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User`s Manual - Motor Systems, Inc.

1. Keypad Programming Template Summary and Page Reference of All Commands Used with the SmartStep IDeal Programming Commands Acceleration 6 2 Function Key 6 8 Loop Until 6 18 Square Root 6 26 Break 6 2 Go Home 6 10 Loop While 6 19 IS Stop Move 6 27 Distance Absolute 6 3 Go Immediate 6 11 Move Continuous 6 20 Time Delay 6 27 Distance to Change 6 4 Start Move 6 13 Message 6 22 B3 Velocity 6 28 Deceleration 6 6 Go to Subroutine 6 14 On Condition 6 23 Bag Wait 6 29 Distance Incremental 6 6 Go to Program 6 14 O
2. LY Auto Address 8 40 W End Prog Definition 8 40 Orig Configuration 8 41 817 9 Upload All 8 41 ib Delete Program 8 40 M2 Ends UA or UL 8 41 ih Define Program 8 41 Upload Program 8 41 Dwnld Prog to RAM 8 40 8 9 Load All 8 41 IS Run Program 8 41 59 RS 232 Echo Enable 8 40 List Programs 8 41 Tell Software Version 8 41 Operators Functions and Expressions see pages 7 6 thru 7 7 Name Program Bd Less Than increment by n 8g Name Variable Subtract Greater or Equal to Ell Decrement Variable EZA Logical AND Multiply EXE Less or Equal to Decrement by n Ill Logical OR Divide Bitwise Boolean AND Shift Left IE Logical NOT Equal Igi Bitwise Boolean OR gt gt Shift Right Not Equal Greater Than kad Increment Variable Built In Variables see pages 7 3 thru 7 5 11 thru AI6 Analog input 1 6 Read Only 1TW Scans input 1 4 for BCD digit Read Only AROWREL Current status of any arrow key Read Only 2TW Scans input 1 8 for BCD digit Read Only CPOS1 Commanded position of axis 1 Read Only TIME Elapsed time ms since last Read Only power up or reset EPOS1 Encoder position of axis 1 Read Only CRCS Val of setup checksum Read Only POS1 Current position of axis 1 Read Only CRCP Val of progra
3. Name Variable amp amp Logical AND Logical OR Logical NOT I Not Equal Add 5 Subtract Multiply Divide Equal gt Greater Than Less Than gt Greater Than or Equal to lt Less Than or Equal to amp Bitwise Boolean AND Bitwise Boolean OR Increment Variable Increment by n Decrement Variable Decrement by n lt lt Shift Left gt gt Shift Right Refer to Chapter 7 Programming Your Application for more details and examples of how to use the above operators functions and expressions 6 30 Chapter 7 Programming Your Application Chapter 7 Programming Your Application The purpose of this chapter is to give the programmer the information necessary to begin developing an application with a SmartStep Also in this chapter are several practical examples that may be copied and modified More program examples are available in Application Developer by selecting Help Command Help SmartStep Programming Overview Before beginning to develop a machine control program with a SmartStep the user must decide how the SmartStep fits into the overall machine control hierarchy The information in this chapter applies to the following three ways that an SmartStep may be used 1 Ina stand alone mode where the SmartStep controls all the Inputs Outputs and motion 2 With a PLC where the PLC runs the machine and calls on th
4. 4 17 USING DELETE DEL patcr dde 4 19 CHAPTER 5 CONFIGURING YOUR SYSTEM 4 eere eere ee eee enses esee ee 5 1 CONNECTING YOUR HARDWARE ecce eene nennen nene nn n nna se ases sss s eee e e eee e tei e tere n nnne nane assesses eene 5 3 CONFIGURING Y GUR S YSTEM zzi Herrero E DRE EURO gues sous desud aussie SEE 5 8 CONFIGURING YOUR STEPPER MOTOR eeeeeen II ne nn nnne nrar sereset eene e nenne retina nenas asas sss sense ennt 5 9 CONFIGURING Y OUR ENCODER oisein senere E eere tob ese it es testet etueo d e eeu eus 5 15 CONFIGURING YOUR MECHANICS oes sabes beste lese elu ovis T CORE ME Ced cedens Ee te ERE ER TUUS 5 18 CONFIGURING YOUR INPUTS amp OUTPUTS I O ssssssssssseseeseeeeee eene 5 22 CONFIGURING YOUR INPUTS eee e Teo ve Ie OE ce epe Ee 5 22 CONFIGURING Y OUR OUTPUTS ecce e te ete euet eere eat ee apo sebo voee E E OEEO e bn ee essor eese eco rou 5 27 CONFIGURING YOUR OUTPUT 5 8 eee vical oeecvsdec ce ve EE Ue PES SUUS Ye 5 30 CONFIGURING YOUR END OF TRAVEL SWITCH POLARITY eeeeeeeeeeeeee nnne nnne nnn nnns 5 31 CONFIGURING YOUR JOG PARAMETERS
5. syntax IVi variable min max Units n a Range 1 1 40 display position characters variable any legal variable name min the minimum range value optional max the maximum range value optional Default n a v1 00 This command allows an operator to input variable information under program control It is typically used with the message command MS to prompt for operator input of the variable specified in IV The cursor is placed on the display at character position i The program waits until a number is entered before continuing execution The command will not allow you to type past the end of either line on the display Variables will store 4 digits to the right of the decimal place When minimum and or maximum range values are specified the IV command will not accept inputs from outside this range When a value outside the range is entered one of the following messages is displayed on the keypad Input below minimum Press ESC to resume e Input above maximum Press ESC to resume These variables can then be used in a math equation conditional expression or to set any command parameters Example DA DC VE AC LP IF TD etc A variable can be used anywhere in a program where a real number or integer could be used Due to the nature of converting decimal numbers to binary and back care must be taken in performing math on variables used in LP statements LP will truncate the non int
6. OPTO44 88 OPTO44 88 As Serial Node to PC Chapter 5 Configuring Your System Recommended Wiring Practices for IDC Controls When configuring your SmartStep please follow the wiring practices listed below e Earth ground your machine at one point using a star configuration Multiple earth grounds can cause a ground loop see Preventing Ground Loop diagram below Avoid long cable runs The longer the cables the lower the signal to noise ratio in your application Use shielded motor and encoder cables along the entire cable run Separate the signal wires I O encoder etc from the motor wires AC power wires and other sources of noise in your application Avoid extending cables in the field via junction boxes terminal strips or Molex connec tors These types of connectors are typically unshielded as is wire going into and out of the connector and are places where noise may be injected into the system Connect cable shields at the control end of your machine Connect the motor cable shield to GND and connect
7. WHT RED WHT ORG RED ORANGE Wire Color on Quick Drive Disconnect Cables Connection IDC Quick Red w Black B Disconnect z Cable Red w White B Green GND P N QF4 12 Red w Yellow A Red A Gray colored Quick Disconnect Cables are shielded connect shield to GND 9 20 Chapter 9 Hardware Reference P21 P22 Hybrid Step Motor Specifications oo 81 403 20 1 02 031 02 TE Em 05 02 8X 24 AWG CONDUCTOR gt X 2 NE CABLE X 144 0 LONG MIN 70 02 Ll WITH FOIL SHIELD AND DRAIN B AF APPROXIMATE SIZE 23 DIA 2500 o 2 2495 g 1800 00 4 O 9 ad on Ta 002 Alc 2 001 005 Y S JS TEE ud N e 2500 2495 2X 4 40 UNC 2B 10 ZLTA 4 5 04 EQ SP AS SHOWN 11 02 4X 6 205 010 THRU DOALA P21 2 205 MAX ONA ZT 812 BC EQ SP AS SHOWN m 19 010 AIC 255 ON A 72625 BC P22 3 090 MAX 02 S Ty 010 Note specs are for both series and parallel wiring unless preceded by T Series or V Parallel Electrical Specs P21T P21V P22T P22V Continuous Stall Torque oz in N m 100 0 7 200 1 4 Recommended Current Phase Amps 0 7 1 23 1 0 2 0 Winding Resistance Ambient Ohms 19 4 7 15 3 7 Inductance mH 79 20 64 16 Max
8. Product Support amp Warranty Warranty amp Repairs IDC warrants this product to be free of defects in material and workmanship for a period of two 2 years from the date of shipment to the end user Products that have been improperly used or damaged in the opinion of IDC are not subject to the terms of this warranty IDC maintains a repair facility at its factory in Rohnert Park California for products manufactured by IDC Prior approval by IDC is required before returning any product for any reason All returned packages must be accompanied by an RMA Return Material Authorization number To obtain return authorization contact your local IDC distributor or IDC Please note the following procedure 1 Obtain the model and serial number of the defective unit Prepare a purchase order for possible repair cost in the event that the unit is not warranted 3 Contact your IDC distributor or IDC 1 800 277 1066 for an RMA 4 Provide information describing the nature of the failure The better the information the faster we ll have your problem resolved 5 Shipunit prepaid to the address below be sure to include your RMA on the shipping label Attn Repair Department Dahaner Motion 7C Raymond Avenue Salem NH 03079 Appendix A IDC Actuator Ratios Appendix A IDC Electric Actuator Ratios Configuring inch amp mm Units on SmartSteps Used With IDC Actuators One of the first steps in setting u
9. 1 Press RUN gt TEST gt TRACE 2 Enter the program name or number 3 Press ENTER ed loops and the number of nested routines The bottom line DI8000 shows the command to be executed when you press ENTER Each time you press ENTER the displayed command will be executed Pressing ESC halts program execution TRACE mode is not currently supported during homing operations The top line displays the program number the number of nest 5 1 1 GS 0 OUTPUT This feature allows you to test the SmartDrive s outputs as T 1 well as the devices to which it is connected by forcing them on m est PONE e and off 1 Press RUN gt TEST gt OUTPUT 2 Press lt keys to scroll through outputs 1 8 3 Press f keys to turn the output ON and OFF veh output os 4 Press ESC and you will be prompted as shown here 5 Make your selection and the display will immediately 0 0000 return to the Main Display 00000000 00000000 MOVE forward and backward This allows you to verify basic motor This selection moves your motor shaft one user defined unit TEST MOVE encoder and amplifier operation Axis 1 1 Press RUN gt TEST gt MOVE 2 Press F1 F2 or F3 to select the axis to move Chapter 4 Using the Keypad SHUTDN Shutdown Selecting SHUTDN allows you to enable or disable the axis When a drive is disabled the amplifier is off and your motor has no power The shaft
10. OUTPUT 3 2 See page 9 10 and 9 11 for important information on making connections to the OPTO44 and OPTOS88 Racks OUT OPTO OUTPUT 5 OUT2 COM OUT3 OUTA COM OPTO OUTPUT 6 Add 0 7 inches for Greyhill Discrete G5 modules OPTO OUTPUT 7 OPTO OUTPUT 8 Typical OPTO Module Tr OOOO0O909909 O0O0O0C O0O0O00 0O90O0O0O909099 OO0O0O0O90O0O00 r 3 6 9 10 Making OPTO Rack Connections OPTO44 and OPTOSS Racks allow the continued use of discrete inputs and outputs while providing the added dimension of opto conditioning With this added dimension comes an important CAUTION that must be observed when using either of these OPTO Racks OPTO44 Connections Chapter 9 Hardware Reference CAUTION Do not use discrete inputs IN1 134 and discrete outputs OUTA if a corresponding module is being used I1 14 and O1 O4 Failure to observe this caution may result in damage to system components Discrete inputs INS IN8 and discrete outputs OUTS OUT8 may be used anytime because there are no corresponding OPTO positions Example of Using OPTO44 Discrete I O In the illustration below OPTO inputs 1 and 2 and OPTO outputs 2 and 4 are being used In this case discrete inputs IN1 and IN2 and discrete outputs OUT2 and OUT4 must not be
