stops at the desired stopping location regardless of brake wear The brake wear algorithm is implemented in and can be enabled or disabled by the user When disabled CHOO functions as a standard timing channel When enabled the brake wear compensation algorithm is automatically performed for TDC stops See section 3 for complete details on this feature 1 5 MOTION SPEED SIGNAL The motion signal is a user enabled feature which uses CH17 Two user programmable parameters are used in conjunction with the motion signal low speed threshold and high speed threshold When enabled as a motion signal CH17 is on when the speed RPM is between the low and high speed thresholds When the speed is below the low speed threshold or above the high speed threshold CH17 is off When disabled CH17 functions as a standard timing channel 53041 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION
18. RTS 7 CTS 8 DSR 6 DTR 4 DB9 com1 to PROG Port Cable DB25 MALE DB9 FEMALE COMPUTER INTERFACE PROG PORT TXD 2 2 RXD RXD 3 3 TXD sc 7 5 sc RTS 4 CTS 5 DSR 6 DTR 20 DB25 com1 to PROG Port Cable 3041 User s Manual SYSTEMS Electronics Group APPENDIX A RS 232 PIN OUTS CABLES This Page Intentionally Left Blank 53041 User s Manual SYSTEMS Electronics Group APPENDIX B FIELD WIRING CONNECTOR PIN OUTS R1 R2 qp RESOLVER INTERFACE 00 S1 10 011 20 012 S2 30 013 RESOLVER S3 40 014 S4 ks 50 O15 60 016 CHANNEL OUTPUTS fo CHANNEL 00 i INPUT GENERAL PURPOSE CHANNEL O1 _ o1 INPUTS CHANNEL 02 INPUT O CHANNEL 03 gt INPUT 1 m 3041 RESOLVER NTERFACE POSITION RPM SELECT SWITCH CHANNEL Ji POS RPM PROGRAMMING PORT POSITION a RPM DISPLAY FREQUENCY OUTPUTS 1KPPR AAA 128PPR 3041 16 CHANNEL PLS MODULE 53041 User s Manual SYSTEMS Electronics Group B 1
19. TURES OF PLSdev PLSdev incorporates the following features 1 2 3 4 5 6 7 Offline Channel Set point Programming set points for each channel can be entered with easy to use set point programming commands and saved on disk for download to the S3041 at a later time This allows the channel programming to be implemented without having an S3041 present Online Channel Set point Programming using the same set point programming commands and menus used with the off line channel programming the user can alter channel set points in the S3041 module directly using an RS 232 cable which connects the S3041 module to COMI of the IBM PC or compatible running PLSdev This allows machine timing to be altered while in operation PLS Configuration the configuration of the S3041 is set using PLSdev This includes defining the number of PLS timing channels in the module scale factor remote display strobe time brake wear compensation enable and parameter setting CH17 speed window enable and parameter setting Download Channels to PLS this allows channels edited in off line mode or previously uploaded channels to be downloaded to the S3041 module This feature allows quick replacement of an S3041 module by eliminating the need to reprogram the channel set points by hand Upload Channels from PLS uploads channel set points and configuration parameters from the S3041 module to disk files Printouts the set points of al
20. anced 090 130 fully advanced 139 179 retarded by 49 147 187 retarded by 8 147 187 no change In all cases above normal TDC stops were performed with INPUTI high S3041 User s Manual SYSTEMS Electronics Group 93 SECTION 3 BRAKE WEAR COMPENSATION Note In the above chart when the stopping location was within the allowed error 5 degrees or less no change was made in the set point Also once the set point was set to 90 130 that no further compensation occurred even though the press still stopped outside the allowed error This is because the compensation window was set at 90 270 degrees The algorithm only programs the set point within the compensation window If no limit on the amount of compensation is desired simply set the compensation window to 000 000 This allows to be reprogrammed anywhere 53041 User s Manual SYSTEMS Electronics Group 24 SECTION 4 MAIN PROCESSOR INTERFACE The timing channels of the S3041 are read as input bytes which are accessed by specifying the slot 00 14 and the byte 0 for channels 00 07 1 for channels 10 17 The slot address is the left slot of the two slots the 53041 occupies When the S3041 is specified in the system configuration of the main processor board the timing channels are automatically read as part of the I O update The channels are mapped to two input variables X with the following format Input byte Xaab Input bit Xaab c
