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Resolver Input Module

1. 4 2 1 4 2 2 Module Figure 4 4 Module in a Local Rack Single Register Reference Use this method to reference a 16 bit register as a single input Resolver input data update period and interrupt control registers are typically referenced using this method The symbolic name of each register should be as meaningful as possible nnnnn IODEF SYMBOLIC_NAME SLOT s REGISTER r Bit Reference Use this method to reference individual inputs on the module Common clock status and control bits are typically referenced using this method The symbolic name of each bit should be as meaningful as possible nnnnn IODEF SYMBOLIC NAME Q SLOT s REGISTER r BIT b where nnnnn BASIC statement number This number may range from 1 32767 4 8 4 4 4 2 3 4 3 SYMBOLIC A symbolic name chosen by the user ending with 96 This indicates an integer data type all references will access register r SYMBOLIC A symbolic name chosen by the user and ending with This indicates a boolean data type and all references will access bit number b register r SLOT Slot number that the module is plugged into This number may range from 0 15
2. TRUE clock enable 5000 5001 Place additional initialization software here 5002 6000 6001 The next statement synchronizes the task with the external 6002 event via the interrupt Task execution will be suspended 6003 until the interrupt occurs If this task is the highest 6004 priority task waiting to execute at the time of the 6005 interrupt it will become active If it is not the 6006 highest priority task it will remain suspended until 6007 all higher priority tasks have executed at which point 6008 it will become active 6009 6010 WAIT ON RESOLVER EVENT 7000 7001 The next statements perform the interrupt service routine 7002 7010 RESOLVER_VALUE RESOLVER 10000 END Control Block Task Example The following is an example of a control block task that handles interrupts from the input module defined in section 4 4 1000 COMMON RESOLVER IN 6 Resolver data 1005 COMMON ISCR VInterrupt status amp control 1010 COMMON CCLK MCommon clock enable 1020 COMMON UPDATE Resolver conversion time 1200 LOCAL RESOLVER VALUE 6 Resolver value 2000 2001 Define the conversion parameters 2002 2010 UPDATE_TIME 100 Convert every 50 milli seconds 3000 3001 The following statement connects the name RESOLVER EVENT 3002 the interrupt defined in ISCR The event name chosen should 3003 be as meaningful as possible T
3. REGISTER Specifies the register that is being referenced This number may range from 0 4 BIT Used with Boolean data types only Specifies the bit in the register that is being referenced This number may range from 0 15 Examples of Local I O Definitions The following statement assigns the symbolic name POSITION to register 0 of the input module located in slot 4 1020 POSITION SLOT 4 REGISTER 0 The following statement assigns the symbolic name CCLK_ON to bit 6 of register 3 on the input module located in slot 7 2050 IODEF CCLK_ON SLOT 7 REGISTER 3 BIT 6 Remote Definition This section describes how to configure the module when it is located in a rack that is remote from the processor module referencing it Refer to figure 4 5 Remote I O Master Module Remote Slave Processor Module 4 3 1 Remote Slave Master Rack Remote Slave Figure 4 5 Module in a Remote Rack Single Register Reference Use this method to reference a 16 bit register as a single input Resolver input data and update period registers are typically r
4. 1230 LOCAL EVENT_DISTANCE Resolver travel from event to scan 2000 2001 Define the conversion parameters 2002 2010 UPDATE 100 MConvert every 50 milliseconds 3010 EVENT NAME RESOLVER_EVENT INTERRUPT_STATUS ISCR amp TIMEOUT 12 4010 CCLK TRUE MCommon clock enable 6008 6010 CALL SCAN LOOP TICKS 9 EVENT RESOLVER EVENT 7000 7001 The next statements catch the occurence 7002 of the strobe and reset it 7003 7010 CALL TRANSITION INPUT STROBE STATUS 0 amp OUTPUT STROBE_RESET 7020 STROBE_ACK NOT STROBE_RESET 4 7 4 7 1 4 7 2 4 7 3 7025 7026 The next statement calculates the distance 7027 traveled from the occurrence of the external 7028 event until this scan 7029 7030 CALL PULSE MULT INPUT RESOLVER amp RESET STROBE 8 INITIAL VALUE RESOLVER_IN_EXT 8 MULTIPLIER 16385 amp OUTPUT EVENT_DISTANCE 7036 The next statement calculates the distance traveled 7037 from the last scan until this scan 7039 7040 PULSE MULT INPUT RESOLVER_IN MULTIPLIER 16385 amp OUTPUT PERIOD_DISTANCE 7046 7047 The next statement calculates the correction 7048 required to synchronize the external event to 7049 the program 7050 7060 DIFFERENCE INPUT1 PERIOD_ DISTANCE amp INPUT2 EVENT_DISTANCE amp OUTPUT RESOLVER_VALUE 10000 END Restrictions This section describes lim
5. Description 2 1 2 1 Mechanical Description 2 1 2 2 Electrical Description eere ee eme er eene 2 1 Installation aaa ehm mh SR C 3 1 31 d nr re een IRE RS 3 1 3 2 Initial Installation e 3 1 3 3 Module 3 5 Programming zu 6 una an ae a aa RR 4 1 4 1 Register Organization 4 1 42 Local l O Definition comic 4 2 4 2 1 Single Register Reference 4 3 4 2 2 Bit Reference HR 4 3 4 2 3 Examples of Local I O Definitions 4 4 4 3 Remote I O 4 4 4 3 1 Single Register Reference 4 5 4 3 2 BitReference cic cise rea ete nemen 4 6 4 3 3 Examples of Remote I O Definitions 4 6 4 4 Reading and Writing Data in Application Tasks 4 6 4 4 1 BASIC Task Example 4 7 4 4 2 Control Block Task Example 4 7 4 5 Using Interrupts in Application Tasks 4 8 4 5 4 BASIC Task Example 4 9 4 5 2 Control Block Task Example 4 9 4 6 Using the External Strobe 4 10 4 7 Restrictions nee e kh EEEE ENE EY 4 11 4 7