11. GO Sets acceleration and deceleration to 2 DE 5 VE12 DA6 GO Accel stays at 2 decel changes to 0 5 VE20 DAO GO Acceleration and deceleration remain at 2 and 0 5 AC4 DA2 GO Acceleration and deceleration become 4 DI3 GO DE reset to 1 by AC1 before the move is made Break syntax BR v1 20 Units selected from the EDIT SETUP MECH menu Default n a The Break command instantly breaks a loop block in which it is defined and continues program execution from the loop s terminating EB command This allows for more complex loop conditioning than LU or LW commands Example A 0 Define variable A B 0 Define variable LP Define loop block IF A gt 10 Check if A is greater than 10 IF2 0 Check if input 2 is off BR Break loop EB EB A Increment variable A by 1 EB BR command jumps here MS1 A is greater than 10 Display message DA Chapter 6 Programming Commands Distance Absolute syntax DA r v1 00 Units selected from the EDIT SETUP MECH menu Range unit scaling dependent Default n a DA sets the next move position referenced from absolute zero The absolute zero position is established after a Go Home move GH and or with the Set Position SP command Absolute positioning is typically used in applications where you are moving to a number of known locations or if your ph
12. 1 00 FULL DEPTH r 4 40UNF 2B THRU 2 1 2 14NPS 0 23 0 21 THRU 4 3 875B C 0 317 0 307 Pd Jl ot NH SEE Seide ER ed e EDER a Z 9001 A n 0 3750 0 3745 3 L d OLOA 2 74 SQ REF H Dr ieee 3 27 SQ MAX 0 19 T Series V Parallel Electrical Specs S32T S32V S33T S33V Continuous Stall Torque oz in N m 300 7 1 400 5 3 Notes Recommended Current Phase Amps 2 8 5 6 3 5 7 0 Parallel V wiring Winding Resistance Ambient Ohms 1 03 26 96 24 50 duty cycle Inductance mH 10 2 5 10 2 5 max above 5 rps Max Winding Temperature F C 212 100 212 100 900 rpm Mechanical Specs S32T S32V S33T S33V IDC step motors 2 2 5 5 require a torque Rotor Inertia oz in s kg m 0 017 3 51x1077 0 0265 3 51x10 safety margin of at Axial Shaft Load Ibs 50 222 50 222 least 3095 Radial Shaft Load 0 5 inches Ibs 14 5 64 4 14 5 64 4 Motor Weight Ibs kg 5 1 2 3 8 3 3 8 Step Angle full step degrees 1 8 1 8 SERIES CONNECTION PARALLEL CONNECTION m YELLOW Wiring WHT YEL WHT RED RED Wire Color on Quick Drive Disconnect Cables Connection IDC Quick Red w Black B Disconnect Cable Red w White B Green G
13. 2 With the motor running at the speed indicated in the WAVEFORM TEST SPEED row see previous table alternately select between SINUSOID and 4 3rd to determine which setting produces the smoothest running condition 3 Press ESC to return to STEPPER SETUP Chapter 5 Configuring Your System Fine Tuning Offsets These potentiometers adjust the phase offset between Phase A and Phase B To adjust Offsets 1 Run motor unloaded at the Offset Test Speed indicated in Motor Reference 2 2 Alternately adjust the pots for smoothest running condition WARNING The Offset potentiometers see photo are located near other holes in the SmartStep housing Do not insert your Offset screwdriver in the holes adjacent to the Pots CAUTION label You could be injured by electrical shock See the circled holes in the illustration on the right ligh Voltag Configuring Rest Mode REi EDIT gt SETUP gt MOTOR gt TYPE gt STEPER gt REST Default OFF When Rest Mode is enabled motor current is reduced to 1 Amp if no motion occurs for 12 minutes Full current is restored when the next move starts Enabling REST reduces motor heating and improves fan life in applications where the machine is powered up but may not run for extended periods of time e g a machine that is operated during two shifts but is left on 24 hours a day 1 Use arrows 1 to select ON or OFF Axis Rest Mode 2 Press ESC to return
14. VEL VMAX ACCEL 1 MECH SETUP AMAX Axis One Dist Units lt revs DIST is used along with RATIO to select your distance units and unit label distance values specified in the system will be expressed in the units selected here The relationship between motor revolutions system mechanics and the distance label chosen here is defined with the RATIO command defined below Use the keys to select distance units from the following list mils arcmin inch degrees feet radians yards grads steps cm 96 meter arcsec revs mm index Notes e You can change DIST or RATIO at any time Changing them will not change the associated DI or DA values in a program i e DI100 will command a 100 inch move instead of a 100 step move if the DIST units are changed from Steps to Inches e Make certain that your Gear Ratio GR option is set to accurately reflect the Distance Unit e If steps is chosen the control automatically fixes the RATIO see following Chapter 5 Configuring Your System Configuring the Gear Ratio GRi i gt SETUP gt MECH gt RATIO E Default 1 to 1 The RATIO option is used to scale DI and DA moves to your preferred distance units RATIO sets the ratio of motor revolutions per DIST unit Up to 5 digits on either side of the ratio can be entered to properly scale your DIST units Make certain that the RAT
15. The motor seems to The Inductance or anti reso Change Confirm the Induc whine nance setting likely requires tance setting The SmartStep adjustment operates best with motors 4 mH or above If this does not help try the anti resonance set ting 10 1 Chapter 10 SmartStep Troubleshooting 10 2 Symptom The SmartStep ON LED is yellow The SmartStep ON LED is red Can t Communicate over RS232 but keypad works Can t Communicate over RS232 and keypad does NOT work Hit A Limit Amplifier Fault FLASH fault FLASH has been corrupted A Fault has occurred If the keypad works the Smart Step RS232 port is working Something else is configured wrong wiring configuration address The keypad is disabled The serial port is not working An EOT switch has been activated Multiple drive faults have occurred Possible Causes Possible Remedies The operating system and user programs must be reloaded with application developer The specific fault can be diag nosed by plugging in a keypad or using serial status com mands SS SA SD Refer to Chapter 5 RS232 Troubleshooting for in depth help Check the label to make sure you don t really have an RS485 version Either connect to RS485 or call IDC or your dis tributor to exchange units Enable keypad through dip Switch on back of keypad and try again Call IDC or your distributor for application assistanc
16. er used J1 Connects to 25 pin c Connector on SmartStep Om 1 2 11 INPUT 1 D 79 2 QD 12 IP COM D N3 O 12 OPTO INPUT 2 qp 13 conj D c INS OPTO 3 gt Y OPTO INPUT 3 6 19 M Module 14 E Connection OPTO INPUT 4 Terminals l4 QD com O1 dc OPTO INPUT 1 ia PA 01 ID 027 02 03 10 03 04 04 OPTO INPUT 2 D com ours CD ours D outs OPTO INPUT 3 69 INPUT 4 er DO NOT USE DO NOT USE IN5 IN8 ALWAYS USABLE ON OPTO44 RACK DO NOT USE DO NOT USE OUTS OUT8 ALWAYS USABLE ON OPTO44 RACK Discrete I O D Shell Connection Terminals Chapter 9 Hardware Reference OPTO88 Connections OPTO Module Connection Terminals 9 12 CAUTION Do not use any discrete input or output for which a corresponding OPTO module is installed The OPTO44 Rack allows usage anytime of discrete I O IN5 IN8 and OUTS5 OUTS but this does not apply to the OPTOSS Rack Failure to observe this caution may result in damage to system components See example and illustration below 16 er 9r lJ ipBeeeooeeeoocoooooo eeoeoeoeeoooeoegeeeoo optoss J1 Connects to 25 I O Connector on SmartStep OPTO OPTO INPUT 2 Module Installed
17. Configuring your system with the keypad begins below Configuring Your Stepper Motor Ses PROG RS232 MISC S SETUP JOG EO SETUB MOTOR ENC MECH Adjustments for Current Waveform Rest Idle Inductance and Anti Resonance can be made while the motor is energized and moving Motor References 1 and 2 on the following page will help you accurately configure your stepper motor Configuring Motor Type MT11 Note When you select MOTOR gt TYPE you will see three motor choice STEPER R SRVO AND L SRVO The SmartStep will only allow you to configure the STEPER option The other options are for configuring servo motors with the versatile keypad gt SETUP gt MOTOR gt TYPE gt STEPER Configuring Motor Current Min 1 STEPPER SETUP CURRENT A RES INDUCT nd gt SETUP gt MOTOR gt TYPE gt STEPER gt CURRENT Default 0 0 Amps Range 0 0 8 0 Amps for SmartStep 0 0 3 0 Amps for SmartStep23 0 0 4 0 Amps for SmartStep 240 The Motor Current parameter sets the motor current for your stepper motor Entering a current outside the valid range will reset the motor current to 0 0 Amps 1 Select CURRENT F1 Default current is 0 0 Amps 2 From the IDC MOTOR REFERENCE table enter the Axis One Motor Curnt Amps current that corresponds with the motor you are configuring 3 Press ENTER Chapter 5 Configuring Your Sys
18. oco ue ue x ui eue vex dle Tene v ee eee e eene o 5 32 CONFIGURING YOUR HOME PARAMETERS eene ee I nn nnn nn nnne sese eene nenne eene r eterne n nnns ases 5 34 CONFIGURING YOUR PROGRAM SETUP PARAMETERS eeeeenn eene nennen nennen nene hen ene nn nenas nnns 5 37 CONFIGURING YOUR SERIAL COMMUNICATIONS ccceeeeeene nn nene nennen nenne 5 39 CONFIGURING YOUR MISCELLANEOUS SETUP PARAMETERS eene nnn nenas nnns enn n sese neni 5 40 CHAPTER 6 PROGRAMMING COMMANDS eese eee esee eene eese e etn n eese tees eros eese e seen sees esee etos eese esee neu 6 1 COMMAND SUMMARY sae sess sese sessi 6 1 IDEALIM COMMANDS 6 2 CHAPTER 7 PROGRAMMING YOUR APPLICATION uuu ccssssnscccessssscccecssssscccceessssccceccssssssees 7 1 SMARTSTEP PROGRAMMING OVERVIEW s cssessssssusecccvesssecavescesercobevssssvessovesseecocenddcvececetesedseecevesscos esseveswensdees 7 1 CREATING OR EDITING PROGRAMS WITH THE KEYPAD ccccccscscsssccccccccccscecesesesessesesessnscesccusaeseeesceeeeeeeesesens 7 1 COMMAND SUMMAR Yerro cota tete reote Pcr ete eese tiv Herve are y IE 7 2 VARIABLES AND ARITHMETIC 7 2 5 7 2
19. 0 p d 009 6 00 152 4 5 44 138 1 SIDE SIDE 6 00 152 4 p Y ICTU m 1 27 32 2 EST NI 2 59 mae 5 92 150 4 Mounting for Minimum Depth Configuration Mounting for Minimum Width Configuration SmartStep MD Option Standard 9 1 Chapter 9 Hardware Reference This page intentionally left blank 9 2 Chapter 9 Hardware Reference Remote Mounting Your FP220 Keypad The keypad can easily be mounted and sealed to NEMA 4 specifications by using the included mounting gasket and 6 foot communication cable Warning Do not attach the gasket to the keypad Attach the gasket with the adhesive side toward the mounting enclosure A pressure seal 1s formed between the gasket and the keypad while the adhesive maintains the seal between the enclosure and the gasket An FP220 Keypad Mounting Template is included with every keypad and a not to scale mounting dimensions drawing can be found on the next page for reference Please pay particular attention to the CAUTION on the template Warning 1 When mounting the keypad on wall type surfaces as shown in the illustration below be absolutely certain that you have accurately estimated the proper length of mounting screws Your keypad may be damaged if a mounting screw is allowed to extend more than 0 20 inches into the keypad 2 When mounting the keypad to a metal surface it is highly advisable that the keypad be insulated from the metal surface by using non c