21. cate the machine at machine zero Read the resolver shaft position from the front of the S3041 select F9 Set Offset and enter the position into the offset field The actual offset number required to make this the zero position will then be calculated by PLSdev and downloaded to the S3041 The actual offset which may not equal the entered position will be displayed in the offset field and the 3041 will then display zero as the position 2 3 PLS CONFIGURATION The PLS configuration is used to define the following PLS parameters in the 53041 number of PLS channels scale factor CH00 brake wear compensation parameters and CH17 speed window parameters The parameters are all set through the Edit PLS Configuration menu selection 2 3 1 NUMBER OF PLS CHANNELS This is the number of PLS timing channels available in the specific module being configured The number of channels should be set as follows for S3041 set number of channels 16 2 3 2 SCALE FACTOR The scale factor is the desired number of divisions per revolution This is programmable from 2 to 512 For 360 degrees per revolution the scale factor should be set to 360 2 3 3 REMOTE DISPLAY STROBE TIME The remote display strobe time parameter is not used by the 53041 S3041 User s Manual SYSTEMS Electronics Group 15 SECTION 2 PROGRAMMING 2 3 4 CHOO BRAKE WEAR COMPENSATION If the brake wear compensation algorithm available in i
22. channel set points data can be printed out through PLSdev When this selection is made a printer selection menu is displayed Select the appropriate printer to be used Once this is done the printouts selection menu is displayed The selections are 1 Print PLS Channel Set points This selection prints the set points for all the channels For each channel the following is printed CHANNEL number DESCRIPTION users documentation PULSE TRAIN yes no ON OFF START SET POINTS ON OFF 1 53041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING The above is the set points data for the respective channel as entered through the channel edit menu 2 Print PLS Configuration This selection prints the configuration parameters as entered in the PLS configuration menu 3 Enter PLS Program Title This selection allows the user to enter a title for the program This title is printed at the top of each page of both the PLS Channel Set points printout and the PLS Configuration printout The title can be up to 60 characters long and can be composed of any printable characters When entry of the title is complete press Enter lt CR gt to save the title If the title or changes to the title are not to be saved press ESC 7 PLS Hardware Confidence Test This selection is used to invoke the hardware confidence test of the S3041 See section 6 for a complete description of the test 8 Sel
23. d To program a channel with a pulse train perform the following 1 Select F5 Pulse Train from the channel edit menu 2 The cursor is located in the ON field of the channel edit menu Enter the on duration in degrees and press Enter lt CR gt 3 The cursor is located in the OFF field of the channel edit menu Enter the off duration in degrees and press Enter lt CR gt 4 The cursor is now located in the START field Enter the location that the pulse train will be initially started at in degrees and press Enter lt CR gt 5 The entire channel will be programmed with the on and off duration throughout the entire channel starting at the start location The first 50 set points or less will be displayed in the set point array Note The set point cursor will not be displayed since the single set point and fine tune commands are not valid if the channel is programmed as a pulse train 53041 User s Manual SYSTEMS Electronics Group 19 SECTION 2 PROGRAMMING This Page Intentionally Left Blank 53041 User s Manual SYSTEMS Electronics Group 20 SECTION 3 BRAKE WEAR COMPENSATION The brake wear compensation algorithm can be used in conjunction with presses which incorporate a top dead center TDC or back dead center BDC stop feature With these presses a timing signal is used to declutch the press for TDC or BDC stops However as the brake wears the press will