6. a fixed position and stopped The external strobe input should now be closed Verify that register 1 contains the same data as register 0 Step 11 Turn off power to the rack Connect the mechanical coupling between the resolver and the motor Turn on power to the system 3 3 Module Replacement WARNING INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE MODULE OR ITS CONNECTING CABLES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY Use the following procedure to replace a module Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Turn off power to the rack and all connections Use a screwdriver to loosen the screws holding the connector to the module Remove the connector from the module Loosen the screws that hold the module in the rack Remove the module from the slot in the rack Place the module in the anti static bag being careful not to touch the connectors on the back of the module Place the module in the cardboard shipping container Take the new module out of the anti static bag it came in being careful not to touch the connectors on the back of the module Insert the module into the desired slot in the rack Use a screwdriver to secure the module into the slot Attach the field terminal connector M N 57C373 to the mating half
7. on configuring your remote system Step 2 Verify that the module be accessed Connect the programming terminal to the system and run the ReSource Software Use the MONITOR function to display the four registers on the input module Repeat steps 7 and 8 in section 3 2 Step 3 Verify that the user application program is correct Review the programming examples in sections 4 4 4 5 and 4 6 Make certain that the I O definitions your configuration task are correct and that the task s using this module have declared these variables COMMON Verify that an update period has been written to register 4 Recall that each count is 500 microseconds 0005 seconds This value specifies the frequency with which the resolver position will be converted to digital numbers Verify that the common clock has been turned on The CCLK OK LED on the faceplate of the module should be lit If the common clock is not present on the backplane the module will not convert the resolver position to digital values If the common clock is being generated from this module remember that bit 6 in register 3 must be set Step4 Verify that the resolver is wired correctly Remove power from the system Disconnect the mechanical coupling between the resolver and the motor Confirm that all the terminal strip connections are tight Refer to figures 3 2 and 3 3 Appendix C also lists the terminal strip connections Apply power to the rack
8. proper interrupt control definitions Refer to the example in section 4 6 Verify that the user application program is correct Verify that the application program that uses the symbolic names defined in the configuration task has defined those names as COMMON Compare your interrupt task with the examples given in sections 4 5 1 and 4 5 2 Make certain that the actions shown in the examples are performed in the same order in your task 5 3 1 5 3 2 5 3 3 No Interrupts Problem The program does not execute but no error codes are displayed on the processor module faceplate If interrupts are never received by the application program and the timeout parameter in the event definition was disabled the task will never execute The watchdog timer for this module should never be disabled Before you can determine why the program did not execute you must first set the timeout parameter in the event definition Run the program again and proceed to section 5 3 2 Hardware Event Time Out Problem All tasks in the chassis are stopped and error code 12 appears on the faceplate of the processor module The interrupt has either never occurred or is occurring at a slower frequency than the value specified in the timeout parameter in the event definition Use the following procedure to isolate the problem Step 1 Verify that the timeout value is set correctly Check the value specified in the timeout parameter in the event def
9. reset whenever power is turned on to the system or a board reset command occurs 2 1 The module produces 26 volt rms 2381 Hertz sine wave reference output signal which is capable of driving a 400 ohm load This reference signal is transformer isolated and short circuit protected through a current limiter The module also receives 11 8 volt rms sine and cosine signals from the resolver as well as the 26 volt rms reference There are 5 LEDs on the faceplate of the module The top LED labeled DIRECTION indicates the direction of rotation of the resolver When it is on the resolver is rotating clockwise The next LED labeled FDBK OK indicates that the resolver is connected to the module The next LED labeled CCLK OK indicates that the common clock is on The fourth LED labeled IPS OK indicates that the isolated power supply is working Finally the bottom LED labeled OK indicates whether the common clock is on and the isolated power supply is functional See figure 2 3 T 2200 pf Figure 2 1 External Strobe Input Circuit Figure 2 2 Low Leakage Requirement for Devices Driving Strobe Input 2 2 RESOLVER INPUT 57C411 RELIANCE ELECTRIC Figure 2 3 Module Faceplate 2 8 3 0 INSTALLATION 3 1
10. the DCS 5000 Enhanced BASIC Language Instruction Manual J 3600 for more information Control Block Task Example The following example will read the resolver data every 55 milliseconds and store the inverted value in the symbol READING The resolver s shaft position will be sampled every 500 microseconds 1000 COMMON RESOLVER 9 MResolver data periodic 1010 COMMON CCLK ENG MCommon clock enable 1020 COMMON UPDATE TIME 6 Update period for resolver conv 1400 1500 LOCAL READING Current negative value of input 1600 4 5 2000 1 500 2010 CCLK TRUE on the clock 4000 4001 Place any additional initialization software here 4002 4998 Scan every 55 msec 4999 5000 SCAN LOOP TICKS 10 5010 RESOLVER_IN OUTPUT READING 10000 END The symbolic names defined as COMMON reference the inputs defined in the sample configuration task above The symbolic name READING is local to the BASIC task and does not have I O associated with it Refer to the DCS 5000 Control Block Language Instruction Manual J 3601 for more information Using Interrupts in Application Tasks The input module supports an interrupt on the periodic resolver to digital conversion Interrupts are used to synchronize software tasks with the resolver to digital conversion Conversion rates may