20. Example SS returns 0001 cr means there are no amplifier faults and no programs running SmartStep is ready to process any buffered RS 232C com mand Status rer eror por ot er of ot ot on of on _ Ready to Buffer 1 Ready to buffer RS 232C commands RS 232C Commands 0 Initializing from a power up or reset or unchecked errors exist Any buffered commands sent will be discarded FLASH Error 2 12 Non volatile memory checksum error all programs were deleted on power up 0 Non volatile memory checksum OK Program Running 3 1 Running a program 0 Not running a pre defined program FK Active 4 1 Paused waiting for a function key 02 Not waiting at a FK command WT Active 5 1 Paused waiting for a input condition O Not waiting at a WT command TD Active 1 Paused at a time delay 0 Not waiting at a TD command Waiting for IV 7 12 Paused waiting a variable input O Not waiting at a IV command Buffer Full 12 RS 232C buffer 75 full Total Capacity 2k 0 RS 232C buffer less than 60 full Axis 1 Fault 12 Amp fault following error move stopped by limit Switch see SAi and SDi for more detailed fault information 0 No faults Axis 2 Fault 10 1 Amp fault following error move stopped by limit Switch see SAi and SDi for more detailed fault information 0 No faults RESERVED State undefined should be masked Program Select 1 BCD and Binary program select scannin
21. Hardware connection is accomplished also by referring to Chapter 9 Hardware Reference The second category is Configuring Your System which is the software setup of your application This includes setting motor current scaling units I O configuration and more of the software configuration can be done via the keypad or via serial communication using Application Developer The configuration details presented here are from a keypad user s perspective via the keypad menu structure and step by step keypad instructions Serial communication users should refer to this chapter for detailed explanations of configuration parameters Details on using the Application Developer can be found in Chapter 8 Programming with Serial Communication For PC terminal users non Windows PC users or PLC users the equivalent 2 character ASCII configuration commands are detailed in Chapter 8 In this chapter the 2 character ASCII command appears in brackets next to the keypad command Application Developer users will find that the Windows dialog boxes follow the keypad menu structure very closely Typical SmartStep Application Stand alone B M The SmartStep easily interfaces with a PC PLC the Keypad or can be used as a stand alone machine controller Block diagrams of several SmartStep based applications are shown below EA D SmartStep mum As Node to PLC
22. OPTO INPUT 3 Module Installed OPTO INPUT 4 OPTO INPUT 5 OPTO INPUT 6 OPTO INPUT 7 OPTO INPUT 8 OPTO INPUT 1 OPTO INPUT 2 OPTO INPUT 3 OPTO INPUT 4 Module Installed OPTO INPUT 5 Module Installed OPTO INPUT 6 OPTO INPUT 7 OPTO INPUT 8 Example of Using OPTOSS Discrete I O In the illustration on the left OPTO inputs 2 3 and 6 and OPTO outputs 4 and 5 are being used The corresponding discrete I O inputs 2 3 and 6 and outputs 4 and 5 must not be used D Ou DO NOT USE IN2 QD Ot DO NOT USE IN3 D DS D DO NOT USE iN6 D Discrete I O D D Shell Qe Extension Terminals Ow DO NOT USE OUT4 DO NOT USE OUTS D D QD Chapter 9 Hardware Reference Using OPTO44 and OPTOS88 Wiring Examples DC I O 400000020209 M 12 13 13 4 User Input VDC m AC I O 1 Line 2 dieters Line 2 E or Neutral User Load i Phase or Sooo ee eee Neutral i aaa i Line 1 A peer ken i Phase P T MESE amp Outputs H 2 w en p tm 3 8
23. T Series V Parallel Electrical Specs S21T 21V S22T 22V S23T S23V Continuous Stall Torque oz in N m 65 0 46 100 0 71 125 0 88 Recommended Current Phase Amps 1 2 24 1 5 3 0 1 75 3 5 Winding Resistance Ambient Ohms 5 4 1 35 4 8 1 2 4 4 1 1 Inductance mH 18 4 5 18 4 5 18 4 5 Max Winding Temperature 212 100 212 100 212 100 Mechanical Specs S21T S21V S22T 522 S23T S23V Rotor Inertia oz in s kg m 1 66x10 1 17x105 3 31x103 2 34x109 4 97x103 3 51x105 Axial Shaft Load Ibs N 25 111 25 111 25 111 Radial Shaft Load 0 5 inches Ibs N 5 6 25 5 6 25 5 6 25 Motor Weight Ibs kg 1 6 0 73 24 1 1 3 2 1 5 Step Angle full step degrees 1 8 1 8 1 8 Notes IDC Motor Wiring SERIES CONNECTION PARALLEL CONNECTION Parallel V wiring 5096 duty cycle max above 5 rps 300 YELLOW WHT YEL rpm WHT BLK WHT ORG ORANGE ORANGE WHT RED RED WHT BLK Wire Color on Quick Drive Em Disconnect Cables Connection Red w Black B Cable Red w White B Green GND P N QF3 12 Red w Yellow A Red Gray colored Quick Disconnect Cables are shielded connect shield to GND 9 18 IDC step motors require a torque safety margin of at least 3096 Chapter 9 Hardware Reference 532 533 Hybrid Step Motor Specifications F 32 5 01 33 6 43
24. White Violet 23 Black Green 4 Pink 9 Violet 14 White Red 19 White Black 24 Black Gray 5 Yellow 10 Gray 15 White Orange 20 Black Red 25 Black Pink 9 14 Chapter 9 Hardware Reference DB25BO Screw Terminal Breakout Board Pin 13 Common Pin 25 5VDC supply for OPTO44 88 Pin 12 Common Pin 24 5VDC supply for OPTO44 88 Pin 23 Common Pin 10 Common Pin 22 Common DB25BO Screw Pin 9 Common Terminal Pin 8 Input 8 Breakout Pin 7 Input 7 Pin 19 Output 6 Board Pin 18 Output 5 Pin 11 Common DB25BO Pin 21 Output 8 Pin 20 Output 7 Pin 6 Input 6 Pin 5 Input 5 Pin 4 Input 4 Pin 17 Output 4 Pin 16 Output 3 When connected to the ene SmartStep the DB25BO terminals will match the pinouts of the 25 pin con nector as shown here Pin 3 Input 3 Pin 15 Output 2 Pin 2 Input 2 Pin 14 Output 1 Pin 1 Input 1 See page 9 5 for Input and Output schematics Pin 13 Common Pin 25 5VDC supply for OPTO44 88 Pin 12 Common Pin 24 5VDC supply for OPTO44 88 Pin 11 Common Pin 23 Common Pin 10 Common Pin 22 Common Pin 9 Common Pin 21 Output 8 Pin 8 Input 8 Pin 20 Output 7 25 pin Connector Pin 7 Input 7 Pin 19 Output 6 Bnei in 6 Input SmartStep Pin 18 Output 5 Pin 5 Input 5 Pin 17 Output 4 Pin 4 Input 4 Pin 16 Output 3 Pin 3 Input 3 Pin 15 Output 2 Pin 2 Input 2 Pin 14 Output 1 Pin 1 Input
25. 1 01 02 O2 O3 03 04 04 n Brake 24 VDC Line 2 Phase or Neutral Brake Line 1 Phase 9 13 Chapter 9 Hardware Reference OPTO Modules Available from IDC IDC stocks the following OPTO modules which may be specified when ordering a SmartStep OPTO MODULES Order Code p n Module Description Opto 22 P N Greyhill P N A PCB 1210 10 32 VAC VDC Input G4IDC5 70G IDC5NP B PCB 1211 TTL Input G4IDC5K C PCB 1212 35 60V DC Input G4IDC5G 70G IDC5G D PCB 1213 90 140 VAC Input G4IAC5 70G IAC5 E PCB 1214 180 240 VAC Input G4IAC5A 70G IAC5A F PCB 1215 5 60 VDC 3 Amps Output G40DC5 70G ODC5 G PCB 1216 12 140 VAC 3 Amps Output G40AC5 70G OAC5 H PCB 1217 Output 24 280 VAC 3 Amps G40AC5A 70G OAC5A PCB 1218 Input Test Switch G4SWIN J PCB 1219 Analog Input Module 73G IV10 K PCB 1220 Analog Input Module 73G 11420 More information on these OPTO modules is available from the OPTO module manufacturer or your local distributor Wire Color Codes for Optional SS IO and SS IO 6 Cables Color Codes for SS IO and SS IO 6 Cables Wire Color Wire Color Pin Wire Color x Wire Color Pin Wire Color 1 Brown 6 Green 11 White 16 White Green 21 Black Orange 2 Red 7 Light Green 12 Black 17 White Blue 22 Black Yellow 3 Orange 8 Blue 13 White Brown 18
26. C D etc are in program numbers 1 9 To continuously cycle through put a GI SCREEN 1 at the end of each part program 6 9 Chapter 6 Programming Commands 6 10 syntax GH r v1 00 Units velocity units selected from the EDIT SETUP MECH menu Range unit scaling dependent Direction positive 4 direction established in EDIT SETUP MOTOR menu Default n a The GH command initiates a homing routine seeks the home switch to establish a home reference position When it reaches home the position counter is set to zero or to the Home Offset value selected in the EDIT SETUP HOME menu The motor will move at the GH velocity n and direction specified until it either finds a home limit switch or determines that it can not find one between the two end of travel limit switches The Go Home move uses the last acceleration and deceleration specified The exact homing routine used and the ultimate end position of your system s home reference depends upon the values of your EDIT SETUP HOME parameters edge level final approach direction and offset and whether or not you have specified open or closed loop moves in the EDIT SETUP ENCODER menu The control will reverse direction when the first End of Travel limit switch is encountered while searching for a Home switch If the second End of Travel switch is encountered the unit will abort the Go Home move and generate a fault A
27. Gosub to the appropriate program the FK statement are considered valid Example of a 3 screen menu program Program 20 SCREEN 1 MS1 MS3 Select a Part MS21 Part A Part Part C FK1 2 3 17 18 GT FKEY EN Program 18 SCREEN 2 MS21 Part D Part E Part F FK1 2 3 17 18 IF FKEY 17 GT SCREEN 1 EB IF FKEY 18 GT SCREEN 3 EB FKEY FKEY 3 GT FKEY EN Program 17 SCREEN 3 MS21 Part G Part H Part J FK1 2 3 17 18 IF FKEY 17 GT SCREEN 2 EB IF FKEY 18 GT SCREEN 1 EB 6 EN Chapter 6 Programming Commands Name the main program Clears keypad screen Writes a Message Writes a message above function keys Wait for selected key press Jumps to prog 1 2 or 3 if F1 F2 or is pressed Jumps to prog 17 or 18 if the up or down arrow keys are pressed End of Routine Writes a message above F1 F2 F3 Wait for selected key press If Up arrow goto screen 1 If Down arrow goto screen 3 Add offset to FKEY variable to goto correct part subroutine Jumps to part D E F in program 4 5 or 6 End of Routine Writes a message above function keys Wait for selected key press If Up arrow goto screen 2 If Down arrow goto screen 1 Add offset to FKEY variable to goto correct part subroutine Jumps to part G H J in program 7 8 or 9 End of Routine The programs to make Parts A B