24. e Note The program files on the diskette in drive A must be at the root directory This selection along with the back up selection above provides a convenient way to copy programs from one computer to another 3 Make new directory This provides a way to make a new user program directory while inside PLSdev Enter the drive and directory name following the MS DOS conventions of directory names 4 Copy program to another program name This provides a way to copy the current program name to any disk and directory while also allowing the user to copy to a different program name Enter the drive directory and new program name using the MS DOS conventions for directory and file names Do not enter an extension with the program name This copies all the files associated with the program to the different directory and program name This selection can be used to copy the current name to another drive and directory when the program name entered is the same as the current program name This is also used to copy the program to a new program name For instance when one program is similar to another completed program simply copy the old program to the new program name and edit as required S3041 User s Manual SYSTEMS Electronics Group 1 SECTION 2 PROGRAMMING 2 2 2 Channel Edit Menu This menu is invoked for both off line and on line programming and provides a mechanism to enter and edit the set points for the channels The menu c
25. e displayed Verify the RS 232 cable connections between COM1 on the computer and the J1 port on the S3041 Press any key to return to the main development menu and try the download again 53041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING 5 Upload Channels from PLS This selection uploads the set points for each channel from the S3041 and saves it in the channel data file of the currently selected program To upload the data from the 53041 perform the following 1 With both the PC running PLSdev and the S3041 powered up connect COMI on the PC to the J1 port on the S3041 using the appropriate RS 232 cable 2 Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the upload press ESC otherwise press any key to start the upload 3 While the upload is in progress the channel number which is currently being uploaded will be displayed Once all channels are uploaded an upload complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu 4 If the computer was unable to initiate the upload to the 53041 a message stating this will be displayed Verify the RS 232 cable connections between COM1 on the computer and the J1 port on the S3041 Press any key to return to the main development menu and try the upload again 6 Print Channels Both the PLS configuration data and
26. ect PLS Program Select PLS program is used to change to a different existing PLS program or to create a new program once PLSdev has been invoked When the selection is entered the main development menu is cleared and the cursor is placed at the Program Name prompt Enter the desired program name as was done when PLSdev was initially invoked 9 File Utilities The PLSdev program allows you to back up restore make a new directory and to copy the current program to another program name all while inside PLSdev Selecting File Utilities brings up a submenu with the following choices 1 Back up Program This allows the current program to be backed up on a diskette in drive A Install the back up diskette in drive A and press any key when ready This copies all the files associated with the program to the root directory of the A drive Note The files will be stored at the root directory of the diskette not within a sub directory This selection provides a convenient way to back up your program 53041 User s Manual SYSTEMS Electronics Group 10 SECTION 2 PROGRAMMING 2 Restore Program This copies the current program name from the root directory of the A drive to the drive and directory specified with the current program name Install the diskette with the program on it in the A drive and press any key when ready This copies all the files associated with the program name on the A drive to the path specified with the program nam
27. he Download Channels to PLS selection To initiate the off line programming mode select 1 Offline Channel Set point Programming This invokes the channel edit menu and loads the existing channel set points from the channel data file on disk See section 2 2 2 for a description of the channel edit menu and set point programming commands When editing is complete press ESC to return to the main development menu The modified channel set points will then be saved in the channel data file on disk for the selected program 2 Online Channel Set point Programming This selection is used to edit the channel set points in an 53041 module directly To initiate the on line programming mode connect the COMI port on the PC running PLSdev to the J1 port on the S3041 to be programmed Select 2 Online Channel Set point Programming The channel edit menu will be invoked and the existing channel set points in the 53041 will be uploaded and displayed in the menu See section 2 2 2 for a description of the channel edit menu and set point programming commands 53041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING Note Any changes to the channel set points made are updated immediately to the S3041 module This allows set point editing during machine operation if desired When editing is complete press ESC to return to the main development menu The modified channel set points will also be saved in the channel data