11. the operating system and must not be manipulated by the user Refer to figure 4 2 For this module to operate properly the common clock signal must be present on the backplane The common clock signal is a 4 mhz clock that can be connected to all the modules in the rack It can be generated from a number of DCS 5000 I O modules If this module is to drive the common clock bit 6 must be set 4 1 bits register 2 register 3 15 14 13 12 1110 9 8 7 6 R R R R R R RW R R RW R R RW l U Interrupt line ID Interrupt allocated Interrupt clock enable Interrupt enabled Module fault Resolver not connected Common clock off Isolated power fault External strobe reset Position angle increasing External strobe status Interrupt flag status Figure 4 2 Interrupt Control Registers Register 4 contains the update period for reading the resolver position Each count in this register is equivalent to 500 microseconds The update period may range from 500 microseconds to 32 7675 seconds Refer to figure 4 3 bits 15 14 13 12 11 10 9 8 7 register 4 update period 4 2 4 2 Figure 4 3 Resolver Update Register Local I O Definition Before any application program can be written it is necessary to configure or set the definitions of system wide variables i e those that must be globa
12. 1 Writing Data to Registers 4 11 4 7 2 Interrupts in Remote I O Racks 4 11 4 7 3 Feedback Element in a Drive System 4 11 Diagnostics and Troubleshooting 5 1 51 Incorrect entered 5 1 6 2 BUSIEMON 5 3 5 3 lnterrupt Problems iiis 5 4 5 31 Ne interrupts au nen 5 5 5 3 2 Hardware Event Time Out 5 5 5 3 3 Hardware Event Count Limit Exceeded 5 5 5 3 4 Illegal Interrupt Detected 5 6 Technical Specifications Appendix B Module Block Diagram xe rr Ree Rr a Appendix C Field Connections ee Related Components a aed List of Figures Figure 2 1 External Strobe Input 2 2 Figure 2 2 Low Leakage Requirement for Devices Driving Strobe Input 2 2 Figure 23 Module Faceplate iii laa Di epe ees 2 3 Figure 3 1 Rack Slot Numbers 3 1 Figure 3 2 Typical M N 57C360 Resolver Field Connections 3 2 Figure 3 3 Typical M N 57C361 Resolver Field Connections 3 3 Figure 3 4 Changing the Direction of Rotation 3 4 Figure 4 1 Resolver Data R
13. ROGRAMMING TERMINAL INSTRUCTION MANUAL J 3635 DCS 5000 PROCESSOR MODULE INSTRUCTION MANUAL e EEE 518 GUIDE FOR THE INSTALLATION OF ELECTRICAL EQUIPMENT TO MINIMIZE ELECTRICAL NOISE INPUTS TO CONTROLLERS FROM EXTERNAL SOURCES 1 1 2 0 2 1 2 2 Mechanical Electrical Description The following is a description of the faceplate LEDs field termination connectors and electrical characteristics of the field connections Mechanical Description The input module is a printed circuit board assembly that plugs into the backplane of the DCS 5000 rack It consists of the printed circuit board a faceplate and a protective enclosure The faceplate contains tabs at the top and bottom to simplify removing the module from the rack Module dimensions are listed in Appendix A The faceplate of the module contains a female connector socket and 5 LED indicators for module status including one light that indicates when the board is operational on or malfunctioning off Input signals are brought into the module via a multiconductor cable M N 57C373 see Appendix D One end of this cable attaches to the faceplate connector while the other end of the cable has stake on connectors that attach to a terminal board for easy field wiring The faceplate connector socket and cable plug are keyed to prevent the cable from being plugged into the wrong module On the back of the module are two edge connectors that attach to the system backpla
14. Resolver Input Module M N 57 411 Instruction Manual J 3640 1 ae ELECTRIC information this user s manual is subject to change without notice Reli ance Electric Industrial Company assumes no responsibility for errors that may appear in this user s manual WARNING THIS UNIT AND ITS ASSOCIATED EQUIPMENT MUST BE INSTALLED ADJUSTED AND MAINTAINED BY QUALIFIED PERSONNEL WHO ARE FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF ALL EQUIPMENT IN THE SYSTEM AND THE POTENTIAL HAZARDS INVOLVED FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY WARNING INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOVEMENT TURN OFF POWER TO THE MACHINE BEFORE INSERTING OR REMOVING THE MODULE OR 5 CONNECTING CABLES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY CAUTION THIS MODULE CONTAINS STATIC SENSITIVE COMPONENTS CARELESS HANDLING CAN CAUSE SEVERE DAMAGE DO NOT TOUCH THE CONNECTORS ON THE BACK OF THE MODULE WHEN NOT IN USE THE MODULE SHOULD BE STORED IN AN ANTI STATIC BAG THE PLASTIC COVER SHOULD NOT BE REMOVED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT Reliance is a registered trademark of Reliance Electric and its subsidiaries 1 0 2 0 3 0 4 0 5 0 Introduction nu u 0000 0000 ann nn Ee ROCA a E CR 1 1 Mechanical Electrical
15. SINE VOLTAGE 11 8 Vrms COSINE VOLTAGE 11 8 Vrms 90 k Figure 3 3 Typical M N 57 361 Resolver Field Connections Step 6 Insert the cable assembly s M N 57 373 field terminal connector into the mating half on the module Use a screwdriver to secure the connector to the module Note that both the module and the terminal strip connector are equipped with keys These keys should be used to prevent the wrong cable from being connected to the module in the event that the connector needs to be removed for any reason and then reattached later At the time of installation rotate the keys on the module and the connector so that they can be connected together securely It is recommended that for modules so equipped the keys on each succeeding module in the rack be rotated one posistion to the right of the keys on the preceeding module If you use this method the keys on a particular connector will be positioned in such a way as to fit together only with a specific module and there will be little chance of the wrong connector being attached to a module Step 7 Check the wiring and be sure all connections are tight Step 8 With the resolver mechanically disconnected from the motor turn on power to the rack Use an oscilloscope to test the sine and the cosine signals from the resolver These signals measur