28. Position maintenance gain Position maintenance maximum velocity Distance Units Scale distance to preferred user units BKLASH Electronic backlash compensation not implemented Speed units Critical speed limit Acceleration units INPUTS Maximum rate of acceleration deceleration Input functions OUTPUTS OPTOS Output functions OPTO module configuration OUTSTS LIMITS State of output on Power up Fault or Stop End of Travel Switch Polarity Jog acceleration Low jog velocity ENABLE EDGE High jog velocity Enable disable jog in RUN menu Homing method Edge of home switch SWITCH OFFSET Type of home switch Position counter offset DIR Final homing direction positive or negative Program to run on power up if any RS 232C STOP RATE How to scan program select inputs Program Select de bounce time Echo characters Serial address Format Display Decel rate when stop input activated TEST FAULT Enable Test Menu not currently implemented Polarity Fixed Active High in SmartStep ENABLE PASWRD 4 14 Polarity Fixed Active Low in SmartStep Password setup for operator administrator access Chapter 4 Using the Keypad Select POS to Reset the Current Position to Zero POS is a quick way to reset the motor s current position to absolute zero a very useful setup and debugging tool l 2 Press EDIT gt POS F3 You
29. Program a Sets the SmartStep address Set Unit Number To b Sets the program to run on power up Powerup Program No program will run if set to 0 c Sets the debounce Scanning Time of the program select inputs in milliseconds Miscellaneous Setup Stop Scanning Program Select Lines After Allows you to select the conditions under which program scanning stops 8 13 Chapter 8 Programming With Serial Communication File Menu 8 14 Applications programs and configuration files may be stored on disk as DOS files The default suffix is idc The other selections under File are generic to all Windows applications Application Developer untitled idc The open file has not been downloaded 1 cielale Chapter 8 Programming With Serial Communication Program Editor The Program Editor features standard windows editing features Cut Copy Paste Undo Delete and Select are available by pressing the right mouse button An online HELP file may be reached by clicking on the Command Help button shown below 1 IDC Application Developer unt The open file has not been downloaded Program Editor IDeal Commands Reference The following commands are available AC Acceleration Break Loop Current Limit Current Hold Time Distance Absolute Distance to a Change Deceleration Distance Incremental Enable Disable Amplifier End of Block End of Subroutine or Progra
30. Winding Temperature F C 248 120 248 120 Mechanical Specs P21T P21V P22T P22V Rotor Inertia oz in s kg m 0 0035 2 48 x 10 0 0061 4 32 x 10 Axial Shaft Load Ibs kg 10 44 10 44 Radial Shaft Load 0 75 inches 19mm bs 15 66 15 66 Motor Weight Ibs kg 1 9 0 86 2 7 1 23 Step Angle full step degrees 1 8 1 8 IDC Motor Wiring SERIES CONNECTION PARALLEL CONNECTION YELLOW WHT YEL Note IDC step motors require a torque safety margin of at least 30 WHT RED RED nm Encoder Color Code amp Pin out for P amp K Motors 1 Wire Color on Quick Drive Signal Pin Color Disconnect Cables Connection At B Red T T Red wi Black B A C Pink or ed W ac P Kf N IDC Quick T Y uon amp io Disconnect Red w White B gt P j Cable Green GND 71 Yellow Red w Yello A Z U 4 12 a Red A COM T Black Gray colored Quick Disconnect Cables Shld m ux are shielded connect shield to GND Brown NC 9 21 Chapter 9 Hardware Reference P K 31 32 33 Step Motor Specifications 4x 0 218 THRU 3 875 B C EQUALLY SPACED ON La 0 885 0 865 ed 0 665 0 585 _ 4 40 UNC 2B 2877 2873 Motor Dimensions 1 95MAX g x0
31. are shielded connect shield to GND 1 Brown NC 9 23 Chapter 9 Hardware Reference Non IDC Motors 9 24 IDC s S Series motors have custom windings to provide optimum dynamic performance with the SmartStep If you use another manufacturer s motor it should meet the following guidelines 1 2 phase hybrid permanent magnet step motor 4 6 or 8 lead motor 3 Series or parallel inductance rating between 4 60 mH for SmartStep and SmartStep23 and 8 240 mH for SmartStep 240 Higher inductance motors will not damage the drive but they will have limited dynamic performance 4 Aminimum high pot test rating of 500 VDC If possible use the manufacturer s 160 VDC bipolar current rating With 4 lead motors the manufacturer s bipolar current rating translates directly to the SmartStep current setting For the proper current setting for 6 lead unipolar motors use 7096 of the manufacturer s rating For 8 lead motors you have the choice of wiring the motor in series or parallel see Motor Wiring drawing In Series set the current to the manufacturer s bipolar rating In Parallel double the bipolar current rating Care should be taken when running a step motor in parallel to avoid overheating the motor windings A step motor in parallel may be duty cycle and speed limited Check with the motor manufacturer for temperature guidelines With 4 lead motors the manufacturer s inductance rating usually tr
32. motion and terminates program execution No deceleration ramp is used with this command Caution should be used in issuing this command because of the damage instantaneous deceleration could cause to sytems mechanics The Stop commands provides a more controlled halt lt n gt K MN Model Number Returns the unit model number MN command responses are SmartStep SmartStep23 SmartStep240 n MN OS Tell Output States Returns the current state on or off of the 8 Outputs and any of the Optos that are configured as digital Outputs The status is returned as a four digit hexadec imal number preceded by an asterisk Example OS returns 00F6 cr with the Output conditions shown in this table Inputs NN spe Te e e Te 8 7 T8 8T TS E o3 o8 d t l3 Your computer program will have to decode the hexadecimal number to deter mine the state of any output lt n gt OS PA Tell Absolute Position Reports current position in user units based on encoder mode selected Can report specifically commanded or encoder position when PAa n is used Example returns 1 000 the position of axis one lt gt 1 8 35 Chapter 8 Programming With Serial Communication Serial Immediate Status Commands Note All but the S and commands require an address Command Command Description and Application Examples Syntax RS Reset System lt n gt RS Re initializes or warm
33. see note Note Registration Input is only configurable on input 1 for axis 1 System Performance when Using the RG Registration Command The input capture delay is 55 Worst case position error is 9 steps at 50 rps 6 25 Chapter 6 Programming Commands 6 26 Set POSION asro I syntax SP r v1 00 Units selected in EDIT SETUP MECH menu Range varies based upon Distance Units Default 0 SP sets the current absolute position to This command is typically used to readjust or shift a coordinate system It is often done after a series of incremental moves to reset the absolute coordinate frame Example MC GO WTI 1 VEO GO SP10 5 After the move is complete sets the current position of axis 1 to 10 5 5 ROOD vi sapin ncbUnix QU IEEE URBE DM M LUN SER syntax SQr var v1 00 Units n a Range 0 0001 to 214748 3645 Default n a The SQ command calculates the square root of a number and returns the result in a user defined variable The n parameter in the syntax can be a number or a variable parameter however the second parameter must be a previously defined variable for which the square root result is stored If the second parameter is not a defined variable you will get a Bad Variable Name error Following mathematical convention SQ will produce an Invalid Parameter error for negative r values The return value is accurate to the 0 01 place Example The following example program calculate
34. 1 Motor Wiring The A and B phase outputs power the motor windings The two Intlk pins must be jumpered together at each motor connector to enable the drive to apply power to the motor If an interlock wire breaks or the connector is removed the current to the motor is immediately stopped and the drive will fault latch Extending the interlock wire beyond 5 4 inches can lead to noise generated shutdowns CAUTION Note this is a low impedence safety interlock HIGH VOLTAGE circuit Gnd is an earth ground internally connected to the power connector earth ground and to the control s chassis ground This provides a convenient terminal for grounding the motor frame and a motor cable shield IDC Motors Refer to the motor data sheets in Chapter 9 Hardware Reference for wiring IDC motors with Quick Disconnect cables Connecting Non IDC Motors Refer to Non IDC Motor section in Chapter 9 Hardware Reference TTTTTITTTIM 2 Limits Connections A typical IDC position sensor is shown connected to a SmartStep in the illustration below Refer to pages 9 7 and 9 8 for more details on Limits connections PSN Hall Effect Position Sensor Connected to SmartStep e B E B E 5 3 Chapter 5 Configuring Your System 5 4 3 Encoder Wiring An optional encoder port is available to allow for stall detection closed loop positioning and position maintenance En
35. 1 5 0 1666667 0 25 15 to 60 150 to 15240 R3 20T 2 0 1666667 0 33333 1 to 3 10 to 762 R3 30T 3 000 0 1666667 0 5 3 to 6 30 to 1524 R3 50T 5 037 0 1666667 0 83951 3536 to 4212 354 to 10699 R3 100T 10 000 0 1666667 1 66667 10 to 6 100 to 1524 R3 102 1 2 2 2 to 1 20 to 254 R3 152 1 5 2 3 3 to 1 30 to 254 R3 202 2 2 4 4 to 1 40 to 254 R3 502 5 037 2 10 07401 212160 to 21060 21216 to 53492 R3 1002 10 000 2 20 20 to 1 200 to 254 R3 105 1 5 5 5 to 1 50 to 254 R3 155 1 5 5 7 5 75 to 10 750 to 2540 R3 205 2 5 10 10 to 1 100 to 254 R3 505 5 037 5 25 18519 106080 to 4212 10608 to 10699 R3 1005 10 000 5 50 50 to 1 500 to 254 R3 108 1 8 8 8 to 1 80 to 254 R3 158 1 5 8 12 12 to 1 120 to 254 R3 208 2 8 16 16 to 1 160 to 254 R3 508 5 037 8 40 2963 212160 to 5265 21216 to 13373 R3 1008 10 000 8 80 80 to 1 800 to 254 R4 Smart Drive Mechanical Ratio Setting Motor Screw Overall Ratio EDIT SETUP MECH RATIO menu Series Reduction Pitch Mtr Turns Inch Ratio for Inches Ratio for mm R4 10T 1 0 1333333 0 13333 8 to 60 8 to 1524 R4 15T 1 5 0 1333333 0 2 12 to 60 12 to 1524 R4 20T 2 0 1333333 0 26667 16 to 60 16 to 1524 R4 30T 3 000 0 1333333 0 4 24 to 60 24 to 1524 R4 50T 5 110 0 1333333 0 68139 28288 to 41515 2829 to 105448 R4 100T 10 007 0 1333333 1 33430 27456 to 20577 2746 to 52266 R4 101 1 1 1 1 to 1 10 to 254 R4 151 1 5 1 1 5 15 to 10 15 to 254 R4 201 2 1 2 2 to 1 20 to 254 R4 501 5 110 1 5 11044 42432 to 8303 4243 to 21090 R4 1001 10 007 1 10 00729 686
36. 27 Dp MIN 2x EQ SPACED ON A 1 812 B C 0 3148 0 3143 N I 1 2 K 22AWG GROUND WIRE IS GREEN 12 LONG MIN MOTOR LEADS STHROUGH IDC Motor Wiring MOTOR D K T LMAX SERIES CONNECTION PARALLEL CONNECTION YELLOW s BLACKS P31 K31 5000 1250 555 3 70 444 a4 i f B4 P32 K32 5000 1250 555 5 22 5 96 SEE 2 WHT RED C WHTORG RED ORANGE P33 K33 6250 1875 705 6 74 7 48 A RED ORANGE p WHT YEL WHT BLK Note Specs are for both series and parallel wiring unless preceded by T Series or V Parallel Electrical Specs P31 P32 P33 K31 K32 K33 Continuous Stall Torque oz in N m 450 3 2 920 6 5 1260 8 9 580 4 1 1200 8 5 1600 11 3 Recommended Current Phase Amps T 1 5 T 1 6 T 2 0 T 1 5 T 1 6 T 1 7 V 2 9 V 3 3 V 4 0 V 2 9 V 3 3 V 3 3 Inductance mH T 56 T 120 T 100 T 56 T 120 T 117 V 14 V 30 V 25 V 14 V 30 V 30 Max Winding Temperature 212 100 212 100 212 100 212 100 212 100 212 100 Mechanical Specs P31 P32 P33 K31 K32 K33 Axial Shaft Load Ibs N 305 1350 305 1350 305 1350 305 1350 305 1350 305 1350 Radial Shaft Load 0 5 inches Ibs N 65 285 65 285 110 4