28. hresholds CH17 is on If the speed is below the low or above the high threshold CH17 is off Both thresholds are defined in RPM If the CH17 speed window is disabled CH17 will function as a standard timing channel 53041 User s Manual SYSTEMS Electronics Group 16 SECTION 2 PROGRAMMING 2 4 CHANNEL SET POINT PROGRAMMING COMMANDS Three channel set point programming commands are available through PLSdev These are single set point programming set point fine tune and the pulse train programming command The single set point command allows the user to simply type in the complete set point both on and off parameters at the currently selected set point The fine tune command allows the user to either increment or decrement by one the on or off set point parameter of the currently selected set point The pulse train programming command allows the user to program the entire channel with a pulse train of a fixed on and off duration throughout 2 4 1 SINGLE SET POINT PROGRAMMING COMMAND The single set point command is used to enter unique set points in a channel when that channel is not programmed as a pulse train PULSE TRAIN NO Note When the channel is programmed as a pulse train the single set point command cannot be used to modify individual set points in the channel To program a single set point locate the set point cursor large block cursor at the set point to be modified
29. ially must also be programmed with a TDC timing signal This set point is used to stop the press after the brake wear compensation is enabled for the first time Note The press may or may not stop at the desired location the first time the brake wear compensation is enabled If the press does not stop within the allowed stopping error of the desired stopping location the algorithm will automatically advance or retard the CHOO timing set point by the difference between the actual and desired stopping location At the next TDC stop the press should then stop at the desired location Note CH00 will only be advanced or retarded within the compensation enable window and no further If the set point is advanced to the leading edge of the enable window it will not be advanced any further thus no further compensation for brake wear will occur In normal operation the algorithm verifies that the press always stops within the allowed error of the desired stopping location for all TDC stops INPUTI high when press reaches zero speed As brake wear occurs over time the press will overshoot the desired stopping location Once it stops past the allowed error the algorithm calculates the difference and re programs set point advancing it by this difference The press will then stop at the desired location again The set point is programmed with the width specified in the PLS configuration however the algori
30. l channels as well as the PLS configuration can be printed out to provide hard copy documentation PLS Hardware Confidence test Allows the execution of hardware tests embedded in the module to verify the proper operation of the S3041 This is the same test used by the factory to verify the module at completion of manufacturing S3041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING PLSdev is provided as a stand alone program or with the SYSdev shell To install or execute PLSdev from the SYSdev shell refer to the SYSdev Programming Manual for details To install or execute PLSdev as stand alone program refer to the following sections 2 1 2 SYSTEM REQUIREMENTS PLSdev will run on any IBM PC or compatible with the following minimum system requirements 1 DOS 3 1 or greater 2 512K or more RAM 3 Hard disk not required but recommended 4 One 3 5 or 5 25 diskette drive 5 COMI RS 232 port 2 1 3 INSTALLING PLSdev PLSdev consists of two executable files PLSdev exe and S4040T exe To install PLSdev simply install the PLSdev disk in the A or B floppy drive and copy PLSdev exe and S4040T exe to the desired directory on the hard drive 2 1 4 EXECUTING PLSdev To execute PLSdev switch to the directory on the hard drive that PLSdev was installed and type gt PLSdev program lt CR gt where program is the path and name of the PLS channel program to be edited The format of program sh