16. The installation of wiring should conform to all applicable codes To reduce the possibility of electrical noise interfering with the proper operation of the control system exercise care when installing the wiring from the system to the external devices For detailed recommendations refer to IEEE 518 You should use twisted pair 2 twists per inch wiring to from the resolver 3 2 Initial Installation Use the following procedure to install the module WARNING INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE MODULE OR ITS CONNECTING CABLES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY Step 1 Remove power from the system Power to the rack as well as all power to the wiring leading to the module should be off Step 2 Take the module out of its shipping container Take the module out of the anti static bag Be careful not to touch the connectors on the back of the module Step3 Insert the module into the desired slot in the rack Refer to figure 3 1 Use a screwdriver to secure the module into the slot zu 16 Slot Rack Zo 10 Slot Rack zer 6 Slot Rack 13 14 15 Figure 3 1 Rack Slot Numbers 3 1 Step 4 Mount the terminal strip from cable assembly M N 57C373 on a panel The terminal strip should be
17. UT RESOLVER_VALUE 10000 END Using the External Strobe Input Atthe time ofthe external event the resolver position is transferred to register 1 where it will remain until the next event occurs If your application software is reading the resolver position at a periodic rate register 0 the difference between register 0 and register 1 represents the amount of travel from the time that the event occurred until the current scan of the application software A typical application would be detecting the leading edge of an object moving on a conveyor The data captured by the strobe input will be as accurate as the external device driving the input Note that when a strobe input has occurred you must reset the input so that another one can occur This is accomplished by writing a 1 to bit 12 of register 3 The following is an example of a control block task that handles the strobe input from the input module defined in section 4 4 1000 COMMON RESOLVER IN 6 MResolver data 1001 COMMON RESOLVER IN Strobe resolver data 1005 COMMON ISCR status 8 control 1010 COMMON CCLK clock enable 1020 COMMON UPDATE Resolver conversion time 1030 COMMON STROBE STATUS Strobe status 1040 COMMON STROBE Strobe acknowledge 1200 LOCAL RESOLVER Resolver value 1210 LOCAL STROBE_RESET Strobe state 1220 LOCAL PERIOD DISTANCE 6 Resolver travel scan scan
18. an output for each reference throughout the scan The following is an example of a configuration task for the input module 1000 1001 resolver input 1002 1005 IODEF RESOLVER IN 6 SLOT 4 REGISTER 0 1006 IODEF RESOLVER 510 4 REGISTER 1 1010 1011 common clock enable 1012 1015 IODEF CCLK_EN SLOT 4 REGISTER 3 BIT 6 1020 1021 A D update period 1022 1025 IODEF UPDATE_TIME SLOT 4 REGISTER 4 1050 1051 Place any additional configuration statements here 1052 2000 END BASIC Task Example This example will read the resolver input once every second and store the value in the symbol CURRENT VALUE resolver position will be sampled every 100 milliseconds 1000 COMMON RESOLVER_IN Resolver data periodic 1010 COMMON CCLK Mcommon clock enable 1020 COMMON UPDATE TIME 6 MUpdate period for resolver conversion 1400 1500 LOCAL CURRENT VALUE 6 Current value of analog input 1900 2000 UPDATE TIME 6 200 1 second conversion 2010 TRUE Mturn on the clock 4000 4001 Place any additional initialization software here 4002 5000 START EVERY 1 SECONDS 5010 CURRENT_VALUE RESOLVER 10000 END The symbolic names defined as COMMON reference the inputs defined in the sample configuration task above The symbolic name CURRENT VALUE 6 is local to the BASIC task and does not have I O associated with it Refer to
19. ance is not within the 35 to 100 ohm range the resolver is malfunctioning and should be replaced If the problem is still present check the cable for a possible short Reconnect the resolver cable at TB 1 and 2 Remove power from the rack Reconnect the mechanical coupling between the resolver and the motor Reapply power to the system Verify that the hardware is working properly WARNING INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE MODULE ORITS CONNECTING CABLES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY If all of the proper signals are present and the values are still not correct the problem lies in the hardware Verify the hardware functionality by systematically swapping out modules After each swap if the problem is not corrected replace the original item before swapping out the next item 5 2 To test local I O first replace the input module Next replace the processor module s If the problem persists take all of the modules except one processor module and the input module out of the backplane If the problem is now corrected one of the other modules in the rack is malfunctioning Reconnect the other modules one at a time until the problem reappears If none of these tests reveals the problem replace the backplane To test remote first verify th
20. at the remote 1 system is communicating with the drop that contains the input module being tested Next by systematically swapping out modules determine whether the input module is the only module that is not working If more than one module is not working correctly the problem most likely lies in the remote I O system Refer to the the DCS 5000 Remote Instruction Manual J 3629 for additional information If the problem does not lie in the system it probably involves the remote rack To test the remote rack first replace the input module If the problem persists take all of the modules out of the remote backplane except the slave remote module and the input module If the problem is now corrected one of the other modules in the rack is malfunctioning Reconnect the other modules one at a time until the problem reappears If the problem proves to be neither in the remote I O system nor in the remote rack try replacing the backplane Bus Error Problem A 31 or 16 appears on the processor module s LED This error message indicates that there was a bus error when the System attempted to access the module The possible causes of this error are a missing module a module in the wrong slot or a malfunctioning module It is also possible that the user has attempted to write to the wrong registers on the module Use the following procedure to isolate a bus error Step 1 Step 2 Verify that the input module i