37. 4 Enable Disable Amplifier EA 6 6 End of Block EB 6 7 End of Routine EN 6 7 Function Key FK 6 8 Go start a move GO 6 13 Go Home GH 6 10 Go Immediate GI 6 11 Go to a Program GT 6 14 Gosub GS 6 14 If IF 6 15 Input Variable IV 6 16 Loop LP 6 17 Loop Until LU 6 18 Loop While condtion true LW 6 19 Message to Display MS 6 22 Move Continuous MC 6 20 Output OT 6 24 Quote 6 24 Registration RG 6 25 Set Position SP 6 26 Square Root SQ 6 26 Stop on Input ST 6 27 Time Delay TD 6 27 Velocity VE 6 28 Wait WT 6 29 idle mode 5 13 5 14 if command 6 15 incrementing variables 7 7 inductance 5 12 input and output cables wiring color codes 9 14 input characters analog 5 25 BCD program select 5 23 binary program select 5 23 clear command buffer 5 23 data valid 5 26 extend jog 5 23 interrupt run 98 5 23 jog speed 5 24 kill motion 5 24 lock keypad 5 23 motor shutdown 5 25 pause continue 5 25 registration 5 23 retract jog 5 25 stop 5 25 unassigned 5 25 warm boot 5 26 input power requirements specs 9 5 input schematic discrete 9 7 input variable command 6 16 input output accessories 5 6 interrupt run 98 input 5 23 J jog parameters 5 32 jog acceleration 5 32 jog enable 5 33 jog high velocity 5 32 jog low velocity 5 32 jog speed input 5 24 JOG sub menus 4 5 jogging the motor 4 5 K keypad features 4 1 remote mounting 9 3 keypad using the IDC Key
38. 70E 4 4 00E 4 5 50E 4 1 09E 3 1 09E 3 1 62E 3 INERTIA ELA 5 10 Chapter 5 Configuring Your System Configuring Anti Resonance SETUP MOTOR TYPE STEPER A RES Default 0 Range 0 30 The Anti Resonance parameter sets the anti resonance gain level for your motor For example issuing an AR14 would set the anti resonance gain to 14 1 Press A RES Axis One Anti Res 2 Atthis point you have three options 0 Option 1 Enter the Unloaded Anti Res setting for your IDC motor see Motor Reference 1 Skip to step 4 Option 2 Calculate an exact AR setting for your IDC motor see Calculating AR below and Motor References 1 and 2 Go to step 3 Option 3 If you are configuring a non IDC motor turn to Non IDC Electric Motors Calculating AR at the end of Chapter 9 Calculate ARynioaded and go to step 3 if your motor is unloaded If an exact AR value is required use your AR unloaded value to calculate AR see formula below Proceed to step 3 Calculating AR AR AR unloaded K ARynloaded 15 found in Motor Reference 1 K must be calculated using the following formulas K Log N N Jrotor Jrotor is found in Motor Reference 2 155 Jrotor Jioad is customer supplied 3 Enter your Anti Res value this will be a number between 0 and 30 4 Press ENTER NOTE Empirically the AR value will decrease as the increases You can observe this by entering smaller
39. COMMANDS esee Ie e e nnns nnns nnne ee es 8 31 COMMANDS NOT AVAILABLE IN HOSTED MODE 00ss0csesccccscccececsoseccssessssseesvevsssnsncsaenscceneseseveesesesdevees 8 33 SERIAL IMMEDIATE STATUS COMMANDS 8 34 SERIAL SUPERVISORY COMMANDS e eive eee ee obe tex ees aes veas tl euge aves tL Due 8 40 CHAPTER 9 HARDWARE REFERENCE ee eee eee eee eee enne eee eee etn nee eese seen 9 1 MOUNTING YOUR SMARTSTEP eee ex e toe eee eese e eode dre Ce Re eg aae Pe ERU 9 1 REMOTE MOUNTING YOUR FP220 KEY PAD toes cree 9 3 SMARTSTEP SPECIFICATIONS E ea apes a EE Ede 9 5 SMARTSTEP HARDWARE CONNECTIONS cceeeeeeen ee nennen nnne EE niet sese esee eere EE EEE 9 6 SMARTSTEP SCHEMATICS Ee ee eere teste Chev ea eere UR Ee toast baee 9 7 CONNECTING IDC LIMIT SWITCHES TO THE 9 8 CONNECTING AN ENCODER TO nennen eene eene nnne nnns 9 8 SMARTSTEP ACCESSORIES dacs ics repre ee o EU A DERE ER CURE MERE db ev eae v SEES EPA SD DNE 9 9 OPTO RACKS m M et 9 10 M
40. DA DC or MC commands Actual motion of a new profile will occur after a short calculation of the motion trajectory GOi pre calculates the move and waits for Input number 1 to activate before executing This variation is sometimes useful for applications needing very short repeatable move calculation delays It is more often used simply to shorten code since it functions like the combination of Wait on Input and Go WTi GO yet it pre calculates the move Like other commands using I O GOi does not restrict you from using an input even if it has been configured for some predefined function Example 05 DE 05 VESO DIS GO GO initiates calculation of a move profile using buffered parameters 05 unit Accel and Decel Ramp speed 50 5 unit incremental move and then executes it 05 DE 05 50 DIS 602 When input 2 is activated immediate execution of the motion calculation already in the buffer is performed 6 13 Chapter 6 Programming Commands GOSUD TE syntax GSi and GS name v1 00 Units n a Range 1 1 400 name any legal program name Default n a Jumps to program number or name and returns to the calling program when command processing reaches the EN command in the sub routine After the return execution continues at the command immediately following the GS Subroutines may be nested in the standard firmware up to 16 levels deep A Goto GT will clear the subroutine stack preventing future G
41. EGAL VARIABEE NAMES eee INE 7 3 BUILT IN 8 E 7 3 NON VOLATILE VARIABLES rta eder oa dhsvoussediveleassbeusedsivvveseetets 7 5 ARITHMETIC OPERANDS AND 7 6 BOOLEAN OPERATORS amp AND OR sssssssssssssssssssesssesesesesesesesesesesesssssesesesesesesesssssssasssesssesesaraetscseeeeeeees 7 7 LOGICAL OPERATIONS ON EXPRESSIONS 7 7 Table of Contents INCREMENTING AND DECREMENTING VARIABLES ceeeeeennnn n eee nennen enne nene nenne ene nete n nn nnns as sss esee enne 7 7 EXPRESSIONS T reet eL ELM Et 7 7 OTHER TYPICAL PROGRAMMING ssa as aer 7 8 TO CREATE A MESSAGE AND INPUT A VARIABLE ccccceeeesescscsccccescsceccecececeseseseesceesesssnscnnacaeeuseeesceceeeesesesens 7 8 CREATING AN OPERATOR MENU ire NES CERE EUIS 7 8 FAST IN SLOW FEED MOVE USING THE DISTANCE TO CHANGE DC COMMAND cerne 7 9 TURNING ON AN OUTPUT ON THE FLY saci tosis sade eese eoe ve eo te orte eee aen eeebev er eco bee eese 7 9 TO INPUT A 4 DIGIT BCD NUMBER READING 2 DIGITS AT A TIME ccce nm nnne nennen nennen 7 9 READI
42. P43 3 3 HIGH 15 P43 6 6 HIGH 14 K31 1 5 HIGH 24 K31 2 9 HIGH 20 K32 17 HIGH 22 K32 3 4 HIGH 18 K33 17 HIGH 20 K33 20 HIGH 16 K41 2 8 HIGH 18 K41 5 7 HIGH 14 K42 3 2 HIGH 17 K42 6 4 HIGH 13 K43 3 3 HIGH 15 K43 6 6 HIGH 11 3 2 Chapter 4 Using the Keypad Chapter 4 Using the Keypad This chapter will help the first time user understand the basics of using the Keypad The keypad was designed to provide operators the quickest possible way to configure an application and though it functions primarily as an operator interface it is equally effective asa programming and troubleshooting tool If you have chosen to program your application using RS 232C you may want to skip this chapter Keypad Hardware Features describes physical settings and adjustments that facilitate operator access for programming and best viewing of the keypad display Keypad Features and Description of Keys provide an overview of functionality The Keypad Menu Structure section gives the programmer a broad overview of how the setup and programming menus operate Detailed information about each setup parameter is presented in Chapter 5 Configuring Your System While keypad programming and system configuration are defined by IDC run time operation how the machine operator interfaces with the SmartDrive falls completely within your control Here are some of the operating functions you can program with the SmartDrive e Runa program
43. Thomson Select IDC Actuator equivalent N2 TC2 EC2 TC3 EC3 TC4 4 TC5 EC5 IDC Project Wizard SmartStep N Series E Control N2 Series wh T Series Mechanics Units LI CU Finish 9 Clicking on the Next button will bring up the Units setup window The SmartStep lets you program the control in the units that work best for your application IDC Project Wizard SmartStep revs evsisec seconds 10 Select your preferences from the pulldown menus and click on Next 8 7 Chapter 8 Programming With Serial Communication 11 When all parameters have been configured the following window will appear This display gives you the opportunity to review the settings you have made and return using the Back button to any parameter you may wish to change at this time IDC Project Wizard SmartStep Control Mec Units Finish 12 When you are satisfied with the setup of your system click on Finish Note that the Wizard Navigator now indicates that all axes and parameters have been configured After Using the Setup Wizard More Configuration Parameters 8 8 Your basic system setup parameters have been configured by the Setup Wizard and though the system is functional your application will probably require further configuration and fine tuning The remainder of this chapter provides the same setup information as configured by the Setup Wizard plus more detailed information on each parame
44. connected to receive RX of the drive unit and receive RX of the host must be connected to transmit TX of the drive If communication fails try switching connections on either the host or the drive Many serial ports require handshaking Jumper RTS to CTS and DSR to DTR see table Jumpers 9pinD 25 pin D Configure the host to the identical baud rate number of data bits number of stop bits and parity Receiving double characters XX when entering single characters X indicates your computer is set to the half duplex mode Change to the full duplex mode Check your grounds Use DC common or signal ground as your reference Do not use earth ground or shield Check your cable length If any cable is over 50 ft long you should be using a line driver optical coupler or shield Shields must be connected to earth ground at one end only 8 19 Chapter 8 Programming With Serial Communication Daisy Chaining SmartSteps Your SmartStep also supports daisy chaining The unit address range 1 99 can be set via the keypad through Application Developer or with a terminal program using the Unit Number UN command or the entire chain may be addressed at once using the Auto Address AA command Rules for Daisy Chain Operation 8 20 1 Units ona daisy chain must be device addressed numbered in ascending order away from the host device controller in order for the Load All LA EX commands to work properly T
45. deleting execution etc All of these commands are fully defined in this section Command Command Description and Application Examples Syntax EX Ends Upload or Load lt n gt EX Singles the end of a upload all UA or load all LA sequence EX is sent by the SmartStep to the host after completing a UA EX is sent by the host to the SmartStep to terminate a LA LA Load All lt n gt LA Sent to the SmartStep before downloading a long list of setup parameters and programs This command will disable the non addressed units so that each setup parameter doesn t need an address Must be followed by an EX to reestablish the daisy chain communications LS List Programs lt n gt Ls Lists number of programs memory usage and the current available memory of the SmartStep Just like Edit List from the keypad OC Original Configuration lt gt Returns the FLASH to its original factory default state The command buffer is cleared all programs are erased and all configuration settings are returned to their default values PR Define Program lt n gt PRi Starts a program definition Just like the DR command but writes the Smart Steps non volatile EEPROM memory Example PR25 AC 1 VE5 DI10 GO EP uses only a program number Example PR25 P N 170 001 AC 1 VE5 DI10 GO EP uses optional program name RN Run Program lt n gt RNi This commands any program by number only The RN command does not support the optional
