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1746-999-121, Stepper Controller Module

1. Wiring for a Differential Several manufacturers of Stepper Translators provide differential inputs If Interface your Stepper Translator can accept differential line driver outputs follow the interconnection diagram below to connect the Stepper Controller to the translator Differential Input Typical Input Connection 7 24V DC User Refer to page 6 6 Power Supply Electrical Cabinet Ground Bus Wiring to Optocoupler Interface Typical Input Connection Refer to page 6 6 Chapter 6 Installation and Wiring The following diagrams show the circuitry used to interface the Module to a Stepper Translator through two different optocoupler devices The first diagram shows an optocoupler designed for a common power supply connection The second diagram shows an individually isolated optocoupler It is your responsibility to determine which type is used in your specific application and to ensure that connections are properly made Optocoupler Input Common Supply 7 24V DC Electrical Cabinet Ground Bus Chapter 6 Installation and Wiring Wiring to Optocoupler Interface Continued Individually Isolated Optocoupler Typical Input A Connection Baca U Oov Q pag 26 Ll O o CCW Limit CW Limit B Typical Driver Electrical Cabinet Ground Bus 220 Q F5 20mA Max 2209 CW CCW ae Korein YY TI NN 20mA Max Chapter 6 Installation and Wiring Wiring Inform
2. 00000 cece eee e ne aeee System Limitations maka baa Bea alahas exe RSS Discrete Inputs ii eas oce Sad aetate Satan senks ma len a Discrete Outputs 5 ruse bbb RES dae chee Habang eR Input Output Terminals 0 00 cece eee eee Environmental Operating Conditions Storage Temperature 00 a Feedback Circuitry 0 00 a Program Storage Requirements 0000 Processor Compatibility ccc eee eee Bas gt S ko lo le lo a le la le lo Ino In m kh m IN N3 I o 9 Iho IN w I Jo Jo iv Table of Contents Input Output Quick Reference Figures Tables Output Command Word 0 Bit Definition Command Mode Output Words a Command Mode Input Words cence Differential Input Na nagana kd wed edtd bee est dees kas Optocoupler Input Common Supply aaa Individually Isolated Optocoupler suus Ero EP np IN lo la IB l N lo Using This Manual Overview Read this chapter to familiarize yourself with the rest of the manual It p y provides information concerning the e contents of this manual intended audience conventions used hazards of injury or equipment damage Chapter 1 Using This Manual Contents of this Manual This manual provides specific information relevant to the Stepper C
3. e Hold Moves e Resume Moves e Immediate Stop Operations e Homing Operations Jogging Operations e Blend Moves Preset Operations e Reset Errors Diagnostic Mode Use the configuration mode to select the diagnostic mode of operation Once selected the diagnostic mode allows you to test your program and wiring by connecting the loop back wires at the translator The purpose of loop back diagnostics is to test the system wiring for electrical noise The number of pulses received at the feedback should equal the commanded number of pulses at the end of the move If they are not equal the system may be experiencing problems due to electrical noise Chapter 2 Module Overview LED Indicator Diagnostics There are five diagnostic LED indicators provided as shown below Their purpose is to aid in identifying operational problems _ Processor and System O K Pd Commanding a NL STEPPER Controller Commanding Counterclockwise Move Clockwise Motion An error occurred during RUN a No configuration file present command mode operations or invalid configuration CCW CW E RR FLT m 0 e g Chapter 2 Module Overview Input Output Terminals These terminals supply power and inputs to the Module and outputs to attached devices Each can accommodate two 14 gauge wires Release Screw 7 24V DC user power 1 CCW loosen
4. CW or non directional pulse output 2 CW or non directional pulse output 3 CW pulse or direction signal output 4 CCW pulse or direction signal output 5 External interrupt input 6 Home limit switch input 7 Home Proximity limit switch input 8 CW limit switch input 9 CCW limit switch input 10 Pulse train enable disable input 11 A Hi Loopback non directional pulse 12 A Lo Loopback non directional pulse 13 B Hi Loopback direction 14 B Lo Loopback direction 15 Encoder Marker 16 Encoder Marker 17 0 V user power DC common 18 5 Ke ee eo 69 amp 9 69 2 69 69 6969 Release Screw CCW loosen Terminal Block Release Screws These captive screws are attached to the terminal block As the screws are loosened the terminal block moves away from the Module This feature facilitates replacement of the Module without rewiring Chapter 2 Module Overview Chapter Objectives Module Overview Operating Modes Module Operation The information in this chapter will give you a basic understanding of frequency outputs and pulse train configuration which must be considered in the application of the Module The Module is an SLC family compatible Module It is designed for use with an SLC 500 SLC 5 01 SLC 5 02 or SLC 5 03 Processor The motion profile execution is independent of the scan time of the SLC Processor once it is initiated Blended moti
5. 00 000 cece aes 5 Module Operation aaa 1 Chapter Objectives aa 1 Module Overview B A Operating Modes 4i uus Sine Ede ERR OT handang 1 Configuration P ki Command ous eesri m e PRO EVA sey coeds E kl Operation Using the Pulse and Direction Outputs 2 Operation Using the CW and CCW Pulse Train Outputs 2 Fixed Speed Operation 0 00 00 c eee eee eee 3 Origin Home Search Sequence of Operation 3 Resetting the Current Absolute Position 3 Configuration and Programming i Chapter Objectives n n nnna 1 Programming Conventions aaa 1 Configuration and Status Bits a 3 Program Scan scusa dde soe PRI RORERERS AE PANA RANA A SLC Processor Configuration 0 0 0 cece ee eeee Al Processor configuration using APS 05 i Processor configuration using HHT Catalog 1747 PT1 2 ii Table of Contents Module Configuration llle a General Information a a Configuration Error uoo KAB AGE KANG Khan bY ka 3 Configuration mode outputimage table a Configuration mode input image table 5 Invalid Configurations a 5 Programming Command Mode 00000ee eee 6 Output Words SLC Processor to Stepper Controller 6 Output Command Bits for Word 0 0c eee 8 NOTES 2385 nisani ii a NIA uaque did ure T
6. 3 Channel A is high at least part of marker interval Connect to CH A HI of termination point Hi Channel A Lo STEP 1 High marker interval Connect to encoder marker Optional STEP 2 B is high for at least part of marker interval Connect to CH B HI CCW rotation viewing shaft Wire CH B CH A and CH Z to CH B LO CH A LO and CH Z L respectively on the terminal block Chapter 6 Installation and Wiring Encoder Feedback Connections 7 24V DC user power CW or non directional pulse output CW or non directional pulse output CW pulse or direction signal output CCW pulse or direction signal output External interrupt input Home limit switch input Home Proximity limit switch input CW limit switch input CCW limit switch input Pulse train enable disable input A Hi Loopback non directional pulse A Lo Loopback non directional pulse B Hi Loopback direction B Lo Loopback direction Encoder Marker Encoder Marker 0 V user power DC common 6 1 10 The following two diagrams illustrate encoder connections to the Module inputs for both 5 volt and 15 volt encoder power supplies The notes included with each diagram provide specifics on wiring 5 volt encoder feedback connections 1 B 13 AB84H 3 Optical 14 Encoder Electrical Cabinet Ground Bus NOTES 1 Use 3 pair 22 gauge individually twisted and shielde
7. Bit 2 set when immediate stop input is active Position MSW 0 8338 Bit 3 set when external interrupt is active Bit 4 set when home limit switch is active COMMAND OUTPUT WORD 3 Bit5 set when home proximity limit switch is active Position LSW 0 999 Bits 6 through 15 not used COMMAND OUTPUT WORD 4 COMMAND INPUT WORDS 2 and 3 Velocity pulses sec MSW 0 250 report the current position data based on the number of pulses that have been sent to the stepper motor COMMAND OUTPUT WORD 5 COMMAND INPUT WORDS 4 and 5 Velocity pulses sec LSW 0 999 report the axis position based on the feedback from an optional encoder COMMAND OUTPUT WORD 6 Acceleration pulses ms sec 1 2000 COMMAND OUTPUT WORD 7 Deceleration pulses ms sec 1 2000 1 2 9 ALLEN BRADLEY Allen Bradley has been helping its customers improve productivity and quality for 90 years We A ROCKWELL INTERNATIONAL COMPANY design manufacture and support a broad range of control and automation products worldwide They include logic processors power and motion control devices man machine interfaces sensors and a variety of software Allen Bradley is a subsidiary of Rockwell International one of the world s leading technology companies Pad With major offices worldwide m po Algeria e Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bulgaria e Canada e Chile e China PRC e Colombia e Costa Rica e Croatia e Cyprus e Cz
8. O and the mode type is set to configuration mode then reset O 1 0 bit 15 and set Module to command mode Config Error Mode Type Mode Type 1 Error 1 Config 1 Config 0 No Error 0 Command 0 Command I1 I1 EQU EQUAL Source A Source B MOVE Source Dest 0 2 L 0 0 1 U 1 Rung 2 3 If Module is in Command Mode and no error exists but there is an Invalid Position flag set load contents of N9 10 which submits the command to assign to the preset position to the current position Command Error Mode Type Command Mode 1 Error 1 Config Invalid Position 0 No Error 0 Command EQU I1 I1 I1 B3 EQUAL 4 7M Source A 12 15 10 COP COPY FILE Source N9 10 Dest 0 1 0 Length 8 Source B Move Completed Flag I1 U 7 Chapter 5 Application Examples Rung 2 4 Once the preset is complete continue with the next step Command Mode Invalid Position F MOVE Source EQU EQUAL Source A 10 Source B Dest Rung 2 5 If in Command mode and at the origin initiate Abs move to 5000 speed 5000 acceleration 5 and deceleration 5 EQU COP EQUAL COPY FILE Source A Source Dest Source B Length Move Completed Flag I1 U 7 Rung 2 6 Wait here until the previous move completes Move Completed Flag EQU I1 EQUAL Source A Source B Chapter 5 Application Examples Rung 2 7 Delay after loopi