21. be specified from 500 microseconds up to a maximum of 32 7675 seconds in increments of 500 microseconds In order to use interrupts on the input module it is necessary to assign symbolic names to the interrupt control register This is accomplished with IODEF statements in the configuration task Note that interrupts cannot be used with modules located in remote racks Only one task may act as a receiver for a particular hardware interrupt That task should declare the symbolic names assigned to the interrupt control register on the input module as COMMON Once this has been done any reference to those symbolic names within the task will reference the bits or register defined in the configuration task The following is an example of a configuration task for an input module using interrupts 1000 1001 resolver data 1002 1005 IODEF RESOLVER_IN SLOT 4 REGISTER 0 1006 IODEF RESOLVER_IN_EXT SLOT 4 REGISTER 1 1010 1011 interrupt status and control register used by the operating system 1012 1014 STROBE_STATUS SLOT 4 REGISTER 2 BIT 14 1015 ISCR SLOT 4 REGISTER 3 1016 STROBE_ACK SLOT 4 REGISTER 3 BIT 12 1020 1021 common clock enable 1022 1025 IODEF CCLK_EN SLOT 4 REGISTER 3 BIT 6 1030 1031 resolver conversion period 1032 1035 IODEF UPDATE_TIME SLOT 4 REGISTER 4 1050 1051 Place additional configuration statements here 1052 2000 END This c
22. ed at the terminal strip should be a sine wave of approximately 33 4 Vp p 11 8 Vrms 1096 Step 9 Verify the installation by using the Programming Executive Software Refer to the AutoMax Programming Executive Manual J 3630 or J 3684 for more information Use the I O MONITOR function for local I O or remote I O depending upon where the module is located Set register 4 to a value of 1 Read register 2 and verify that bit 10 is set If it is not set register to a value of 64 3 3 3 4 Monitor register 0 Verify that it contains numbers proportional to the shaft position of the resolver and that the numbers increase as the resolver is rotated clockwise The direction of rotation can be reversed by switching the polarity of either the sine or the cosine wires See figure 3 4 CLOCKWISE ROTATION COUNT UP Y SIN SIN SINE COSINE Q COS U COS RESOLVER 570411 CLOCKWISE ROTATION COUNT DOWN SIN SIN COS COS 57C411 RESOLVER OR CLOCKWISE ROTATION COUNT DOWN SIN SIN Q p um COS COS 576411 RESOLVER NOTE 1 wires should be twisted pairs NOTE 2 Reversing the polarity of the wires as shown will also change the perceived shift angle by 180 elec trical degrees Figure 3 4 Changing the Direction of Rotation Step 10 If the external strobe input is being used the shaft should be rotated to
23. eferenced using this method The symbolic name of each register should be as meaningful as possible nnnnn RIODEF SYMBOLIC MASTER SLOT m DROP d SLOT s REGISTER r 4 5 4 3 2 4 3 3 4 4 4 6 Use this method to reference individual inputs on the module Common clock status and control bits are typically referenced using this method The symbolic name of each bit should be as meaningful as possible nnnnn RIODEF SYMBOLIC MASTER SLOT m SLOT s REGISTER r BIT b where nnnnn BASIC statement number This number may range from 1 32767 SYMBOLIC_NAME A symbolic name chosen by the user and ending with This indicates an integer data type and all references will access register r SYMBOLIC A symbolic name chosen by the user and ending with This indicates a boolean data type and all references will access bit number b register MASTER SLOT Slot number that the master remote module is plugged into This number may range from 0 15 DROP Drop number of the slave remote module that is in the same rack as the input module This number may range from 1 7 SLOT Slot number that the module is plugged into This number may range from 0 15 REGISTER Specifies the register that is being referenced This number may range from 0 4 BIT Used with boolean data types only Specifies t
24. egisters 4 1 Figure 4 2 Interrupt Control Registers 4 2 Figure 4 3 Resolver Update Register 4 2 Figure 4 4 Module a Local Rack 4 3 Figure 4 5 Module in a Remote Rack 4 5 1 0 INTRODUCTION The Resolver Input Module is used to input the angular position of a resolver rotor to the DCS 5000 system The module provides 12 bit resolution of one revolution and a 2 bit revolution counter The resolver position may be sampled from 500 microseconds to 32 767 seconds An external strobe input is provided to permit synchronization of the DCS 5000 system to an external event The module can be programmed to interrupt on every sample Typically this module is used to input rotary shaft position for the purpose of determining shaft position or velocity This manual describes the functions and specifications of the module It also includes a detailed overview of installation and servicing procedures as well as examples of programming methods Related publications that may be of interest J 2611 DCS 5000 PRODUCT SUMMARY J 3600 DCS 5000 ENHANCED BASIC LANGUAGE INSTRUCTION MANUAL J 3601 DCS 5000 CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL e J 3602 DCS 5000 LADDER LOGIC LANGUAGE INSTRUCTION MANUAL J 3629 DCS 5000 REMOTE INSTRUCTION MANUAL J 3630 DCS 5000 P
25. er Green External Trigger White Green Stripe C 1 Related Components 800123 R Resolver X1 57 360 800123 5 Resolver X2 800123 T Resolver X5 Designed for both foot mounting and C face mounting 800123 2R Resolver X1 57C361 800123 25 Resolver X2 800123 2T Resolver X5 Designed for direct coupling 57C373 Terminal Strip Cable Assembly This assembly consists of a terminal strip cable and mating connector It is used to connect field signals to the faceplate of the input module le la e al lel el le le O D 1 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication J 3640 1 June 1990 Copyright 2002 Rockwell Automation Inc All rights reserved Printed in U S A