31. mplete details on the set point programming commands If the channel is not programmed as a pulse train a large block cursor is placed in the ON field of the currently selected set point to be edited This cursor can be moved to any set point number using the cursor arrow left right up and down keys Whichever set point the block cursor is located at is the set point that the various set point programming commands will operate on If the channel is programmed as a pulse train the cursor will not be display at all The only commands which are valid once a channel is programmed as a pulse train are the F5 Pulse Train and F8 Clear Chan commands Thus the cursor is not used to select set points since the commands that operate on individual set points are not valid 53041 User s Manual SYSTEMS Electronics Group 12 SECTION 2 PROGRAMMING 2 If no set point is programmed at a given set point number the field is displayed as Otherwise as an example the set point will be displayed as 020 040 where 020 is the location the channel turns on and 040 is where the channel turns off for the given set point SCALE FACTOR This is the scale factor as entered in the PLS configuration Note The scale factor cannot be changed from the channel edit menu but is displayed only for reference MESSAGE This is the field which displays various status messages informing the user of invalid commands 1
32. nter 000 000 for the enable window In addition to the above parameters INPUT1 on S3041 is used to enable the brake wear compensation The adjustment of CHOO is performed when the press is stopped RPM 0 and INPUT is high If INPUTI is low when the press is stopped CHOO is not altered regardless of the stopping location This allows the algorithm to be by passed for inch and single modes as well as emergency stops 53041 User s Manual SYSTEMS Electronics Group dia SECTION 3 BRAKE WEAR COMPENSATION 3 2 OPERATION OF THE BRAKE WEAR COMPENSATION ALGORITHM If the brake wear compensation algorithm is to be used CH00 must be used as the TDC timing signal should be used in conjunction with other user logic to declutch the press for TDC stops INPUTI on the S3041 must also be controlled such that it is high when the press is stopped for TDC stops but is low when an emergency non TDC stop is activated or when in any other non TDC stop clutch mode such as inch or bar is used It is suggested that a 24VDC sourcing output be wired to INPUTI with the appropriate PLC logic controlling this output as described above To enable the CH00 brake wear compensation answer y to the CH00 Brake Wear Compensation enable prompt in the PLS configuration see section 2 3 3 Enter the desired stopping location allowed stopping error timing signal width and compensation enable window Init
33. ontains both information fields and function key commands The information fields are defined as follows CHANNEL This is the number in octal of the currently selected and displayed channel When the channel edit menu is initially invoked channel number 00 is selected and displayed The F1 Next Chan F2 Prev Chan and F3 Select Chan commands are used to select a different channel number DESCRIPTION This field contains the user entered description or channel name which is associated with the channel number The F4 Doc Chan command is used to enter or edit this description PROG MODE This field displays the program mode either OFFLINE or ONLINE depending on whether the channel edit menu was invoked from the Offline or Online selection of the main development menu SET POINTS This is a 10 row by 5 column 50 element array where the set points are entered using the various set point programming commands Note If the channel is not programmed as a pulse train PULSE TRAIN NO that up to 50 unique set points can be entered in the channel If the channel is programmed as a pulse train PULSE TRAIN YES up to the scale factor divided by two number of set points ON 1 OFF 1 can be programmed in the channel In this case only the first 50 set points would be displayed in the channel however the channel would be programmed through out with the on and off duration specified See section 2 4 for co