9. encoder power source connect encoder return to OV user power DC common at the power supply sources Chapter Objectives System Start Up Normal Operation Troubleshooting Safety Precautions Removing the Module Chapter 7 Start Up and Troubleshooting This chapter contains information that will help you perform the following start up troubleshooting and error handling procedures The following instructions apply to initial start up of a Module 1 Apply power to the SLC system and to the attached input and output devices 2 Configure the SLC Processor and the Module as instructed in Chapter 4 of this manual 3 Upon successful completion of the configuration steps the SLC Processor will switch the Module to the command mode of operation There are no provisions for local control of the Module Module status is monitored by the five LED indicators located on the front face of the Module Refer to Chapter 2 of this manual for further information on these LED indicators The ERR error and FLT fault LED indicators on the Module face serve as diagnostic tools for use in general troubleshooting If an operation error occurs during command mode operation the ERR LED will light If there is no configuration file resident in the Module or if the resident configuration file is invalid in any way the FLT LED will light More detailed troubleshooting information is provided in the following list ATTENTION
10. file to word 0 of the output address This method is used in word N9 0 of the data table shown in Chapter 5 of this manual page 5 1 00 0 0 10 CO NE Puse J idi a OR UN Direction CW Plus Direction CCW Minus Direction Operation Using the CW and CCW Pulse Train Outputs If the CW and CCW pulse train outputs are required use the following unconditional rung during configuration to ensure that the Stepper Controller does not change operation 00 0 0 10 a T TILA COW T A Fixed Speed Operation Operation at fixed speed will cause the pulse and direction to accelerate at the programmed acceleration rate and reach the final programmed velocity data Use the Jog or Jog to initiate and stop the motion Chapter 3 Module Operation Important Turning the appropriate bit on will cause the axis to move Turning it off causes the axis to decelerate and stop Origin Home Search Sequence of Operation Information on this subject is contained in Chapter 4 of this manual within the topic Find Home CW Find Home CCW Note that the way in which a search is carried out if a home proximity limit switch is present is different from the sequence when a home proximity limit switch is not present The differences are detailed in Chapter 4 Resetting the Current Absolute Position In the event that an Invalid Position input wor
11. home limit switch is detected In this instance the normal acceleration deceleration and velocity parameters are disregarded The find home command requires the presence of at least one end limit switch whether or not a home proximity switch is present If only one end limit switch is used it is the programmer s responsibility to ensure that the find home command has the correct direction or The Module does not accept a find home command unless the corresponding end limit switch is present CW limit switch for CW command CCW limit switch for CCW command An incorrect find home command generates an invalid command input error If either of the end limit switches is reached during a home operation the motor reverses direction and searches for the home limit or home proximity switch For this reason it is important to set the velocity at a low enough rate to guard against motor lock up during direction changes Note If you are using a home limit switch and a home prox limit switch and a right to left home commmand is required to home the axis mount the home prox limit switch to the right of the home limit switch If a left to right home command is required mount the limit switches opposite to the above See the diagrams below to properly locate the home limit switches Home Limit Switch Prox Limit Switch Hi Transition Hi Transition 4 Home complete wm ir Start Homing CCW Dir
12. must be valid in order to perform an absolute move but not to perform a relative move The current position is not valid following a power up or a configuration operation Important A home operation or a preset must be performed to validate the current position In an absolute move the number of pulses generated by the Module equals the difference between the target position destination and the current position In a relative move the target position defines the distance in pulses that must be traveled relative to the current position Normally both types of move accelerate to the programmed velocity slew speed at the commanded acceleration rate continue at the velocity to a predetermined point and then decelerate to the target position at the commanded deceleration rate to the starting speed and stop This type of move generates a trapezoidal velocity profile as illustrated below Trapezoidal velocity profiles with programmable acceleration deceleration pulse rates Velocity Starting Speed Time However if a commanded move is not long enough to attain the programmed velocity before the deceleration point is reached a triangular velocity profile will be generated This profile is shown below Velocity Starting Speed Time Blended Moves permit more sophisticated velocity profiles The figure below is an example of a move containing 2 segments blended together 4 1 9 Chapter 4 Configurat
13. operations through the Stepper Translator There are translators which require a pulse train and direction to operate Other translators require a CW positive direction pulse train and a CCW negative direction pulse train The CW and CCW designations refer to directions of stepper motor rotation The Stepper Controller can be configured for either type of translator When operating in either the Configuration or the Command mode Module status is reported to the SLC Controller Chapter 3 Module Operation Operation Using the Pulse and Direction Outputs If the Stepper Translator requires pulse and direction outputs configuration output word 0 bit 10 has to be set to a logic 1 since the default state of the Stepper Controller is set up for CW and CCW pulses logic O on bit 10 Assuming the Module is inserted in slot 0 the bit address is O0 0 0 10 The following unconditional rung executed during configuration causes the Stepper Controller to output the proper pulse train and direction bits for a Stepper Translator that requires a pulse train direction input The pulse train and direction signal are illustrated just below the unconditional rung for clarity The programmed speed value controls the frequency of the pulse train and the sign of the destination value controls the direction output of the Stepper Controller An alternate configuration method is to ensure bit 10 of word 0 is true when moving or copying a data
14. possible for the encoder values to be increasing or decreasing independently of the direction of motor rotation 4 1 19 Chapter 4 Configuration and Programming Status Diagnostics Feedback Test To perform a diagnostic feedback test the Module must be configured for diagnostic feedback using the loop back feature and pulse and direction output The external DC power supply must also be active in order to generate the output pulses Wiring for the diagnostic feedback test is shown in the following diagram Configuration Data for Loop Back Diagnostic Test N9 Configuration for Loop Back Diagnostics Test N9 0 31209 23 1 0 0 0 0 0 0 O Ladder Instructions for Loop Back Diagnostics Test This rung is used to test the loopback information Command should equal feedback when the move is complete The Module is shown in slot 1 for this example move complete feedback feedback 1 yes command MSW command LSW test okay I1 EQU EQUAL Source A EQU EQUAL Source A 1 1 2 32753 Source B I1 4 32753 Source B NOTE In the above rung use of the EQU equal test means that source A equals the command in both the MSW and LSW words source B in both cases is the value reported by the loop back diagnostic This rung is used to test the loopback to specific tolerances as defined by the less than and greater than tests If the test fails the error output SLC output 1 is Chapter 4 Configura
15. programmed at different rates if necessary Data File Structures SLC Processor data files can be used to determine the parameters for either simple or complex move profiles The only difference between simple and complex moves is the method used to handshake with the Module If speed blending of two or more moves is required the programmer is responsible for handshaking the information from the SLC processor data file to the proper words assigned to the slot address If either the starting speed or velocity changes with each move segment the logic may be simplified by setting up additional files to transfer data from the files to the Module using a sequencer move or copy instruction Using the N Files for Motion Commands The following example is used to denote an axis move equal to 1001 pulse counts in the CW direction Word N9 23 contains the information in the LSW words which is the fine position in counts These values can range from 0 to 999 Coarse position information is stored in word N9 22 The combination of coarse and fine position information determines how many counts the axis will move If there is no coarse position information a negative sign in the fine position word can be used to denote the axis direction The move segment is made up of N9 22 and N9 23 N9 22 1 counts and N9 23 1 count Motion commands are executed using the copy instruction as indicated in the program example represented by rung 2 2 of the Prog
16. via decimal 3 Change radix to binary 5 1 11 Chapter 5 Application Examples 4 Set MSB 15 of the MSW To enter negative position data by calculating manually 1 Divide the absolute value into MSW LSW 2 Enter the LSW value directly into position LSW 3 Add the value of MSW to 32768 4 Place the value into position MSW For example 1 5999 MSW LSW 5 999 2 Assign position LSW 999 3 5 32768 32763 4 Assign position MSW 32763 Installation and Wiring Chapter Objectives This chapter provides information which will permit you to properly unpack install and wire the interfaces between the Module and the various Stepper Translators that can be used with the Module Also covered are typical input circuitry direct input and encoder input and encoder timing information and encoder feedback connections General Precautions In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other a