26. essed Then either verify that the system is incapable of reaching that speed or else incorporate the necessary hardware software to ensure that this limit will never be exceeded WARNING THE PURCHASER IS RESPONSIBLE FOR ENSURING THAT DRIVEN MACHINERY ALL DRIVE TRAIN MECHANISMS AND THE WORKPIECE IN THE MACHINE ARE CAPABLE OF SAFE OPERATION AT MAXIMUM SPEEDS FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY AND IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT 4 12 5 0 5 1 DIAGNOSTICS AND TROUBLESHOOTING This section explains how to troubleshoot the module and field connections Incorrect Data Problem The data is either always off always on or different than expected The possible causes of this error are a module in the wrong slot a programming error or a malfunctioning module It is also possible that the input is either not wired or wired to the wrong device Use the following procedure to isolate the problem Step 1 Verify that the input module is in the correct slot and that the definitions are correct Refer to figure 3 1 Verify that the slot number being referenced agrees with the slot number defined in the configuration task Verify that the register number and the bit number are correct For remote installations also verify that the master slot and drop numbers are defined correctly Refer to the DCS 5000 Remote Instruction Manual J 3629 for more detailed information
27. he bit in the register that is being referenced This number may range from 0 15 Examples of Remote Definitions The following statement assigns the symbolic name SHAFT to register 0 the input module located in slot 4 of remote drop 3 This remote drop is connected to the remote I O system whose master is located in slot 15 in the master rack 1020 RIODEF SHAFT MASTER SLOT 15 DROP 3 SLOT 4 REGISTER 0 The following statement assigns the symbolic name CLCK_EN to bit 6 of register on the input module located slot 7 of remote drop 2 This remote drop is connected to the remote system whose master is located in slot 6 in the master rack 2050 RIODEF CLCK_EN MASTER SLOT 6 DROP 2 SLOT 7 REGISTER 3 BIT 6 Reading and Writing Data in Application Tasks In order for an input module to be referenced by application software it is first necessary to assign symbolic names to the physical hardware This is accomplished with either IODEF or RIODEF statements in the configuration task 444 4 4 2 Each application program or task that wishes to reference the symbolic names assigned to the input module may do so by declaring those names COMMON The frequency with which tasks read their inputs and write their outputs depends on the language being used Control block tasks read inputs once at the beginning of each scan and write outputs once at the end of scan BASIC tasks read an input and write
28. he watchdog timeout has 3004 been set to 12 clock ticks 66 msec If the time between 3005 interrupts exceeds this value a severe error will be declared 3006 and the system will be stopped For more information refer to the 3007 DCS 5000 Enhanced BASIC Language Instruction Manual J 3600 3008 3010 EVENT NAME RESOLVER EVENT amp 3011 INTERRUPT_STATUS ISCR TIMEOUT 12 4 9 4 6 4 10 4000 4001 The following statement enables common clock from this module 4002 If there is more than one interrupt task in a chassis the task 4003 that enables common clock should always be the lowest priority 4004 task 4005 4010 CCLK TRUE MCommon clock enable 5000 5001 Place additional initialization software here 5002 6000 6001 The next statement synchronizes the task with the external 6002 event via the interrupt Task execution will be suspended 6003 until the interrupt occurs If this task is the highest 6004 priority task waiting to execute at the time of the 6005 interrupt it will become active If it is not the 6006 highest priority task it will remain suspended until 6007 all higher priority tasks have executed at which point 6008 it will become active 6009 6010 CALL SCAN_LOOP TICKS 9 EVENT RESOLVER EVENT 7000 7001 The next statements perform the interrupt service routine 7002 7010 PULSE_MULT INPUT RESOLVER_IN MULTIPLIER 16385 8 OUTP
29. inition The unit is in ticks Each tick is equal to 5 5 msec The timeout value should be at least 2 ticks greater than the interrupt frequency It can reasonably range up to 1 5 times the interrupt frequency Step 2 Verify that the user application program is correct Review the examples in section 4 5 Make certain that common clock has been enabled Step 3 Verify that the hardware is working correctly Systematically swap out the input module the processor module s and the backplane After each swap if the problem is not corrected replace the original item before swapping out the next item Hardware Event Count Limit Exceeded Problem All tasks in the chassis are stopped and error code 1b appears on the faceplate of the processor module A hardware interrupt has occurred but no task is waiting Use the following procedure to isolate the problem Step 1 Verify that the user application program is correct Verify that your interrupt response task contains either a WAIT ON event or CALL SCAN LOOP statement that will be executed Check carefully to determine whether a higher priority task is preventing the interrupt response task from running Make certain that the ordering of your statements agrees with the examples in section 4 5 Step 2 Verify that the hardware is working correctly Verify the hardware functionality by systematically swapping out the input module the processor module s and the backpla
30. itations and restrictions on the use of this module Writing Data to Registers Registers 0 2 are read only and may not be written to by the application software Attempts to write to them will cause a bus error severe system error The following are examples from programs that write to the module and should therefore be avoided Referencing the module on the left side of an equal sign LET statement in a control block or BASIC task b Referencing a resolver input as an output in a control block function Interrupts in Remote I O Racks This module cannot be used in the interrupt mode in a remote rack Feedback Element in a Drive System When this module is used with a resolver in a drive control system you must incorporate an independent method of determining that this module is actually reading proper motor RPM It is necessary to determine this because this module is not capable of detecting a loss of feedback in all situations such as for example a broken coupling between the motor and resolver 4 11 WARNING LOSS OF OR OTHERWISE IMPROPER RESOLVER SIGNAL CAN RESULT IN UNCONTROLLED MOTOR SPEED PROVIDE AN INDEPENDENT METHOD OF SHUTTING DOWN EQUIPMENT IF THIS SHOULD OCCUR FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY AND IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT You must also determine the maximum safe operating speed for the motor connected machinery and material being proc