46. eee dive tte dide tue eet 11 1 CAD MGIB RABY e enm E E 11 1 11 1 WARRANTY amp REPAIRS E 11 2 APPENDIX A IDC ACTUATOR 5 error eres so ee e eere ete ro asa A 1 IN DD EEE M 1 1 KEYPAD PROGRAMMING TEMPLATE INSIDE BACK COVER SUMMARY OF COMMANDS USED WITH SMARTSTEP ccccccccccccccccesecsssceseseseeees BACK COVER iii Chapter 1 Overview Chapter 1 Overview IDC s SmartStep Microstepping Drive is the first programmable all digital motion controller to offer so many features in such a small package The SmartStep provides unmatched flexibility when teamed up with the optional keypad operator interface We recommend at least one keypad for users of all experience levels because it facilitates the most efficient possible configuration and programming of applications Initial configuration and programming in most cases will require only a few minutes using the keypad In addition to being fully programmable from the keypad the SmartStep can also be programmed over RS 232C with IDC s user friendly Application Developer software Serial communication commands may be found in Chapter 8 This m
47. in any segment If no change is specified to one of these parameters the last value will be used It is not valid to issue positional commands DI DA DC GH SP to an axis while it is in a Move Continuous mode However you may make distance based moves on the other axis while running one axis continuously Any command is valid within an MC segment except Distance Commands DA DC amp DI The direction of the move is specified by the sign of the VE parameter If the sign of the VE parameter changes between two segments the control will automatically stop the motor at the programmed rate and change directions to the new speed This makes changing directions based on variable inputs very easy to program using a scaled variable as the VE parameter Once a Move Continuous segment is started it will continue to move at the speed specified by VE until either another VE is commanded the ESC Key is pressed or an End of Travel Kill Motion Interrupt or Stop Input is activated A commanded velocity of zero VEO stops an MC move Motion will also stop if you enter the Edit Help Copy or Delete menus After a continuous move segment has started command processing will continue when constant velocity is reached Other commands are then processed sequentially This allows you to e Have asynchronous inputs change the speed of an axis e Make motion profile changes based on time delays or input states e Manipulate I O while moving as a func
48. lines and the data valid inputs determining which units should listen Configuring this output can greatly reduce panel wiring In the example shown below using the Data Valid input reduced the number of wires by one half Data Valid 2 Unit 1 Selection SmartStep SmartStep SmartStep SmartStep 4 3 2 1 PLC Program Selection Warm Boot System Reset Resets the SmartStep clearing the RAM Buffer and resetting the control to its power up state Programs and setup parameters are not erased This is typically used to restart system when a fault condition occurs The power up program if defined will be run 5 26 Chapter 5 Configuring Your System Configuring Your Outputs Configuring Output Definition ODaaaaaaaa T1 PROGRAMMABLE EDIT gt SETUP gt I O gt OUTPUTS P Default PPPPPPPP The function for each output channel is indicated by a letter along the bottom of the display The first 8 letters are for the dedicated Outputs 1 Use lt and keys to select an Output channel The function of the highlighted output will be displayed on the top line 2 Once your cursor is on the desired output use to select from a list of function configurations for each channel See below Note d h and m lower case are on the keypad but are not used with
49. not require you to create or download any program to the SmartStep s volatile memory See Chapter 6 Programming Commands for complete definitions Command Command Description and Application Examples Syntax WT Wait On Input Condition WTi ii Example WT1 0 GO wait for input 1 to turn off before starting move nWTiii lt n gt WT expression lt n gt WTHi 8 32 Chapter 8 Programming With Serial Communication Commands Not Available In Hosted Mode The following set of commands can only be executed if they are part of or within a program Command Command Name BR Break EB End Block GS Go Sub GT Go To IF If IV Input Variable LP Loop MS Display Message EN End Routine FK Function Key LU Loop Until LW Loop While WT Wait 8 33 Chapter 8 Programming With Serial Communication Serial Immediate Status Commands Serial Immediate Status commands are processed immediately upon receipt rather than waiting in the buffer for previous commands to finish They can be issued while a program is running or while motion is in progress They cannot be stored within a program Using Immediate Status Commands Serial Immediate Status commands are provided for two purposes One is to allow a host control to query the SmartStep in real time for system position and I O status The second is to provide a means to perform in depth troubleshooting via RS 232C These commands w
50. position maintenance deadband in motor steps Valid as a program com mand using an immediate parameter only No variables JA Jog Acceleration lt n gt JAr Example JA 01 01 Units selected by AU command JE Jog Enable lt n gt JEi 0 Jog Disabled 1 Jog Enabled Example JE1 enabled 8 28 Chapter 8 Programming With Serial Communication These are the commands that the Application Developer program uses to configure the SmartStep according Serial Setup Commands to the choices made in the SETUP dialog boxes Command Command Description and Application Examples Syntax JH Jog High Velocity Example JH5 0 5 in units selected by VU command n JHr JL Jog Low Velocity Example JL1 5 1 5 in units selected by VU command lt n gt JLr MD Motor Direction Reference 0 Positive direction 1 Negative direction Example MDO one positive lt n gt MDi MH Motor Inductance a H High Inductance a L Low Inductance lt n gt MHa Motor Current lt n gt Min MR MT Motor Resolution Default 36 000 steps rev fixed resolution in SmartStep Motor Type MT10 fixed motor type in SmartStep n MRi lt n gt MT10 MV OD Maximum Velocity Example MV50 0 axis one 50 in units selected by VU command Output Definition Example OD PPPPPPPP 8 outputs defined as Programmable outputs All 8 output states must be specified See als
51. program distance velocity and acceleration units convenient for your application This menu also allows you to set a maximum allowable speed and acceleration for each axis i Axis Setup SmartStep 8 10 Chapter 8 Programming With Serial Communication Jog Menu The parameters which control your jog operation are configured using the Jog menu shown below Axis Setup SmartStep Limits Menu Your SmartStep has a built in homing function which combines the flexibility of a customized homing routine with the ease of use of calling a canned program Also see the GH command in the IDeal Command Reference chapter for more details on homing 4 Axis Setup SmartStep Chapter 8 Programming With Serial Communication Setup Click on the I O Setup button To define a dedicated function for each discrete 4 input and output scroll through the pulldown lists and select from the available choices i 120 Configuration Bol 1 0 Configuration 8 12 Chapter 8 Programming With Serial Communication Miscellaneous Misc Setup Click on the Misc Miscellaneous button Misc Setup contains two configuration categories that include options available in the PROGRAM SETUP and RS 232C SETUP menus detailed in Chapter 5 Diagnostic Display Format Diagnostic Display Format allows you to customize the data display on the IDC FP220 Keypad This parameter does not apply if you do not have the keypad
52. programming 8 1 S saving a program 4 11 scan conditions 5 37 scan delay 5 38 schematic encoder input 9 8 schematics 9 7 serial communication Application Developer 8 3 commands not available in hosted mode 8 33 daisy chaining drives 8 20 IDeal commands 8 23 immediate status commands 8 34 programming 8 1 programming commands 8 31 RS 232C protocol 8 19 RS 485 protocol 8 21 setup commands 8 27 supervisory commands 8 40 set position command 6 26 SETUP sub menus 4 14 specifications 9 5 environmental requirements 9 5 output power available 9 5 square root command 6 26 stall output 5 29 stop decel rate 5 41 stop input also see scan conditions 5 25 stop on input command 6 27 T TEST sub menus 4 6 time delay command 6 27 toll free technical support 11 11 troubleshooting SmartStep application 10 1 troubleshooting communication problems 8 19 U unassigned input 5 25 unit number 5 39 V velocity maximum 5 20 units 5 20 Index velocity command 6 28 warranty and repairs 11 12 waveform 5 12 W wiring practices IDC recommended 5 2 wait command 6 29 warm boot input 5 26 Keypad Programming Template Use this template to write MS Message to Display command menus or programs exactly as they will appear on the keypad LCD display Each character position on the keypad display is represented by a numbered blank square below Please feel free to make copies of this page for writing your programs
53. recheck con nections Check SmartStep current setting to make sure you did not accidentally dam age a winding by using more current than the motor is rated for Check to see the motor phases are not shorted to one another or to the case of the motor The resistance in each phase should be about the same and only a few ohms If the phases are open or have large resistances the motor is probably damaged and should be replaced Eliminate the regen event by reducing the load or make the move less aggressively by re ducing the commanded accel eration or velocity Check your AC line voltage to verify it is within the SmartSteps s limits Connect motor connector with Interlock 10 3 Chapter 10 SmartStep Troubleshooting Symptom Possible Causes Possible Remedies Following Error Motor stalled Confirm proper motor configu ration current AR mH Make a less aggressive move Wrong encoder resolution set Setting the encoder resolution incorrectly will cause a follow ing error to occur Confirm the settings are correct Encoder Wired Back Encoder position is moving op Check motor and encoder wir wards posite of commanded position ing Reverse phases of either motor or encoder Consult IDC if unsure Encoder Fault Attempted motion in a closed Check encoder wiring and if loop mode and encoder posi the encoder is connected and tion remained unchanged powered properly Error Finding Home Both EOT