34. ould be drive directory name where drive the drive letter of the drive your channel program will be stored on directory the user or working directory where your program will be stored name your user program name without any extension 53041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING Note For the user program name two user program files are actually created by PLSdev one that contains the PLS configuration data for the program another which contains the channel set point data for the program These are the files that are used to edit download and upload to and from the S3041 module Thus when referencing the program through PLSdev no extension should ever be typed in If no program name is entered when PLSdev is invoked the program name will be prompted for by PLSdev before the program proceeds to the main menu Enter the program name as outlined above to proceed 2 2 MENUS The following sections are a description of the various PLSdev menus In general the PgUp PgDn Home End and cursor left right up and down keys all function as defined 2 2 1 Main Development Menu 1 Offline Channel Set point Programming This selection is used to edit the channel set points off line while not connected to an 53041 module All changes made to the channel set points are saved in the channel data file for the selected program The channel set points can then be downloaded to an S3041 module using t
35. ovement the manufacturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 1992 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 1 1 Resolver Interface 1 1 2 Timing Channels 1 1 3 RPM Position Display 1 1 4 Brake Wear Compensation 2 1 5 Motion speed Signal 2 1 6 Programming 3 2 Programming 5 2 1 Introduction to PLSdev 5 2 1 1 Features of PLSdev 5 2 1 2 System Requirements 6 2 1 3 Installing PLSdev 6 2 1 4 Executing PLSdev 6 2 2 Menus 7 2 2 1 Main Development Menu 7 2 2 2 Channel Edit Menu 12 2 3 PLS Configuration 15 2 3 1 Number of PLS Channels 15 2 3 2 Scale Factor 15 2 3 3 Remote Display Strobe Time 15 2 3 4 Brake Wear Compensation 16 2 3 5 CH17 Speed Window 16 2 4 Channel Set Point Programming Commands 17 2 4 1 Single Set Point Programming Command 17 2 4 2 Fine Tune Set Point Command 18 2 4 3 Pulse Train Command 19 3 Brake Wear Compensation 21 3 1 Brake Wear Compensation Parameters 21 3 2 Operation of the Brake Wear Compensation Algorithm 22 3 3 Brake Wear Compensation Example 23 4 Main Processor Interface 25 5 Fault Codes 27 S3041 User s Manual SYSTEMS Electronics Group S3041 User s Manual 6 Hardware Confidence Test 6 1 6 2 6 3 Tests performed Performing the Hardware Confidence Test 6 2 1 Equipment Required 6 2 2
36. puts drive must incorporate differential inputs See figure 7 2 for a typical example of the channel output wiring 53041 User s Manual SYSTEMS Electronics Group 35 SECTION 7 INSTALLATION 7 4 WIRING THE 128PPR AND 1KPPR OUTPUTS The 128 and 1K pulse per revolution outputs are implemented with an MM88C30 differential line driver These outputs provide fixed pulse train signals that can be used to drive digital tachometers etc The devices these outputs drive must incorporate differential inputs See figure 7 2 for a typical example of the 128PPR and 1KPPR output wiring 3041 CHANNEL OUTPUT 128PPR OR 1KPPR OUTPUT DIGITAL TACH ETC i DIFFERENTIAL MM88C30 S INPUT FROM INTERNAL CIRCUITRY Figure 7 2 Typical Channel Output 128ppr or 1Kppr Output 53041 User s Manual SYSTEMS Electronics Group 36 Location of 3041 in Rack Board Size Length Height Width Scale Factor Offset Number of Timing Channels Maximum Number of Set Points per Channel Arbitrary Pulse Train Resolver to Digital Converter Resolution Accuracy Tracking Rate R to D Tracking Rate 53041 Signal Inputs SIN and COS Input voltage nominal Input voltage max Input impedance typ Reference Output Output voltage level Output frequency SECTION 8 SPECIFICATIONS Any I O slot 0 14 9 13 6 30 1 60 2 to 512 0 to scale factor
37. rmly seated The board is held in the rack via captive screws located on the 53041 faceplate To remove the S3041 loosen the captive screws and gently pull the board out of the rack using the handles located on the S3041 faceplate Note When installing or removing the S3041 power to the S3000 rack must be off 7 2 RESOLVER INTERFACE The S3041 PLS module can be used with virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals These include resolvers manufactured by C amp A Autotech Gemco etc A dip switch accessible through an access hole on the left side of the module selects the desired resolver reference voltage either 1 45 VRMS or 3 70VRMS 53041 User s Manual SYSTEMS Electronics Group 233 SECTION 7 INSTALLATION 7 2 1 RESOLVER WIRING Figure 7 1 shows the typical wiring to a generic resolver for stand alone operation S3041 PLS provides reference voltage for resolver The reference signal R1 excites the resolver while the two stator inputs are used to determine the absolute position of the resolver The direction of rotation is determined by the connection S1 and S3 Swapping S1 and S3 will reverse the direction of rotation for the S3041 module RI 4 R2 27 51 52 55 54 ROTOR R R2 S1 52 53 54 SH 3041 RESOLVER STATORS Figure 7 1 83041 Resolver Interface