31. lly accessible to all tasks This section describes how to configure the input module when it is located in the same rack as the processor module that is referencing it Refer to figure 4 4 Processor Module x W MM 275W POWER SUPPLY RESOLVER INPUT 57 411 POWER PSREADY O SYSTEM READY O BLOWN FUSE NORMAL PROGRAM ICH BATTERY BACKUP afefe Je 2 a o To a
32. mounted to allow easy access to the screw terminals Be sure that the terminal strip is close enough to the rack so that the cable will reach between the terminal strip and the module The cable assembly is approximately 60 inches long Step 5 Attach the resolver but leave the mechanical coupling between the resolver and the motor unconnected Fasten the field wires from the resolver to the terminal strip Typical field connections are shown in figures 3 2 and 3 3 Use twisted pair wire connected as shown for the cabling between the resolver and the terminal strip in the control enclosure Recommended twisted pair wire is Belden 9497 cable or equivalent Maximum operating cable length is dependent upon the type of cable you use Make certain that all field wires are securely fastened M N 57C360 RESOLVER Terminal Strip in Control Enclosure 1 FROM MODULE 2 REFERENCE D 2 N n TO MODULE 9 SINE MEMM REFERENCE VOLTAGE 26 Vrms SINE VOLTAGE 11 8 Vrms COSINE VOLTAGE 11 8 Vrms 600600 AJOJN Figure 3 2 Typical 57C360 Resolver Field Connections 3 2 M N 57C361 RESOLVER Terminal Strip in Contro Enclosure N FROM MODULE gt 0 OO TO MODULE SINE MEMMF REFERENCE VOLTAGE 26 Vrms
33. ne Electrical Description The input module contains a tracking resolver to digital converter that produces a 12 bit digital number proportional to one electrical revolution of a resolver The digital position may be sampled in one of two ways The most common method is to specify the sampling period The period may range from a low of 500 microseconds to a high of 32 7675 seconds in increments of 500 microseconds The second method is to sample the position when an external event occurs This method is useful when it is necessary to synchronize the DCS 5000 with the occurrence of a particular event Using an external strobe input is a simple method of synchronizing your application software to the exact position of an object when an external event occurs See figure 2 1 for details about the electrical characteristics of the external strobe input circuit Because of the high input impedance of the strobe input the device driving the input must have low leakage See figure 2 2 The module can be programmed to generate an interrupt whenever it does a periodic sample This mode allows you to synchronize task execution with the conversion of new data The converted data will be latched when the interrupt is generated The module contains a 2 bit electronic counter that can count a total of 4 electrical resolver revolutions This 2 bit counter is contained in the most significant two bits of resolver position registers 0 and 1 This counter is
34. ne After each swap if the problem is not corrected replace the original item before swapping out the next item 5 5 5 6 5 3 4 Illegal Interrupt Detected Problem All tasks in the chassis are stopped and error code appears on the faceplate of the processor module A hardware interrupt has occurred but no event has been defined Step 1 Step 2 Verify that the user application program is correct Verify that your interrupt response task contains an EVENT statement that will be executed Check carefully to determine whether a higher priority task is preventing the interrupt response task from running Make certain that the ordering of your statements agrees with the examples in section 4 5 Verify that the hardware is working correctly Verify the hardware functionality by systematically swapping out the input module the processor module s and the backplane After each swap if the problem is not corrected replace the original item before swapping out the next item Technical Specifications Ambient Conditions e Storage temperature 40 85 C Operating temperature 0 C 60 C Humidity 5 90 non condensing Maximum Module Power Dissipation e 10 Watts Dimensions Height 11 75 inches e Width 1 25 inches Depth 7 375 inches System Power Requirements 5 Volts 1700 ma 12 Volts 95 ma 12 Volts 95 ma Resolver Specifications F
35. on the module Make certain that the connector is the proper one for this module see step 6 in 3 2 Initial Installation Use a screwdriver to secure the connector to the module Turn on power to the rack 3 5 4 0 PROGRAMMING This section describes how the data is organized in the module and provides examples of how the module is accessed by the application software For more detailed information refer to the DCS 5000 Enhanced BASIC Language Instruction Manual J 3600 4 1 Register Organization The input module contains a total of five 16 bit registers Registers 0 and 1 contain resolver position data The resolver to digital converter provides 12 bits of resolution Register 0 is updated with new position information at the rate specified in register 4 Register 1 is updated whenever the EXTERNAL STROBE goes from false to true These registers are read only Refer to figure 4 1 bits 15 14 18 12 11 10 9 8 7 6 j 1 1 1 1 register 0 resolver data 1 register 1 resolver external latch data 1 1 1 i electronic revolution counter Figure 4 1 Resolver Data Registers Registers 2 and 3 are the interrupt status and control registers Both registers contain the same information Register 2 is read only Register 3 is read write If the module is located in a remote rack you must read the status from register 2 With the exception of bit 6 and bit 12 this register is controlled by