17. 1 bit 2 bit 3 bit 4 bit 5 bits 6 15 determines the active level of the CW limit switch determines the active level of the CCW limit switch determines the active level of the pulse train disable input determines the active level of the external interrupt input determines the active level of the home limit switch input determines the active level of the home proximity limit switch input not used Output words 2 and 3 Defines the starting or base speed of the Module The starting speed is the minimum speed at which every move begins and ends Programming Command Mode Chapter 4 Configuration and Programming Status The starting speed must be higher than the speed at which low frequency resonance occurs in the stepper motor and is dependent on motor characteristics The format for starting speed data is Word 2 Starting speed most significant word MSW Word 3 Starting speed least significant word LSW Configuration mode input image table The data format of the input image table when the Module is in the configuration mode is Input word 0 bits 0 5 8 10 identical to like numbered bits in output table bits 6 7 and 11 not used bit 13 configuration error 1 error 0 no error bit 14 Module OK 1 Module operational 0 fatal error encountered bit 15 1 when in configuration mode 0 when in command mode Input word 1 bits 0 5 same as corresponding bits in output word 1 bits 6 15 not used Input wo
18. 10 Red ERR LED is lit The Module is not seeing the 0 to 1 transition required for each new move either absolute or relative To avoid this condition it is recommended when programming that you unlatch bits 0 and or 1 each time a move is in progress Note that this will not cause a problem when toggling between absolute and relative moves Module completes one move and stops This could be the result of a poorly seated Module Check that the Module is properly inserted in its slot If the Module appears to be properly seated request help from Allen Bradley Technical Support Be sure to provide a copy of the program involved and as many other details as you can about the circumstances that trigger the fault to assist in the solution of the problem Module Ready bit goes false during operation Limit switch inputs are detected by and their states are reported by the Module software If they are not reading properly 1 check input signal levels 2 check state setting in configuration 3 check wiring Limit switch data can be read by accessing configuration mode input word 1 Incorrect limit switch states can be altered by setting the respective bits in configuration mode output word 1 refer to the Configuration Mode topic in Chapter 4 of this manual Limit switch inputs This condition can be due to any of the following errors improper voltage level is being provided to the encoder by the encoder power supply imp
19. 15 not used CONFIG OUTPUT WORDS 2 and 3 Word 2 starting speed most significant word MSW Word 3 starting speed least significant word LSW CONFIG INPUT WORD 0 Bit setwhen CW limit switch is configured Bii setwhen CCW limit switch is configured Bi set when pulse train enable disable switch is configured Bi3 setwhenanex interrupt is configured Bit setwhena home limit switch is configured Bit setwhena home proximity limit switch is configured Bite notused Bit notused Bits setwhena quadrature encoder is configured Bit9 setwhen diagnostic feedback is configured Bitto setwhen output pulse type is pulse train and direction Bitti notused Biti2 reset when limit switch home operation is configured set when marker pulse home is configured Bits configuration error 0 no error 1 error Biti14 ModuleOK 0 fatal error encountered 1 module operational Bit 15 0 command mode 1 configuration mode CONFIG INPUT WORD 1 Bit 0 reflects active level of the CW limit switch configured Bit 1 reflects active level of the CCW limit switch configured Bit 2 reflects active level of te pulse train disable input configured Bit 3 reflects active level of the ext interrupt input configured Bit 4 reflects active level of the home limit switch input configured Bit 5 reflects active level of the home prox limit switch input configured Bits 6 through 15 not use
20. Applications Parameters Storage no local storage uses SLC processor Module Address Determined by chassis location e Homing Method Determined by backplane configuration Processor Compatibility e Compatible SLC Processors SLC 500 SLC 5 01 SLC 5 02 and SLC 5 03TM Appendix Input Output Quick Reference CONFIG OUTPUT WORD 0 Bit 0 set when a CW limit switch is used Bit 1 set when a CCW limit switch is used Bit 2 set when the pulse train enable disable input is used Bit 3 set when an external interrupt is used Bit 4 set when a home limit switch is used Bit 5 set when a home proximity limit switch is used Bit 6 not used Bit 7 not used Bit 8 set when a quadrature encoder is used Bit 9 set when a diagnostic feedback is used Bit 10 0 output pulse type is CW CCW pulse train 1 output pulse type is pulse train and direction Bit 11 not used Bit 12 0 limit switch home operation 1 marker pulse home operation Bit 13 not used Bit 14 not used Bit 15 0 command mode 1 configuration mode CONFIG OUTPUT WORD 1 Bit 0 determines the active level of the CW limit switch Bit 1 determines the active level of the CCW limit switch Bit 2 determines the active level of the pulse train disable input Bit 3 determines the active level of external interrupt input Bit 4 determines the active level of the home limit switch input Bit 5 determines the active level of the home proximity limit switch input Bits 6 through
21. B ALLEN BRADLEY Stepper Controller Module Catalog No 1746 HSTP1 User s Manual January 1997 P N 999 121 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will the Allen Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation the Allen Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of the Allen Bradley Company is prohi
22. C5 0 ACC 2 The preceding two rungs are repeated for the remaining eight segments to be output send next 1 blend blend move move mode data read blend move data 1 6 1 6 0 6 FJ p 8 9 12 set when all set to program segments output p blend move profile C5 0 0 6 U DN 11 set when all segments 1 blend set when Pid Lun profile output move mode profile is to be MOV performed C5 0 1 6 MOVE Source 8192 Dest O 6 0 AHAH DN 9 Module Status Inputs 4 1 17 Chapter 4 Configuration and Programming Status While the Module is operating in the command mode its status is reported to the SLC Processor via the command mode input image table This input file has the following format Input Word 0 bit 0 is set when the axis is moving CW bit 1 is set when the axis is moving CCW bit 2 is set when Module is in hold state bit 3 is set when axis is stopped typically used with an immediate stop or a pulse train disable bit 4 is set when axis is in home position bit 5 is set when axis is accelerating bit 6 is set when axis is decelerating bit 7 is set when current move is complete not used with jog type moves bit 8 is set when Module is in blend move mode bit 9 send next blend move data bit bit 10 is reset if position is valid bit 11 is set when input error exists bit 12 is set when command error exists bit 13 is set when configuration error exists bit 14 is set w
23. ENG 8 Absolute relative move commands a 9 Programming Simple Moves aa 43 General Information a NG Data File Structures a 43 Using the N Files for Motion Commands 43 Quadrature Encoder Input 0 cee eeee 14 Use of Direct Inputs 525a es ka aw x be Red Ee ERE ERES 44 Programming Blended Moves 000ceeeeeaes 15 General Information a 15 Blend move programming routine 0005 16 Module Status Inputs 00 ccc eee eee eee eee 18 Input Word 0 nannan eee eens 18 NOTES sch is Seat aden Geos KK USA ees 18 Input Word 1 2 eee II 19 NOTES pa aNG BUGA nana we es ee ieee seas 19 Input Words 2 and 3 10 ccc cee eee eee 19 Input Words 4 and 5 naa eee eee 19 Diagnostics Feedback Test 00 0 aa 21 Configuration Data for Loop Back Diagnostic Test 21 Ladder Instructions for Loop Back Diagnostics Test 21 Application Examples esee 1 Chapter Objectives PAA 1 Data table used for the program listing for Sample Module Check Procedure Aa Processor Configuration Files a 1 Program Listing for Sample Module Check Procedure 2 Program Listing for Sample Move a 4 Report Options Summary a Ai Data lable AA suka dal eles 11 Entering Negative Position Data lusus mil Table of C
24. Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Hazardous voltages may exist in the control cabinet even with the circuit breaker in the off position Recommended practice is to disconnect and lock out control equipment from power sources and discharge stored energy in capacitors if present If it is necessary to work in the vicinity of energized equipment the safety related work practices of NFPA 70E Electrical Safety Requirements for Employee Workplaces must be followed DO NOT work alone on energized equipment Removal of the Module is facilitated by captive screws on the Terminal Block refer to Chapter 2 Chapter 7 Start Up and Troubleshooting Problem Resolution Either a major Module malfunction or lack of power from the backplane is indicated Check for power from the backplane first if power is present the Module must be replaced No green RUN LED Module is improperly configured Refer to the topic Configuration Mode in Chapter 4 of this manual for additional information Red FLT LED is lit This means that invalid data has been copied into one of the command mode output words position velocity acceleration and or deceleration The invalid data must first be corrected in the appropriate N file of the SLC Processor and the error then reset The error is reset by resetting bit 15 of the configuration mode output word 0 to a logic