54. skipped Loop Until LU defines loops where the condition is checked at the end of the loop block The standard software allows up to 16 nested loops one inside the other A GT command within an LW loop will terminate the loop clear the loop stack and jump to the new program Following are examples of programs using LW Example 1 A 0 LW A lt 10 DI10 GO A A 1 EB In this example the loop is executed times with a final position 110 distance units Example 2 A 10 LW A gt 20 DI10 GO EB In this example the loop is immediately skipped since the A gt 20 condition is false Example 3 LWXX1X1 MS1 Inputs 3 amp 5 are on EB GT Inputs Off In this example the loop will continue to execute as long as inputs 3 and 5 are on Example 4 LW4 1 MS1 Input 4 is on EB GT Input Off In this example the loop will continue to execute as long as input 4 is on 6 19 Chapter 6 Programming Commands MC 6 20 Move syntax v1 00 Units n a Range n a Default n a MC sets move profiles to continuous move utilizing AC and VE parameters Move Continuous is enabled on an axis with the sign MC enables the mode for axis one MC enables the command on axis two MC enables both axes DI DA and DC commands reset the mode to distance Each Move Continuous segment must contain a GO command Accelerations and velocities may be changed
55. switches were acti Check if home switch is con vated without finding a home nected and that the home Switch Switch is properly configured as NORM OPEN or NORM CLOSED Invalid Program Attempted to access an empty Verify program number or de program i e GT GS fine program called Program Too Large Program exceeds 1024 bytes Split program into smaller pro in length grams or reduce program size Insufficient Memory stored user programs ex Reduce program size or de ceed 60K lete programs Invalid Program Program number value ex Verify program name and num ceeds 400 or program name ber does not exist Unknown Command A command not in the IDeal Check program for data entry programming set has been is errors sued Command Is Too Long Command and parameter Reduce command string size string exceeds 80 characters Too Many Parameters Parameter list exceeds Reduce parameter list size amount supported by com mand Invalid Parameter Parameter type is invalid with Verify parameter with com command mand syntax 10 4 Chapter 10 SmartStep Troubleshooting Symptom Possible Causes Possible Remedies Bad Command Syntax Command and parameter list Check program for data entry has invalid syntax errors Too Many Nested LPs Program exceeds 16 nested Reduce nested loops loops Too Many Nested GSs Program exceeds 16 nested Reduce nested gosubs gosubs Too Many Nested EBs Program
56. the encoder shield to COM on the control Do not connect the logic common COM of the IDC control to earth ground on your machine or to the GND terminal on the control drive Separating earth ground from logic common minimizes the potential for ground loops Use shielded cables inside your panel if control is panel or cabinet mounted for I O and encoder wiring Use differential line driven encoders with shielded twisted pair encoder cables Single ended TTL encoders are susceptible to noise and should be avoided For optimum noise immunity use IDC motors and encoders with IDC controls Insert an ungrounded adapter to Preventing Ground Loop break the ground loop J Do Not Connect lt Pig tail Wire ie Additional Wiring Practices When Connecting an IDC Control to a PLC e Connect the PLC logic common and the IDC COM terminals together e Disconnect the jumper between Pull Up or P Up and 12 VDC on the IDC control Connect the positive terminal of the PLC power supply to Pull Up or P Up and con nect the Power Supply common to the COM terminal on the IDC control or to the PLC logic common these should both be at the same potential e IDC inputs are Sourcing so PLC ouputs connected to IDC inputs should be Sinking DC outputs are Sinking so PLC inputs connected to IDC ouputs should be Sourcing Chapter 5 Configuring Your System Connecting Your Hardware
57. to New leaves OPRATR password unchanged Example 3 PW Clears both the OPRATR and ADMIN passwords lt n gt PWaaaa aaaa RE Rest n 1 Enables Rest Mode n 0 Disables Rest Mode lt n gt REi SN Scan Conditions Conditions stopping program select line scanning are represented by 1 Ee se Tu Tu Tr Tr e E pue 0 Continue program select scanning Stop program select scanning on this condition Example SN 0111111 all input conditions except pressing the ESC key stop program select line scanning SR Stop Deceleration Rate Example SR100 100 rps Note Stop Deceleration Rate units are always in rps and are not user selected lt n gt SRr r UN Unit Number Example UNS sets unit address to 5 lt n gt UNi VU Velocity Units units sec where units is a string defined by the DU command units min where units is a string defined by the DU command Example VU2 axis one set to rps n VUi WA Waveform 1 1 4 3rd harmonic 1 0 SINUSOID n WAi 8 30 Chapter 8 Programming With Serial Communication Serial Programming Commands The commands in this category may be sent to the SmartStep s buffer and executed on a first in first out FIFO basis This execution does not require you to create or download any program to the SmartStep s volatile memory See Chapter 6 Programming Commands for complete defini
58. will be queried as shown Press YES F1 or NO F3 Select LIST to View Program Memory Usage LIST provides a way to view your program memory usage Standard program storage in your IDC SmartDrive is 6K bytes maximum single program is 1 024 bytes and will store up to 199 programs The 30K memory option will store up to 400 programs Note one byte equals one character in a program and on the keypad display 1 TUNING Press EDIT gt gt LIST to display the number of programs stored in your Smart Drive Press to display the total amount of memory your programs have used Press to display the number of bytes of memory you still have available Pressing continuously will take you through the list of programs displaying the number of bytes being used by each program Necessary only on brushless servo Smart Drives Reset Position YES NO DIRECTORY MORE PROGRAMS 18 DIRECTORY MORE BYTES USED 1186 DIRECTORY 1 BYTES FREE 4958 DIRECTORY MORE 5 untitled 56 bytes Chapter 4 Using the Keypad Using HELP If you have a question while using the keypad pressing HELP will display a help message related to the currently active menu Help messages are often several lines which you can scroll through using the 1 and keys When you are finished reading a help message press ESC to return to the menu Pressing HELP in the Main Menu HELP ex
59. 0 is set to the offset value 1 Use the numeric keys to enter a new home offset value in DIST units A home offset allows you to have separate systems with identical programs in them All you have to change is the home offset value for each machine It helps reduce start up time since your home limit switch can now be almost anywhere It also reduces the time necessary to get a system back up and running should your home switch ever get damaged or moved Example Home Offset 1 0000 When the control finds the home position it sets the position counter to 1 0000 distance unit The absolute zero position counter is now referenced 1 unit behind the mechanical home position All absolute moves will be referenced from the absolute zero position Configuring Home Final Direction HFi cor gt SETUP gt gt FINAL ae renee lt POSITIVE gt Default POSITIVE Specify the final approach direction of your Go Home GH move with this option This is the direction used to search for the encoder index mark Z channel after the appropriate home switch edge is found 1 Use 1 keys to select the final approach direction 5 35 Chapter 5 Configuring Your System Configuring Homing Mode HMi EDIT Axis One Home Mode SETUP HOME MODE f Switch Only Default Switch Only The Homing Mode parameter establishes how a Go Home GH command will execute homing routines There a
60. 00 33 to 80 EC3 50 05B 5 038 5 08 25 59 284988 to 11136 112200 to 111360 EC3 70 05B 7 000 5 08 35 56 327736 to 9216 129030 to 92160 EC3 10 04A 1 000 6 35 6 35 254 to 40 1 to 4 EC3 15 04A 1 500 6 35 9 53 3810 to 400 15 to 40 EC3 20 04A 2 063 6 35 13 10 8382 to 640 33 to 64 EC3 50 04A 5 038 6 35 31 99 284988 to 8909 112200 to 89088 EC3 70 04A 7 000 6 35 44 45 327736 to 7373 129030 to 73728 EC4 5 Smart Drive Mechanical Ratio Setting Screw Overall Ratio EDIT SETUP MECH RATIO menu Series Reduction Pitch Mtr Turns Inch Ratio for Inches Ratio for mm 5 0 328 1 000 0 79375 0 79 254 io 320 T to 32 EC5 15 32B 1 500 0 79375 1 19 3810 to 3200 15 to 320 EC5 20 32B 2 000 0 79375 1 59 508 to 320 2 to 32 EC5 50 32B 5 110 0 79375 4 06 107777 to 26570 42432 to 265696 EC5 100 32B 10 007 0 79375 7 94 174346 to 21949 68640 to 219488 EC4 10 25B 1 000 1 016 1 02 254 to 250 1 to 25 4 15 25 1 500 1 016 1 52 3810 to 2500 15 to 250 EC4 20 25B 2 000 1 016 2 03 508 to 250 2 to 25 EC4 50 25B 5 110 1 016 5 19 107777 to 20757 42432 to 207575 EC4 100 25B 10 007 1 016 10 17 174346 to 17148 68640 to 171475 EC4 5 10 10B 1 000 2 54 2 54 254 to 100 1 to 10 EC4 5 15 10B 1 500 2 54 3 81 3810 to 1000 15 to 100 EC4 5 20 10B 2 000 2 54 5 08 508 to 100 2 to 10 EC4 5 50 10B 5 110 2 54 12 98 107777 to 8303 42432 to 83030 EC4 5 100 10B 10 007 2 54 25 42 174346 to 6859 68640 to 68590 4 Appendix A IDC Actuator R
61. 1 9 15 Chapter 9 Hardware Reference SS PNP BO Screw Terminal Breakout Board INSIDE THE SS PNP BO BREAKOUT BOARD 9 Vs for U1 A U1 A From Output Pin of SmartStep Com from SmartSte ee mmm 9 16 The SS PNP BO Breakout Board converts NPN outputs to PNP out puts on the SmartStep The input terminals In1 In8 are connected directly to the non converted NPN inputs in the SmartStep Connect I O to terminals as shown in the illustration on the left In1 In8 input see Input Schematics on page 9 5 OT1 OT8 PNP outputs PUp pull up Com common from SmartStep An external power supply must be connected as shown in the illustra tion below right Maximum source current 100 mA per output See A2580 Schemati Connecting an External Power Supply 1 Connect to PUp Terminal 412VDC PUp Pull up or 24VDC External 12VDC or 24VDC I Sourcing Power Supply OT Output Output Connect to Terminals Com Terminal COM r U1 A Detail Chapter 9 Hardware Reference 12 Hybrid Step Motor Specifications 1 85 47 0 0 866 0 865 4 40UNC x 0 17 el 22 0 21 97 DEEP MIN ON A 24 AWG LEADS A 1 725 4 8 GROUND 0 197 0 196 12 IN 300mm LONG h 5 00 4 98 BOTH ENDS L 1 22 31 0 SQ REF 0 40 0 39