36. onfiguration defines all of the information most commonly used on the module Unused definitions should be deleted by the user 4 5 1 4 5 2 BASIC Task Example The following is an example of a BASIC task that handles interrupts from the input module defined in section 4 4 1000 COMMON RESOLVER 9 Resolver data 1005 COMMON ISCR VInterrupt status amp control 1010 COMMON CCLK ENG MCommon clock enable 1020 COMMON UPDATE Resolver conversion time 1200 LOCAL RESOLVER VALUE 6 Resolver value 2000 2001 Define the conversion parameters 2002 2010 UPDATE_TIME 1000 Convert every 5 seconds 3000 3001 The following statement connects the name RESOLVER_EVENT to the 3002 interrupt defined in ISCR The event name chosen should 3003 be as meaningful as possible The watchdog timeout has 3004 been set to 120 clock ticks 660 msec If the time between 3005 interrupts exceeds this value a severe error will be declared 3006 and the system will be stopped For more information refer to the 3007 DCS 5000 Enhanced BASIC Language Instruction Manual J 3600 3008 3010 EVENT NAME RESOLVER EVENT 3011 INTERRUPT STATUS ISCR 6 TIMEOUT 120 4000 4001 The following statement enables common clock from this module 4002 If there is more than one interrupt task in a chassis the task 4003 that enables common clock should always be the lowest priority 4004 task 4005 4010
37. only 5 1 5 2 Step 5 Step 6 If everything is working properly but the direction of rotation is backwards it may be reversed by switching the polarity of either the sine or the cosine wires as shown in figure 3 4 Verify that the input circuit is working properly Connect an oscilloscope to the proper points on the terminal strip and confirm that the voltages are correct The resolver reference voltage across TB 1 and 2 should be a nominal 26 Vrms If itis 26 Vrms check the jumpers on the terminal strip One jumper should connect TB 1 and 3 Another jumper should connect TB 2 and 4 Rotate the resolver s shaft and measure the sine voltage TB 5 and 6 and cosine voltage TB 7 and 8 Both voltages should range from 0 volts to approximately 11 8 Vrms If the resolver reference TB 1 and 2 is not a nominal 26 Vrms measure the D C resistance of the resolver Disconnect the resolver cable from the terminal strip TB 1 and 2 and measure the resistance across the disconnected wires The resistance should be in the range of 35 to 125 ohms If the resistance is within this range the input module is malfunctioning and should be replaced If the resistance is not within this range disconnect the cabling from the resolver and measure the resistance directly on the resolver If this resistance is reading within the 35 to 100 ohm range the resolver is operating properly Check the cabling for a possible short If the resist
38. ot corrected replace the original item before swapping out the next item To test local I O replace the input module the processor modules s and finally the backplane For remote determine whether the input module is the only module that is not working If it is not the problem most likely lies in the remote system Refer to the DCS 5000 Remote Instruction Manual J 3629 for additional information If the problem does not lie in the remote System it probably involves the remote rack To test the remote rack systematically swap out the input module the slave remote module and finally the backplane After each swap if the problem is not corrected replace the original item before going on to the next swap If none of these actions correct the problem troubleshoot the remote l O system Interrupt Problems Problem No interrupts at all or too many unexpected interrupts signified by error codes on the screen Note that this module must be in the same rack as the processor module that is to receive the interrupts Go through the following steps first before going on to the more specific troubleshooting steps Step 1 Step 2 Verify that the input module is in the correct slot and that the I O definitions are correct Refer to figure 3 2 Verify that the slot number being referenced agrees with the slot number defined in the configuration task Verify that the configuration task contains the
39. requency of operation 2381 Hz e Minimum rotor impedance 400 Ohms e Transformer ratio 26 11 8 External Strobe Minimum Trigger Time 1 millisecond A 1 Module Block Diagram AC BUS RESOLVER INPUT MODULE 57C411 ADDRESS ADDRESS DECODER BUS REFERENCE SINEWAVE GENERATOR REF OUT 2381 Hz CONTROL LINES CONTROL LOGIC gt RESOLVER ANALOG TO DIGITAL CONVERTER GATE DATA BUS COSINE lt 5 O a 2 COUNTER ISOLATED 15 VDC POWER SUPPLY CCLK INTERRUPT 5 1 MEG OHM MULTIBUS STROBE INTERRUPT lt lt CONTROL EXT TRIGGER LOGIC gt BOARD CCLK ON Multibus is a Trademark of Intel Corporation B 1 Field Connections Function Wire Color Code Reference Output Brown Reference Output White Brown Stripe Reference Input Red Reference Input White Red Stripe Sine Input Orange Sine Input White Orange Stripe Cosine Input Yellow Cosine Input White Yellow Stripe External Trigg
40. s in the correct slot and that the I O definitions are correct Refer to figure 3 2 Verify that the slot number being referenced agrees with the slot number defined in the configuration task Verify that the register number is in the range of 0 4 For remote installations also verify that the master slot and remote drop number are defined correctly Refer to the DCS 5000 Remote I O Instruction Manual J 3629 for more information on configuring your remote system Verify that the module can be accessed Connect the programming terminal to the system and run the ReSource Software Use the MONITOR function to display the four registers on the input module If the programmer is able to monitor the inputs the problem lies in the application software refer to step 3 If the 5 3 5 4 5 3 Step 3 Step 4 programmer cannot monitor the inputs the problem lies in the hardware refer to step 4 Verify that the user application program is correct Registers 0 through 2 of the input module cannot be written to If a BASIC task caused the bus error the error log will contain the statement number in the task where the error occurred If a control block task caused the error you will need to search the task for any instances where you wrote to an input Verify that the hardware is working correctly Verify the hardware functionality by systematically swapping out modules After each swap if the problem is n

Resolver Input Module

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