25. ake place 2 Reaching either the CW or CCW limit switch during a normal move or jog operation is treated in the same manner as a pulse train enable disable input That is the motor stops and the current position becomes invalid The one shot jog feature defined in the Jog Commands later in the chapter must then be used to move the motor away from the limit switch 3 The data format of output words 1 7 is decimal 4 Most significant words MSW contain the 1000s places the upper four digits of the velocity and position data The least significant word LSW contains the 1s 10s and 100s places the lower three digits 5 A negative position value is indicated by setting the most significant bit in output word 2 6 The position parameter has a range of 48 388 607 7 The velocity parameter has a range of starting speed velocity 250 000 8 The acceleration and deceleration parameters have a range of 1 lt acceleration deceleration x 2000 and is measured in pulses per millisecond per second Chapter 4 Configuration and Programming Status Absolute relative move commands Set bit 0 to command an absolute move Set bit 1 to command a relative move Bit 15 the most significant bit of command mode output word 2 msw position can be used to denote a ccw move A 1 produces a ccw move while a O produces a cw move Note that CCW and CW refer to direction of stepper motor rotation The current position of the axis
26. and information is transferred between the SLC Processor and the Stepper Controller with each scan of the SLC ladder The configuration and status bits are boolean values that can be assigned or read easily by the SLC ladder program Word 0 and word 1 of the address assigned to the Stepper Controller are allocated to status and command words Status bits are defined in Module Status later in this chapter Detailed use of the configuration bits is described in Configuration Mode later in this chapter The Module provides new information to the SLC backplane every 250 microseconds The SLC Processor must be configured to accept the Stepper Controller as an I O device This can be done with either the Hand Held Terminal HHT or APS software running on a personal computer Although the configuration steps are similar using either method they are not identical The two methods are described separately below Processor configuration using APS 1 Locate an open slot in your chassis The Module can be used with any SLC Processor Chapter 4 Configuration and Programming Status Assign your SLC Processor if not done previously a Using APS press F3 Offline PRG DOC F1 PROCSSR FUNCTNS and F1 CHANGE PROCSSR again to assign your processor and Module b Press F2 to select a processor or F5 to assign a Module Assign the Module to an open slot a Using APS highlight an open slot b Press F5 MODIFY SLOT Highlight last en
27. ation for TTL The following wiring diagram shows the connections between the Module and Interface a Stepper Translator that requires a TTL Interface The 5 volt supply to the TTL interface can be either internal to the translator itself or a separate power supply selected by the user This design is probably the most sensitive to noise due to the single ended high speed nature of the TTL device For this reason it should be used only where the Stepper Translator is close to the Module that is no more than five cable feet in an enclosure that is well shielded from EMI noise when the enclosure doors are closed TTL Interface Typical Input Connection 7 24V DC Refer to page 6 6 Stepper Controller Ground Bus Chapter 6 Installation and Wiring Typical Input Circuitry Two basic circuits are used for inputs to the Module the direct input circuit for home limit switches overtravel limits and interrupt devices and the second type for encoder inputs Both circuits are shown below Direct input equivalent circuit 2 2K Encoder input equivalent circuit HI 210 210 Chapter 6 Installation and Wiring Typical Encoder Timing A typical encoder timing diagram is shown below For actual connections Diag ram consult your encoder manufacturer s timing diagram For all encoder types if the direction phasing of the feedback is backwards correct this condition by reversing the channel A and channel B connections STEP
28. ation rate and deceleration rate The minimum amount of information required to define a new move segment is a change in both the absolute target position and the velocity Changes in acceleration and deceleration rates are not required If both a new target position and a new velocity are not specified the command error input bit is set Blend move profiles can be programmed in a single block and the segments stored in the internal memory of the Module Each blend move profile is programmed as a series of absolute moves which means the axis position must be valid for a blend move operation to take place The first segment of each blend move profile always starts at the programmed starting speed and accelerates up to the programmed velocity The starting speed for the next segment in the profile is equal to the velocity specified for the previous segment Important The final segment stops at the specified starting speed and must have a programmed velocity equal to the starting speed or a command error is generated A command error is also generated if a direction reversal is encountered during a blend move operation Because the data for a blend move profile is stored in the Module memory a profile can be run more than once Since blend moves are made up of a series of absolute moves the starting position for each blend move profile must be the same each time the profile is initiated Note that other move or homing operations can be pe
29. bited Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid the hazard recognize the consequences Important Identifies information that is especially important for successful application and understanding of the product PLC PLC 2 PLC 3 and PLC 5 are registered trademarks of Allen Bradley Company Inc SLC SLC 500 PanelView RediPANEL and Dataliner are trademarks of Allen Bradley Company Inc IBM is a registered trademark of International Business Machines Incorporated Table of Contents Important User Information 1 Using This Manual leere 1 MUT Em a Contents of this Manual llle 2 Intended Audience c cece cece eee eee eens 3 Conventions 0 0 ccc cece eee n 3 Module Overview 00cceeeeeee eee eeneeeee 1 Chapter Objectives nnn nnana 1 Stepper Controller Module Overview 000e0ee 1 Operating Modes 0 00 cc cece ence eee 2 Configuration Mode a 2 Command Mode Operation 000 0 cece eee 3 Diagnostic Mode 0c c cece cee eee nee 3 LED Indicator Diagnostics 0 00000 cece eee 4 Input Output Terminals a 5 Terminal Block Release Screws
30. can Module refers to the Stepper Controller catalog number 1746 HSTP1 Physical outputs refers to actual outputs on the Stepper Controller SLC Processor refers to an SLC 500 family processor Stepper Translator refers to the interface between the Stepper Controller and the stepper motor that converts pulse train outputs into power signals used to run the motor Position Loop refers to the ability of a controller to accurately position a mechanism to a precise point based on a dynamic comparison of command data and feedback from a sensor Engineering Units refer to decimal fractions of units of measurement e g inches millimeters and degrees CW refers to rotation or movement in a clockwise direction CCW refers to rotation or movement in a counter clockwise direction Chapter 1 Using This Manual 1 4 Chapter Objectives Stepper Controller Module Overview Module Overview The Module overview will permit you to understand the basic functions of the Module and hardware requirements The Module catalog number 1746 HSTP1 is an SLC 500 family compatible device It can be used with any SLC 500 Processor The Module is configured through the SLC 500 backplane and requires no switch settings Motion can be programmed in either direction for over 8 000 000 counts of absolute position An optional incremental encoder may be used to verify the position reached by the axis The Module does not auto
31. d CONFIG INPUT WORDS 2 and 3 Word 2 reflects the starting speed most significant word as configured in output word 2 Word 3 reflects the starting speed least significant word as configured in output word 3 1 1 Appendix A Input Output Quick Reference COMMAND OUTPUT WORD 0 COMMAND INPUT WORD 0 Bit 0 absolute move Bit 0 set when the axis is moving CW Bit 1 relative move Bit 1 set when the axis is moving CCW Bit 2 hold motion Bit 2 set when the module is in a hold Bit 3 resume motion Bit 3 set when the axis is stopped Bit 4 immediate stop Bit 4 set when the axis is in home position Bit 5 find home Bit 5 set when the axis is accelerating Bit 6 find home Bit 6 set when the axis is decelerating Bit 7 jog Bit 7 set when the current move is complete Bit 8 jog Bit 8 set when the module is in a blend move mode Bit 9 preset position Bit 9 send next blend move data bit Bit 10 reset errors Bit 10 reset is position is valid Bit 11 program blend move profile Bit 11 set when input errors exist Bit 12 read blend move profile Bit 12 set when a command error exists Bit 13 run blend move profile Bit 13 set when a config error exists Bit 14 preset encoder porition Bit 14 set when the module is OK Bit 15 mode flag 0 command Bit 15 mode flag 0 command 1 config 1 config COMMAND OUTPUT WORD 1 COMMAND INPUT WORD 1 reseved Bit 0 set when CW limit switch is active Bit 1 set when CCW limit switch is active COMMAND OUTPUT WORD 2
32. d 0 bit 10 is false occurs while in command mode and no position error actually exists a command to preset position assigns a predetermined position value as the absolute position This establishes the current absolute position of the axis and allows subsequent absolute moves to take place A typical ladder diagram showing the command to preset position is provided in rung 2 3 of the Program Listing for Sample Move in Chapter 5 of this manual 3 1 3 Chapter 3 Module Operation Chapter Objectives Programming Conventions Configuration and Status Bits Program Scan SLC Processor Configuration Chapter 4 Configuration and Programming This chapter provides information to help you configure both the SLC Processor and the Module This chapter also contains instructions for you to correctly program the Module for the command mode of operation Since the SLC Processor does not support numbers as large as 8 000 000 the number must be entered as two distinct integer values that can be programmed within the capabilities of the SLC Processor The value is equated to two 16 bit integer values that provide a coarse and fine resolution The least significant word allows for a range of 0 to 999 counts The most significant word MSW provides thousands of counts For example to output 8 000 000 counts set the most significant word to 8 000 and the least significant word LSW to 0 Configuration status and comm