38. s to be used it must be enabled in the PLS configuration If enabled the following additional parameters must be set DESIRED STOPPING LOCATION The desired stopping location in degrees of the press when a normal top dead center or back dead center stop is performed ALLOWED STOPPING ERROR The amount of deviation in degrees from the desired stopping location that is allowed before the brake wear compensation algorithm modifies the timing TIMING SIGNAL WIDTH The width in degrees that the compensation algorithm will program the set point when it is modified COMPENSATION ENABLE WINDOW The window in which the brake wear algorithm will be allowed to move set point for brake wear compensation See section 3 for more details on the brake wear compensation algorithm and the use of the above parameters If the brake wear compensation is disabled CHOO will function as a standard timing channel and the brake wear parameters above will be ignored 2 3 5 CH17 SPEED WINDOW If CH17 is to be used as a speed window it must be enabled in the PLS configuration If enabled the following additional parameters must be set LOW SPEED THRESHOLD If the speed is below this threshold CH17 is off HIGH SPEED THRESHOLD If the speed is above this threshold CH17 is off The two thresholds above define a window such that if the speed is between or equal to the low and high t
39. tests performed by the hardware confidence test 1 Micro controller RAM test 2 Channel 00 07 PLS memory test 3 Channel 10 17 PLS memory test 4 Channel 20 27 PLS memory test 5 Channel 30 37 PLS memory test 6 PLS memory address access test 7 RS 232 CHAN port test Tests through 6 are not optional and are always performed Test 7 is optional and may be disabled if desired All tests are automatic and require no interaction once the test is initiated Each test performs a complete check of the respective hardware area of the 53041 If a fault is detected the test is stopped and a test fault code is displayed to indicate the nature of the hardware failure 53041 User s Manual SYSTEMS Electronics Group 29 SECTION 6 HARDWARE CONFIDENCE TEST 6 2 PERFORMING THE HARDWARE CONFIDENCE TEST WARNING The hardware confidence test should not be performed in an S3041 installed in a users control system Unpredictable output states may result while the test is being performed 6 2 1 EQUIPMENT REQUIRED In order to perform the 53041 hardware confidence test the following is required 1 IBM PC or compatible with PLSdev installed 2 RS 232 interface cable to connect COMI on the PC to J1 port on the 3041 3 S3000 rack and PS3007 power supply 4 S3041 to be tested 6 2 2 EXECUTING THE TEST To execute the test perform the following steps 1 Install S3041 in any I O slot of S3000 rack and power up the rack
40. thm assumes the leading off to on transition is used to actually declutch the press 53041 User s Manual SYSTEMS Electronics Group 22 SECTION 3 BRAKE WEAR COMPENSATION 3 3 BRAKE WEAR COMPENSATION EXAMPLE In this example the algorithm is implemented on a press which normally requires 180 degrees to stop 1 2 stroke The parameters are set as follows CH00 Brake Wear Compensation Enabled Desired Stop Location Allowed Stopping Error Timing Signal Width Compensation Enable Window yes 000 005 040 090 270 The following chart shows the automatic reprogramming of the set point by the algorithm as a function of the actual stopping location of the press Note These are not consecutive stops but instead a sampling of stops over a period of time Actual Stop Choo Stopping Example Set Point Location 1 180 220 003 2 180 220 005 3 180 220 007 4 173 213 359 5 173 213 016 6 157 197 000 7 157 197 010 8 147 187 001 9 147 187 054 10 093 133 003 11 093 133 011 12 090 130 008 13 090 130 032 14 090 130 035 15 090 130 311 16 139 179 352 17 147 187 358 New Ch00 Set Point 180 220 180 220 173 213 173 213 no change no change advanced by 7 no change PR 157 197 advanced by 16 157 197 no change 147 187 advanced by 10 147 187 no change 093 133 advanced by 54 093 133 no change 090 130 fully advanced 090 130 fully advanced 090 130 fully adv
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