33. d pair Belden 9504 or equivalent 2 Use I pair 18 gauge twisted and shielded cable 3 Encoders must have 5V compatible differential line drive outputs on channels A B and Z DS8830 or equivalent A B 845H 4 5V from encoder power source connect encoder return to OV user power DC common at the power supply sources 7 24V DC user power CW or non directional pulse output CW or non directional pulse output CW pulse or direction signal output CCW pulse or direction signal output External interrupt input Home limit switch input Home Proximity limit switch input CW limit switch input CCW limit switch input Pulse train enable disable input A Hi Loopback non directional pulse A Lo Loopback non directional pulse B Hi Loopback direction B Lo Loopback direction Encoder Marker Encoder Marker 0 V user power DC common Chapter 6 Installation and Wiring 15 volt encoder feedback connections 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 16 AWG A B845H 3 Optical Encoder Case Ground Electrical Cabinet Ground Bus NOTES 1 Use 3 pair 22 gauge individually twisted and shielded pair Belden 9504 or equivalent 2 Use I pair 18 gauge twisted and shielded cable 3 Encoders must have 15V compatible differential line drive outputs on channels A B and Z DS8830 or equivalent A B 845H 4 15V from
34. diagnostic The three operating modes are summarized below Configuration Mode The configuration mode is commanded by setting the mode flag bit 15 in output word 0 to 1 In this mode the Module is configured through the SLC Processor to perform specific operations that the user desires The configuration mode defines the basic operation of the Module Important The Module does not operate until it has been configured at least once The Module can be configured to e Determine which inputs will be used e Set whether just the encoder marker or a prox limit switch and encoder marker combination is used for homing e Determine if a quadrature encoder will be used e Select whether the Module output is a pulse train with direction command or a CW pulse train and CCW pulse train e Select between configuration mode and command mode NOTE Some output combinations are not valid For example using feedback diagnostics and quadrature encoder or using a marker pulse and a home limit switch If any invalid combinations are sent the configuration error input bit will be set Chapter 2 Module Overview Command Mode Operation All stepper motor operations are performed in command mode This mode is entered by setting the mode flag bit 15 in output word 0 to 0 In command mode the SLC Processor can issue commands and activate different operations or moves The actions you can command are e Absolute Moves e Relative Moves
35. ech Republic e Denmark e Ecuador e Egypt e El Salvador e Finland e France e Germany e Greece e Guatemala e Honduras e Hong Kong e Hungary e Iceland e India e Indonesia e Israel e Italy e Jamaica e Japan e Jordan e Korea e Kuwait e Lebanon e Malaysia e Mexico e New Zealand e Norway e Oman e Pakistan e Peru e Philippines e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Switzerland e Taiwan e Thailand e The Netherlands e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela e Yugoslavia World Headquarters Allen Bradley 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication Number 1746 999 121 June 1996 P N 1746 HSTP1 Supersedes March 1995 Copyright 1995 Allen Bradley Company Inc Printed in USA
36. ection Valid Home Configuration Prox Limit Switch Home Limit Switch Hi Transition Hi Transition r3 Axis Stop Home sum m Start Homing Invalid CCW Direction Invalid Home Configuration l L j L Jog CW and Jog CCW commands cause the axis to operate in the jog mode at the programmed velocity and in the designated direction If the 4 1 11 Chapter 4 Configuration and Programming Status velocity specified for the jogging operation is below the programmed starting speed the starting speed is ignored However if the specified velocity is above the starting speed the axis jog move begins at the starting speed accelerates to the specified velocity and runs at that velocity until one of the following occurs e The jog command bit is turned off e An external interrupt input is activated e The immediate stop output bit is set e The emergency stop input is activated When either the jog command is turned off or the external interrupt input is activated the axis decelerates to the starting speed and then stops The valid axis position will be retained If however either an immediate stop output bit is set or the pulse train enable disable input is activated the axis stops and the position is invalid When it is necessary to move the stepper motor while one of the inputs is active the jog bit can be made to cause the Module to output one
37. ed 5000 acceleration 5 and deceleration 5 command move error complete position MSW position LSW copy file info 1 I1 EQU EQU COP 7k EQUAL EQUAL COPY FILE Source A Source A Source N9 30 12 7 Dest 0 1 0 Source B Source B Length 8 Rung 2 5 Reset errors command error copy file info I1 COP COPY FILE Source N9 40 Dest 0 1 0 Length 8 Rung 2 6 END Chapter 5 Application Examples Program Listing for The following sample program is designed to first validate the configuration Sam ple Move file and then in the command mode take the Module through a series of moves both absolute and relative at prescribed rates of acceleration deceleration and velocity then cycles between relative moves The elements of the following ladder diagram are summarized in the Data Table following the ladder diagram Output O 2 0 and the binary bits are for information and triggering external events Rung 2 0 Set sequencer to step 0 MOV MOVE Source Dest Rung 2 1 If a configuration error exists Module not configured then load configuration file beginning with word N9 0 Config Error 1 Error 0 No Error EQU x EQUAL Source A N7 0 4 0 COP COPY FILE Source N9 0 Dest 0 1 0 Length 8 Source B Move Completed Flag I1 U 7 Chapter 5 Application Examples Rung 2 2 If no configuration error occurred as a result of executing rung
38. ess Data Radix TT N9 0 Ea 63 x o o 0 we foe fete tof cope 5 0 nes e 0 pe 8 ala so a eee N9 20 I O Configuration for FIXSTP2 Rack 1 1746 A2 2 slot Backplane ojojoj o Catalog Number 1747 L20CIF 12 DC Card Description SNK 8 RLY I O Module ID code 3512 Not Configured Chapter 5 Application Examples Program Listing for Sample Module Check Procedure The following ladder diagram represents a sample program that can be used for a check of the Module It is not intended as an actual operation program Rung 2 0 Configure the module config error copy file info COP COPY FILE Source N9 0 Dest 0 1 0 Length 8 Rung 2 1 config 1 config error 0 command command mode I1 I1 011 AHA pa 13 15 Rung 2 2 Preset the position to O command 1 config position error 0 command invalid copy file info COP COPY FILE Source N9 10 Dest 0 1 0 Length 8 I1 I1 I1 HAHAHHA 12 15 Rung 2 3 Do absolute move to 20 000 counts speed 5000 acceleration 5 and deceleration 5 1 config command position 0 command error invalid position MSW position LSW copy file info H a ki EQU EQU COP _ Wa _ Vi EQUAL EQUAL COPY FILE Source A Source A Source N9 20 15 12 Dest 0 1 0 Source B Source B Length 8 Chapter 5 Application Examples Rung 2 4 Do a relative move by 20 000 counts spe
39. et Position Reset Errors Program Blend Move Profile Read Blend Data Run Blend Move Profile Preset Encoder Position Mode Flag1 Configuration Mode 0 Command Mode Chapter 4 Configuration and Programming Status Command Mode Output Words 15 14 13 12 1 109 8 7 6 5 4 3 2 1 0 Word 1 WORD 1 reserved 15 14 13 12 1 109 8 7 6 5 4 3 2 1 0 Word 2 Position WORD 2 MSW 0 to 8388 1000s 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 Word 3 Position WORD 3 LSW 0 999 1s 15 14 13 12 11 109 8 7 6 5 4 3 2 1 O0 Word 4 Velocity pulses sec WORD 4 MSW 1000s 0 250 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 Word 5 Velocity wos TT TEE TT TEE T Jis 0 to 999 pulses sec 15 14 13 12 11109 8 7 6 5 4 3 2 1 0 Word 6 Acceleration WORD 6 pulses ms sec 1 to 2000 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 Word 7 Deceleration WORD 7 pulses ms sec 1 to 2000 4 1 7 Chapter 4 Configuration and Programming Status Output Command Bits for Word 0 Bit Description 0 Absolute Move 1 Relative Move 2 Hold Motion 3 Resume Move 4 Immediate Stop pulse train off 5 Find Home Up 6 Find Home Down 7 Jog Up 8 Jog Down 9 Preset Position 10 Reset Errors 11 Program Blend Move Profile 12 Read Blend Data 13 Run Blend Move Profile 14 Preset Encoder Position 15 Mode Flag 1 Configuration Mode 0 Command Mode NOTES 1 A Oto 1 transition of the above control bits must occur to cause the associated operation to t
40. he designated slot in your SLC controller rack Refer to your SLC controller user manual 2 Wire the input and output devices as instructed in the following information Wiring Starting and Stopping the Module Chapter 6 Installation and Wiring Refer to the following information on typical interface requirements before beginning this procedure ATTENTION The following information is merely a guide for proper installation The Allen Bradley Company cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation To meet the installation requirements of Underwriters Laboratories Inc standard UL 508 for industrial control equipment follow the guidelines below e Use 60 75 C copper wire when wiring the 1746 HSTP1 system e Tighten the terminals on the 1746 HSTPI1 to 5 Ib in e Use Class 1 or Class 2 wiring for the terminals on the 1746 HSTPI system For more information refer to standard UL 508 or the National Electric Code ATTENTION The Module Enable Disable control circuitry includes solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit is required Chapter 6 Installation and Wiring
41. hen Module is OK bit 15 mode flag for configuration mode 0 for command mode NOTES 1 Direction of travel CW or CCW is established looking at the shaft end of the stepper motor 2 Bit 11 Input Error is set by activating either the CW or CCW limit switch or by an immediate stop input It can only be cleared by a home or a preset operation The input error flag is not set if the correct end limit is reached during a normal home move operation since reaching the end limit is an integral part of the home move operation 3 Bit 14 Module OK is set as long as the Module is operating normally Only a fatal error can reset this bit Chapter 4 Configuration and Programming Status Input Word 1 bit O is set when CW limit switch input is active bit 1 is set when CCW limit switch input is active bit 2 is set when immediate stop input is active bit 3 is set when external interrupt input is active bit 4 is set when home limit switch input is active bit 5 is set when home proximity limit switch input is active bits 6 7 not used bit 8 Home Invalid Bit bits 9 15 not used NOTES 1 When set bit 3 external interrupt indicates that the Module has initiated a controlled stop only during a jog operation The stepper motor decelerates to the programmed starting speed and then stops The current position information is retained 2 When set bit 2 indicates an external pulse train enable disable function has occurred T
42. his identifies an uncontrolled stop in which normal deceleration did not occur and axis position data is lost This bit will be set when a command is applied to input terminal 11 on the front panel of the module 3 When set bit 8 indicates that either the system has detected the wrong prox to home switch sequence i e prox switch detected after already reading a transition on the home switch or two different overtravel limit switches have been detected during a home operation Input Words 2 and 3 Input words 2 and 3 report current position data based on the number of pulses that have been sent to the stepper motor Note that this value may be different from the encoder value in words 4 and 5 Input Words 4 and 5 Input words 4 and 5 report the axis position based on either feedback from an optional encoder attached to the stepper motor or diagnostic feedback when configured Note that this value may be different from the current position in words 2 and 3 The value has a range of 48 388 607 counts equalling the limits of the Module The optical encoder values must be mechanically coupled to the motor The optical encoder values are not updated to the SLC backplane unless a command is issued to the translator Encoder direction values may be independent of the motor direction e g motor direction may be the plus direction while encoder values decrease The optical encoder values do not change unless the stepper motor is turning It is
43. input table bit 15 and waits for the configuration file to be transferred over the backplane from the SLC Processor Configuration Error If there is no configuration file present or if it is invalid for any reason the configuration error input bit 13 in configuration mode input word O is set If the new configuration file is acceptable it is mirrored in the input image table and the error input bit 13 is set to false 0 Important The Module is ready to operate when the Module OK bit 14 in configuration input word O is 1 Configuration mode output image table In the Configuration Mode the proper setup configuration is selected to match the Module to the Stepper Translator Module parameters are defined by the configuration file which is resident in the SLC Processor s memory Configuration mode is entered by setting bit 15 of output word 0 At the same time that bit 15 is set the required configuration data must be transferred to the Module No operating commands can be acted upon by the Module until a valid configuration is received The configuration file has the following format 15 14 13 12 11 10 9 8 6 A E OUTPUT WORD 1 OUTPUT WORD 2 OUTPUT WORD 3 Chapter 4 Configuration and Programming Status Output word 0 defines the user s configuration that is what types of inputs are present Important bit O bit 1 bit 2 bit 3 bit 4 bit 5 bits 6 and 7 bit 8 bit 9 bit 10 bi
44. ion and Programming Status Blended velocity profiles to permit high speed traverse and low speed positioning moves Velocity Starting Speed Time Upon successful completion of each move the move complete bit 7 of command mode input word 0 will be set permitting the next move to proceed Failure to complete a move will generate an error signal which will set the appropriate error flag in the command mode input word image table bit 11 12 or 13 Hold move command causes a controlled deceleration to the starting speed and stop Upon completion of the hold stop the hold state input bit 2 word 0 of the command mode input word image table is set While the hold move is in effect velocity and acceleration or deceleration parameters can be changed Specifying a new position however has no effect If no error occurs during a hold move operation the interrupted move can be resumed with new velocity and acceleration or deceleration parameters upon receipt of a resume move command Important If a hold move command is issued during a blend move operation the Module will run the blend move profile to completion and then set the command error bit word 0 bit 12 in the command mode input image table Resume move command permits a previously held absolute or relative move to continue from the point of the hold An interrupted blend move cannot be continued by a resume move command however The hold state inp
45. matically close a position loop in engineering units The feedback hardware can accept frequencies of up to 250 kHz for use as either loop back diagnostics or differential incremental encoder feedback devices The Module can be programmed for either incremental or absolute moves depending on the application The Module supports two differential outputs to suit the type of Stepper Translator used which provide the following control commands e CW or non directional pulse output e CCW or direction signal output Discrete inputs are provided for e External Interrupt e Home Limit Switch e Home Proximity Input e CW Travel Limit Switch Input e CCW Travel Limit Switch Input e Pulse Train Enable Disable Input Differential inputs are provided for e Encoder Channel A and A NOT e Encoder Channel B and B NOT Encoder Marker Channel Chapter 2 Module Overview zaa uu Stepper EBBB S5 Controller SLC E Power 7 to 24V DC Supply User Power Suppl A A X pply SLC Naa Processor Standard O Module y Stepper 05 9 Translator Optional Encoder Pie Optional Feedback Wiring Power Control Wiring to Translator e Wires The 24V may be obtained from the SLC Power Supply depending on application power requirements Motor and translator furnished by the customer Operating Modes The Module operates in three different modes configuration command and
46. ng back to allow the stepper to see the relative move bit go low Command Error 1 Error 0 No Error EQU P EQUAL Source A Source B TON TIMER ON DELAY Timer T4 0 Time Base 0 01 Preset 300 Accum 297 EN DN Rung 2 8 Relative move by 10 000 pulses speed 5000 acceleration 5 and deceleration 5 EQU EQUAL Source A COP COPY FILE Source Dest Length Source B MOV MOVE Source Dest Chapter 5 Application Examples Rung 2 9 Wait here until the previous move completes and the turn relative move bit off Move Completed Flag EQU EQUAL Source A Source B Rung 2 10 This rung evaluates the move status of the system If the move request was successfully performed the timer is activated to provide a dwell between moves The delay makes sure that the relative bit is seen as off before the next move Command Error 1 Error 0 No Error I1 EQU EQUAL Source A TON TIMER ON DELAY Timer T4 Time Base 0 01 Preset 300 Accum 0 Source B EN DN Chapter 5 Application Examples Rung 2 11 Do a relative move by 10 000 speed 5000 acceleration 5 and deceleration 5 EQU T4 B3 EQUAL Source A DN COP COPY FILE Source N9 30 Dest 0 1 0 Length 8 Source B MOV MOVE Source Dest Move Completed Flag I1 U 7 Rung 2 12 Wait here until the previous move completes and turn
47. on allows for complicated move profiles consisting of two to 16 segments The blended move profiles are stored in the Module s internal memory as a series of absolute moves Since the sequence of moves is stored in the internal memory of the Module it can be executed more than once Other move or homing operations may be performed between blended move profiles The Module is capable of controlling absolute position over a range of 48 388 607 pulses with a programmable velocity of 1 to 250 000 pulses per second and acceleration deceleration rates between 1 and 2 000 pulses per millisecond per second The Module is able to perform an origin search also called homing and to automatically reset the absolute position to zero upon detection of an encoder marker when an origin search function is requested by the SLC Processor The three operating modes of the Stepper Controller are configuration mode command mode and diagnostic mode Configuration The Configuration mode permits the selection of the proper setup configuration to match the Stepper Translator without setting any switches and without special software Until the configuration mode has been properly set the Stepper Controller will not operate Enabling loopback diagnostics is done using the configuration mode In the diagnostic mode a check is made for noise in the interconnecting wiring as well as a check of the program itself Command The Command mode directs all stepper motor
48. ontents Installation and Wiring Leere Chapter Objectives 1 sed aes Ex uer ww Lure ea s General Precautions a Complying with European Union Directives EMC Directive pa a AK KAG owas HANG NGA ERR Installation AA PP oF aes Eee ek od WINO MEC Starting and Stopping the Module aaa Wiring for a Differential Interface a Wiring to Optocoupler Interface cece eee Wiring to Optocoupler Interface Continued Wiring Information for TTL Interface 0200000e Typical Input Circuitry 2 7s ban RR Direct input equivalent circuit a Encoder input equivalent circuit lisse Typical Encoder Timing Diagram aa Encoder Feedback Connections 00eee neues 5 volt encoder feedback connections 15 volt encoder feedback connections Start Up and Troubleshooting Chapter Objectives aaa System Start DD sed d acte sor Eder E ENG KG baal eee S Normal Operation a Troubleshooting a Safety Precautions 20 0 0 c cece ee eee eee Removing the Module a Specificaliolis s acs soma marem nna xin es Chapter Objectives aa Industry Standards a General Specifications cece eee eee ee LED Indicators ea AA ka din DEAD imena Kode AARAL Power Requirements
49. ontroller Module Catalog Number 1746 HSTP1 The following table identifies the chapters titles and contents Ger Cons 1 Using This Manual An overview of this manual 2 Module Overview Module Overview its operation and hardware features 3 Module Operation Describes interface selection the Module s use of inputs and outputs and operating modes 4 Configuration and Provides the steps necessary to configure the Programming Status SLC Processor and Stepper Controller Illustrated sequencer configuration and command data files 5 Application Examples Interconnection diagrams for various hardware 6 Installation and Wiring interfaces for communication with the Stepper Controller 7 Start Up and Start up normal states of LED indicators Troubleshooting troubleshooting and error handling information 8 Specifications Temperature humidity input output voltage timing and cabling information Intended Audience Conventions Chapter 1 Using This Manual This manual is designed for the qualified first time user who has a working knowledge of SLC 500 products If necessary obtain the proper training before using the Stepper Controller The following terms are used throughout this manual Input file refers to the Module s Input Data file This file is updated during the SLC Processor input scan Output file refers to the Module s Output Data file This file is updated during the SLC Processor output s
50. pplicable ESD protection handbook ATTENTION An incorrectly applied or installed Module can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION Only personnel familiar with the Module and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage Chapter 6 Installation and Wiring Complying with European Union Directives Installation If this produce is installed within the European Union or EEC regions and has the CE mark the following regulations apply EMC Directive This apparatus is tested to meet Council Directive 89 336 Electromagnetic Compatibility EMC using a technical construction file and the followingstandards in whole or in part e EN 50081 2 EMC Generic Emissions Standard Part 2 Industrial Environment e EN 50082 2 EMC Generic Immunity Standard Part 2 Industrial Environment The product described in this document is intended for use in an industrial environment and is not intended for use in a residential commercial or light industrial environment To meet CE requirements you must comply with the wiring and grounding recomendations made in this chapter 1 Install the Module in t
51. pulse in the specified direction This is referred to as a one shot jog and can be made to occur during any 0 to 1 transition of the jog bit while the velocity is set to zero speed Preset position sets the current axis position to the programmed value The desired position value is copied into the current position input words If the position is currently invalid issuing the preset position command causes the position to become valid Reset errors clears all non fatal errors detected by the Module A non fatal error is one from which the Module can recover An example of a non fatal error is a request for an absolute move when the current position is not valid A non fatal error inhibits all Module operations until the reset errors command is issued Preset encoder position sets the current encoder position to the programmed value implied in command words 2 and 3 Programming Simple Moves Chapter 4 Configuration and Programming Status General Information Certain applications merely involve a series of moves to discrete positions with a wait between moves In this case simply place the value for each position in words 2 and 3 of the slot address of the Module then turn on bit 0 of word 0 of the slot address Once the axis is moving bit O can be turned off The values for the velocity acceleration and deceleration are controlled by words 4 and 5 6 and 7 respectively This allows acceleration and deceleration to be
52. r error Red Fault lights when the Module is not configured Power Requirements e Backplane 5 Volts DC 2A e User Power 24 Volts DC 09A Max System Limitations Number of modules per chassis is limited by the SLC power supply and applications scan time requirements Chapter 8 Specifications 1 2 Discrete Inputs e External Interrupt 7 24 VDC Single Ended e Home limit switch 7 24 VDC Single Ended e Home Proximity Input 7 24 VDC Single Ended e CW travel Limit input 7 24 VDC Single Ended e CCW travel Limit input 7 24 VDC Single Ended e Emergency Stop 7 24 VDC Single Ended e Encoder Channel A 5 VDC Differential e Encoder Channel B 5 VDC Differential e Encoder Marker Channel 5 VDC Differential Discrete Outputs e CW or non directional pulse output Differential Output e CCW pulse or direction signal output Differential Output Input Output Terminals These terminals supply power and inputs to the Module and outputs to attached devices They can accommodate two 14 gauge Wires Environmental Operating Conditions e Operating Inlet Air Temperature 0 to 60 C 32 to 140 F e Altitude up to 2000 M 6562 Ft e Humidity 5 to 95 non condensing Storage Temperature e 40 to 85 C 40 to 185 F Feedback Circuitry e None required e Optional Differential A quad B Encoder with marker Channel Program Storage Requirements e Applications Program Storage no local storage uses SLC processor e
53. ram Listing for Sample Module Check Procedure in Chapter 5 of this manual Note that if a new move instruction includes only a position change program execution times can be shortened by using a MOV instruction in place of a COP copy instruction to send the data to the Module Function Address N9 20 4 1 13 Chapter 4 Configuration and Programming Status Quadrature Encoder Input The Module supports a quadrature encoder with differential line driver outputs The marker channel of the encoder is optional and provides an additional level of accuracy to the original home position reference position if required The same circuitry is used for the loop back diagnostics and the quadrature encoder The quadrature encoder output is read directly as counts and passed through to the backplane as the feedback value in words 4 and 5 Important If the encoder is used it must be disconnected from the controller whenever loop back diagnostics are being performed Use of Direct Inputs There are a total of six direct inputs to the Module They are External Interrupt Input Home Limit Switch Input Home Proximity Switch Input CW Limit Switch Input CCW Limit Switch Input and Pulse Train Enable Disable Input They connect to Module Input Output terminals 6 through 11 respectively The Module responds to these direct inputs as follows e External Interrupt Input When this input is turned on the axis decelerates to the prog
54. rammed starting speed and then stops This input works only when a jog operation is being performed The axis will not stop if this input is activated during any other type of move operation e Home Limit Switch Input Activating this input indicates to the Module that the current find home operation is complete and stops axis motion e Home Proximity Switch Input Activating this input during a find home operation affects the homing sequence Refer to Find Home CW Find Home CCW earlier in this chapter for further information e CW or CCW Limit Switch Input If either of these inputs is activated during a find home operation the motor reverses direction and begins looking for the home limit switch or home proximity switch as applicable If either the CW or CCW limit switch input is activated during a normal move or jog move operation the pulse train output is disabled immediately the present position then becomes invalid e Pulse Train Enable Disable Input If this input is activated the Module pulse train output to the motor ceases and the present position becomes invalid Programming Blended Moves Chapter 4 Configuration and Programming Status General Information The blend move command permits the Module to blend motion segments together to create more complex move profiles A move profile can consist of 2 to 16 segments Each segment is defined by four parameters absolute target position velocity acceler
55. rds 2 and 3 are identical to output words 2 and 3 Invalid Configurations The following configurations can be programmed but are not acceptable to the Module and will cause the configuration error input word O bit 13 to be true and turn on the red FLT LED indicator if attempted Aconfiguration file that does not provide the ability to home the Module either by means of a home limit switch and home limit switch operations or quadrature encoder and marker pulse operations e A configuration file that does not contain a limit endpoint either CW or CCW e Aconfiguration file that specifies both quadrature encoder and diagnostic feedback Aconfiguration file that specifies a marker pulse home without specifying both a quadrature encoder and a home proximity limit switch e A configuration file that specifies a home proximity limit without specifying the home limit switch Aconfiguration file that specifies diagnostic feedback with CW and CCW pulse outputs Aconfiguration file that calls for a starting speed outside the design range 1 250 000 pulses per second Chapter 4 Configuration and Programming Status Output Words SLC Processor to Stepper Controller Output Command Word 0 Bit Definition 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 LLL TL IL LL dL 1 df d P JWoDo Absolute Move Relative Move Hold Motion Resume Move Immediate Stop pulse train off Find Home Find Home Jog Jog Pres
56. rformed between reruns of the same blend move profile Important A command error is generated if a blend move is started from a different position 4 1 15 Chapter 4 Configuration and Programming Status Blend move programming routine Following is a description of how a typical blend move profile is programmed For this discussion it is assumed that the Module is in slot 6 of the SLC rack The related ladder diagram follows the final step in the programming routine 1 The SLC Processor sets the program blend move profile bit 0 6 11 2 The Module responds by setting the blend move mode bit 1 6 8 and send next blend move data bit 1 6 9 3 In response to the send next blend move data bit the SLC Processor writes the data for the first blend move segment into the command mode output image table and sets the read blend data bit O 6 12 4 The Module checks the first segment s data If this data is not correct the Module sets the command error bit 1 6 12 If the data is correct the Module resets the send next blend move data bit 1 6 9 5 Resetting the send next blend move data bit causes the SLC Processor to reset the read blend data bit O 6 12 6 The Module again sets the send next blend move data bit in response to resetting the read blend data bit 7 The sequence described in steps 3 6 is repeated until all the segments making up the blend move profile have been read The minimum number of segments i
57. roper signal level from the encoder encoder miswired or the Module has not been configured to accept encoder input IMPORTANT The Module operates differently when loop back diagnostics are active this mode uses a pulse train and direction bit versus quadrature encoder pulses Correct the encoder power supply voltage level or reconfigure the Module as applicable Encoder is not reading 7 1 2 Chapter Objectives Industry Standards General Specifications Specifications This chapter defines module design characteristics both electrical and mechanical and operating parameters relating to its application and compatibility with other system components e Backplane isolation to protect other Modules and the processor from external transient voltages Motion is inhibited whenever the power up sequence is in progress or the SLC processor is placed in program mode Number of Axes Applicable Interfaces Pulse Train Switching Speed Range Acceleration Acceleration Step Rate LED Indicators 1 Stepper motor driver 7 to 30 ma 5 VDC 1 to 250 000 pulses per second 1 to 2000 pulses per second Trapezoidal velocity profile 4 milliseconds or less Color Description Green RUN indicates the processor is running Extinguished in case of watchdog timeout Green CW indicates motion in the clockwise direction Green CCW indicates motion in the counter clockwise direction Red Error indicates data transfe
58. s 2 the maximum number is 16 8 When the last segment has been sent to the Module the SLC Processor program resets the program blend move profile bit O 6 11 and exits the blend move mode 9 The Module then resets the blend move mode bit 1 6 8 and the send next blend move data bit 1 6 9 10 When a blend move profile is to be run the SLC Processor sets the run blend move profile bit O 6 13 Note that no blend move profile can be run until this bit has been set 11 When the run blend move profile bit has been set the Module sets the blend move mode bit 1 6 8 and then executes the profile program 12 After all segments in the profile have been run the Module sets the move complete bit 1 6 7 and resets the blend move mode bit 1 1 8 13 Steps 10 11 and 12 can be repeated as long as the profile is started from the same position each time Chapter 4 Configuration and Programming Status set when 1 blend all segments set to program move mode output upper position word lower position word blend move profile MOV Sf Source 2048 8 DN Dest O 6 0 send next q blend blend move controls which move mode data segment output 1 6 1 6 CTU C5 0 11 8 9 1 send next blend move determines which data segment to output copy segment 1 data 1 6 EQU C5 0 ACC 1 9 send next blend move determines which data segment to output copy segment 2 data 1 6 EQU
59. t 11 bit 12 bit 13 and 14 bit 15 To guard against a configuration error certain bits in output word O must be set Either bit 0 or bit 1 or both must be set and either bit 4 or bit 4 and bit 5 must be set This is true whether or not the indicated limit switch is present in the system Also there are certain output combinations that obviously are not valid e g setting both bit 8 and bit 9 Using an invalid output combination will also result in a configuration error being generated when a CW limit switch is used set when a CCW limit switch is used set when the pulse train enable disable input is used set when an external interrupt is used set when a home limit switch input is used set when a home limit proximity limit switch is used not used set when a quadrature encoder is used set when diagnostics feedback is used 1 when output pulse type is pulse train and direction 0 when output pulse type is CW pulse train and CCW pulse train not used 0 for limit switch home operations 1 for marker pulse home operations not used 1 for configuration mode 0 for command mode Output word 1 Defines the active levels of the inputs The bits are set for high true logic 1 for input of 7 VDC or higher or normally open NO or reset for low true 0 V logic 1 or normally closed NC Note that the active levels of the inputs are taken into account only when the corresponding input is present in output word 0 bit 0 bit
60. the relative move bit off Set the sequence back to step 4 Move Completed Flag EQU EQUAL Source A Source B Chapter 5 Application Examples Rung 2 13 This rung evaluates the error status while in Command Mode Should an error exist this rung resets the error flag s Command Error 1 Error Nor in 0 No Error Config T I1 l B3 12 COP COPY FILE Source N9 40 Dest 0 1 0 Length 8 Rung 2 14 END Chapter 5 Application Examples Report Options Summary Data Table Data Radix DECIMAL Command Address Word N9 09 N9 10 N9 20 N9 30 N9 40 N9 50 o 1 absolute 2 relative 512 preset position 1024 reset errors See Configuration Chapter 4 page 4 3 N9 0 configuration N9 10 preset position N9 20 30 502 motion commands N9 40 reset errors Entering Negative Position Data The position data is sign magnitude There are three ways to easily assign a negative number e Using the ladder e Manipulating the bits manually e Calculating manually To enter negative position data using the ladder 1 Divide the aboslute value into most MSW and least significant LSW words 2 Use bitwise inclusive or with MSW and 32768 3 Place the result in the position MSW LSW To enter negative position data by manipulating the bits manually 1 Divide the absolute value into MSW LSW 2 Enter both MSW and LSW into the position MSW LSW
61. tion and Programming Status turned on and the unit must be power cycled to reset it based on this ladder logic move complete 1 yes less than 0 err Latch error output I1 LES 0 0 LESS THAN Source A I1 L 1 5 0 Source B 0 greater than test val err GRT GREATER THAN Source A 1 1 5 0 Source B N7 10 10 4 1 21 Chapter 4 Configuration and Programming Status Command Mode Input Words 15 14 13 12 11109 8 7 6 5 4 3 2 1 0 Word 0 Input Status Bits 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 Word 1 WORD 1 Status Bits 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 Word 2 MSW Current Position Value 1 to 8388 thousands 15 14 13 12 1 109 8 7 6 5 4 3 2 1 0 Word 3 LSW WORD 3 Current Position Value 0 to 1000 15 14 13 12 1 109 8 7 6 5 4 3 2 1 0 Word 4 MSW Encoder Position 1 to 8388 thousands 15 14 13 12 1 109 8 7 6 5 4 3 2 1 0 Word 5 LSW Encoder Position 0 to 1000 15 14 13 12 1 109 8 7 6 5 4 3 2 1 0 Reserved WORD 6 15 14 13 12 11 109 8 7 6 5 4 3 2 1 0 Reserved WORD 7 Chapter 4 Configuration and Programming Status 4 1 23 Chapter Objectives Processor Configuration Files Application Examples This chapter contains a number of application examples in the form of ladder diagrams to help you construct actual programs for the Module using the SLC Processor Data table used for the program listing for Sample Module Check Procedure Addr
62. try entitled OTHER Press ENTER Enter Module ID Code 3512 the ID of the Stepper Controller Eight input and eight output words are automatically created by the ID code Use the data monitor function to enter parameters into the bit B or Integer N file Use F1 to change between binary and decimal Processor configuration using HHT Catalog 1747 PT1 1 Locate an open slot in your chassis The Module can be used with any SLC Processor Assign your SLC Processor if not done previously Assign the Module to an open slot a Using an HHT press F3 EDT I O b Select an open slot with the cursor and press F2 MOD SLT F3 OTHER Enter Module ID code 3512 the ID of the Stepper Controller Eight input and eight output words are automatically created by the ID code Use the EDT DAT function to enter parameters into your bit or integer files Important The HHT has a default radix of binary for the bit file B and integer for the integer file N Radices cannot be changed Module Configuration Chapter 4 Configuration and Programming Status General Information The Module must be properly configured before any operations may begin The Module enters the configuration mode on power up or upon setting the configuration output word 0 mode bit 15 to 1 When configuration mode is set the Module stops command mode operations if applicable sets the configuration mode flag in the configuration mode
63. ut flag turns off when the resume move command has been acted upon A move can be held and then resumed a number of times until one of the following occurs e The axis reaches its target position e An error condition occurs e Some other command is issued Immediate stop pulse train off command brings a current move operation to a stop without deceleration ramp Bit 4 of command mode input word 0 is set The position invalid bit bit 10 also sets if the axis was moving at the time the immediate stop command is issued Important Itis possible to perform a Relative Move after an Immediate Interrupt has occurred However you can not resume a absolute move xum mecnm AE PEE AA Chapter 4 Configuration and Programming Status Find home CW and Find home CCW commands the way in which these commands are executed is dependent on whether or not a home proximity limit switch is present as selected in the configuration output image table When a find home command is issued with a home proximity limit switch present the axis accelerates to the programmed velocity and runs at that speed until the home proximity switch is detected The axis then decelerates to the starting speed and runs at that speed until the home limit switch is contacted or marker is detected depending on which is configured and then stops Without a home proximity limit switch present the axis speed moves at the configured starting speed until the

1746-999-121, Stepper Controller Module

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