62. 40 to 6859 6864 to 17422 R4 104 1 4 4 4 to 1 40 to 254 R4 154 1 5 4 6 6 to 1 60 to 254 R4 204 2 4 8 8 to 1 80 to 254 R4 504 5 110 4 20 44177 169728 to 8303 16973 to 21090 R4 1004 10 007 4 40 02916 274560 to 6859 27456 to 17422 R4 106 1 6 6 6 to 1 60 to 254 R4 156 1 5 6 9 9 to 1 90 to 254 R4 206 2 6 12 12 to 1 120 to 254 R4 506 5 110 6 30 66265 254592 to 8303 25459 to 21090 R4 1006 10 007 6 60 04374 411840 to 6859 41184 to 17422 Appendix A IDC Actuator Ratios Steps for Entering Custom Distance Units when ratio for inches is known Instruction Example Select User Units Select a preferred unit of measure for linear distance This will be used for Penis programming distance and can be used for velocity and acceleration as well Determine Overall Mechanical Ratio Look up actuator mechanical inch ratio Units must be motor turns 625 inch motor turns inch Convert Ratio to Turns User Unit Convert turns inch ratio by multiplying or dividing by the same factor you 6 25 2 54 comin would to convert inches to your preferred user unit 24606 Convert Decimal Ratio to Ratio of Two Integers A Multiply by the power of ten required to move decimal point to the far of right Note that a maximum of six digits can be entered into the Smart oe lE Drive it might be necessary to round of the number from step 3 above This is the numerator of the integer ratio B The power o
63. 552 72239 to 115520 EC2 10 05B 1 5 08 5 08 254 to 50 1 to 5 EC2 15 05B 1 471 5 08 7 47 6350 to 850 25 to 85 EC2 20 05B 2 5 08 10 16 508 to 50 2 to 5 EC2 50 05B 5 022 5 08 25 51 242341 to 9500 9541 to 9500 EC2 100 05B 10 005 5 08 50 83 183487 to 3610 72239 to 36100 EC2 10 04A 1 6 35 6 35 254 to 40 1t04 EC2 15 04A 1 471 6 35 9 34 6350 to 680 25 to 68 EC2 20 04A 2 6 35 12 70 508 to 40 2104 EC2 50 04A 5 022 6 35 31 89 242341 to 7600 9541 to 7600 EC2 100 04A 10 005 6 35 63 53 183487 to 2888 72239 to 28880 A 3 Appendix A IDC Actuator Ratios EC3 Smart Drive Mechanical Ratio Setting f Motor Screw Overall Ratio EDIT SETUP MECH RATIO menu Se ries Reduction Pitch Mtr Turns Inch Ratio for Inches Ratio for mm EC3 10 16B 1 000 1 5875 1 59 254 to 160 1 to 16 EC3 15 16B 1 500 1 5875 2 38 3810 to 1600 15 to 160 EC3 20 16B 2 063 1 5875 3 27 8382 to 2560 33 to 256 EC3 50 16B 5 038 1 5875 8 00 284988 to 35635 112200 to 356352 EC3 70 16B 7 000 1 5875 11 11 327736 to 29491 129030 to 294912 EC3 10 10B 1 000 2 54 2 54 254 to 100 1 to 10 EC3 15 10B 1 500 2 54 3 81 3810 to 1000 15 to 100 EC3 20 10B 2 063 2 54 5 24 8382 to 1600 33 to 160 EC3 50 10B 5 038 2 54 12 80 284988 to 22272 112200 to 222720 EC3 70 10B 7 000 2 54 17 78 327736 to 18432 129030 to 184320 EC3 10 05B 1 000 5 08 5 08 254 to 50 1 to 5 EC3 15 05B 1 500 5 08 7 62 3810 to 500 15 to 50 EC3 20 05B 2 063 5 08 10 48 8382 to 8
64. 8 49 9 23 ETTET TOTE RED ORANGA Note Specs are for both series and parallel wiring unless preceded by T series or V parallel Electrical Specs P41 P42 P43 K41 K42 K43 Continuous Stall Torque oz in N m 1250 8 8 2300 16 2 3250 22 9 TBD 3000 21 2 TBD Recommended Current Phase Amps T 2 8 T 3 3 T 3 3 T 2 8 T23 2 T23 3 5 7 6 6 6 6 5 7 V 6 4 V 6 6 Inductance mH T 60 T 84 T2112 T 60 T 60 T2112 15 21 V 28 15 V 15 V 28 Max Winding Temperature F C 212 100 212 100 212 100 212 212 100 212 Mechanical Specs P41 P42 P43 K41 K42 K43 Rotor Inertia oz in sec 0783 1546 2293 0783 1546 2293 Axial Shaft Load Ibs N 404 1790 404 1790 404 1790 404 404 1790 404 Radial Shaft Load 0 5 inches Ibs N 125 550 110 489 110 489 125 110 489 110 Motor Weight Ibs kg 11 18 4 25 7 11 18 7 25 7 Step Angle full step degrees 1 8 1 8 1 8 1 8 1 8 1 8 EN Encoder Color Code amp Pin out Wire Color on Quick Drive for P amp K Motors 14 Disconnect Cables Connection Signal Pin Color Red w Black B Ar B Red IDC Quick Pink or a Disconnect Red w White B Purple E Cable Green GND B N Green B P Blue PIN QF4 12 Red w Yellow A 71 Yellow Red Z U Orange Gray colored Quick Disconnect Cables TOV K Wnite
65. 89 65 285 65 285 110 489 Motor Weight Ibs kg 5 84 11 9 5 84 11 9 Step Angle full step degrees 1 8 1 8 1 8 1 8 1 8 1 8 ZR Encoder Color Code amp Pin out Wire Color on Quick Drive tor Motors Disconnect Cables Connection Signal Rin golon A B Red Red w Black B A Pink or Purple E 9 IDC Quick Red wi White Br B N Green Disconnect Green GND B P Blue Cable Red Yellow A 7 Yellow Z U Orange P N QF3 12 Red A 5V K White Gray colored Quick Disconnect Cables COM T Black 5 are shielded connect shield to GND Shid Brown NC 9 22 Chapter 9 P K 41 42 43 Step Motor Specifications 0 328 THRU EQUALLY SPACED ON A 4 950 B C 4x In 43255Q 1 385 1 365 a 0 665 0 585 0 1875 0 1855 i 0 7500 0 7495 4 H gu Z ea Hardware Reference 0 3148 0 3143 4 40 UNC 2B x 0 27 Dp MIN 2x EQ SPACED ON A 1 812 B C 2 23MAX bi LN 22AWG GROUND WIRE IS GREEN 12 LONG MIN MOTOR LEADS PARALLEL CONNECTION 0 813 0 830 L 0 48 1 2 NPS THROUGH 079 j bam gt a 2 184 2 188 Aces EMAX Motor Dimensions IDC Motor Wiring MOTOR X LMAX SERIES CONNECTION P41 K41 4 46 5 20 P42 K42 6 48 7 22 WHT YEL WHT BLK P43 K43
66. AKING RACK CONNECTIONS eri norais E ce veo ER 9 11 OPTOAT CONNECTIONS 9 11 OPTO8S CONNECTIONS ceteri cesset a e a 9 12 USING OPTO44 AND OPTOSS WIRING 9 13 OTPO MODULE AVAILABLITY cedes certes ce tct sete tee eere ene ctv te 9 14 WIRE COLOR CODES FOR SS IO AND SS IO 6 CABLES cccccccccsscccsccecccececececsesecesesesesescsnncneesceeseeeeseeeeeess 9 14 DB25BO SCREW TERMINAL BREAKOUT BOARD eee I e enne een enne ene re nene nnn nenas sese senis 9 15 SS PNP BO SCREW TERMINAL BREAKOUT BOARD cccccccccccceececesesesesseesccscsnsncecaeceecseeeuceeeeeeeeseseseeneenens 9 16 IDCSMOTORBS 9 17 NONSIDCIMOTORS tone Queda 9 24 CHAPTER 10 SMARTSTEP TROUBLESHOOT ING eee eeeee e eee enero nose e anos esset enses 10 1 Table of Contents PRODUCT SUPPORT vt cot voe essas eee tatus svr e ee ebur eres e aeu abeo eee auk eara eed Ves 11 1 FACTORY AUTHORIZED DISTRIBUTORS eee reo oerte e ME NE E Suo Nee nene EE Eb ce pup d 11 1 REGIONAL OFFICES ea ete bleu etie tete te e 11 1 TOLL FREE TECHNICAL SUPPORT eet te eee vo tea e eau Cin voee rue
67. AR settings until the motor begins to hiss then increasing your AR setting slightly 5 Press ESC to return to the STEPPER SETUP menu Chapter 5 Configuring Your System 5 12 Configuring Motor Inductance MHa gt SETUP gt MOTOR gt TYPE gt STEPER gt INDUCT Default HIGH The SmartStep works best with motors higher than 4 mH The Motor Inductance parameter configures the drive for a high or low inductance motor Motors above 10mH are considered HIGH for SmartStep and SmartStep 23 Motors above 40mH are considered HIGH for SmartStep 240 Axis One Inductance 2 Using Motor Reference 1 select HIGH or LOW Inductance using 1 keys f STEPPER SETUP WAVEFORM REST IDLE 3 Press ESC to return to the STEPPER SETUP menu Configuring the Waveform WAi EDIT gt SETUP gt MOTOR gt TYPE gt STEPER gt WAVEFRM Default SINUSOID The Waveform parameter configures the SmartStep for either a pure sinusoid waveform or a 4 3rd harmonic waveform Depending on motor design and the current level at which it is being driven it may be advantageous to distort the sinusoidal waveform to achieve better low speed smoothness and step to step accuracy With skewed rotors or 50 48 tooth geometry pure sine will usually produce the best results 1 Press WAVEFRM F 1 Waveform is configured only once per motor model for better low speed smoothness lt f SINUSOID
68. Configuring Passwords PWaaaa aaaa PASSWORD SETUP OPRATR ADMIN CLEAR ERI gt SETUP gt MISC gt PASWRD Default None In addition to the keypad DIP switches user definable passwords also enable you to restrict access to the RUN EDIT COPY and DEL menus Enter your desired password using the same keypad entry techniques described in Chapter 1 Use lt gt and DEL keys to edit the password 2 Press ENTER to register the password SmartStep allows up to two types of passwords OPRATR Operator and ADMIN Passwords and Menu Accessibility This Password Will Give You Access to These Menus OPRATR only RUN EDIT COPY DEL ADMIN only RUN EDIT COPY DEL OPRATR ADMIN ADMIN RUN EDIT COPY DEL OPRATR RUN only All RUN functions except TEST General Password Rules e Passwords can be a maximum of 4 characters consisting of 0 9 upper and lower case letters A Z or a combination of numbers and letters e If no password is entered there is no restriction e Entering the wrong password or pressing ESC at the password prompt will return the keypad to the standard run time display Select EDIT SETUP MISC PASWRD CLEAR to delete all passwords NOTE Subsequent attempts to RUN or EDIT a program do not require the password to be entered each time You will be prompted to Use Last F1 or Reset F3 Select Use Last to run or edit another program Select Reset t
69. Default YYYYYYY The SCAN menu allows you to select which events will cause the control to stop scanning program select configured inputs Itis used to enable or disable stop scan events If a given stop scan event is enabled the system will stop scanning the inputs for program numbers when that condition occurs The SmartStep must be reset via a Warm Boot input or by cycling power to start program scanning after an active Stop Scan event This option has no effect if the inputs have not been configured as program select inputs either BCD or Binary Each event is represented by one of seven Y N positions on the bottom display line 1 Use lt and keys to select a stop scan condition The selected event will be listed to the right of these 7 characters ESCape STOP LIMIT LIMIT KILL FAULT or INTerrupt 2 Use keys to enable Y or disable the selected event 5 37 Chapter 5 Configuring Your System Configuring Scan Delay DYi 8can Debounce EDIT gt SETUP gt PROG gt DELAY DELAY ms Default 100 ms The DELAY time sets the amount of time the control requires the program select inputs BCD or Binary to remain stable before the control will recognize and run a program The minimum time is 2 ms If program select inputs are not stable for a time equal to or greater than the specified delay the program will not be executed 1 Use the numeric keys to enter a value in ms Note S
70. EB VE7 DI 3 GO EN The motor will perform an incremental 1 unit move at speed 30 three times and then a 3 unit move at speed 7 in the other direction Chapter 6 Programming Commands 6 18 LU Loop Until Condition True syntax LU See Below v1 00 Units n a Range n a Default n a The Loop Until LU command defines a loop block in which loop iterations are based on a conditional result The syntax for LU which is identical to the IF command is as follows Syntax LUi xx LUxx LU Mathematical expression or expressions 2 where 1 starting input number 1 8 SmartStep 1 16 SmartDrive X 0 Input Off x Input On x anything else ignore input changes Mathematical expression Any valid conditional or logical expression Note An End of Block EB command must be used with every LU command The LU loop will continue to iterate until the specified conditional result is true LU checks the conditional at the end of the loop block therefore the block is always executed at least once even if the condition is true on the first iteration Loop While LW defines loops where the conditional is checked at the beginning of the loop The standard software allows up to 16 nested loops one inside the other A GT command within a LU loop will terminate the loop clear the loop stack and jump to the new program Following are examples of programs using LU Example 1 A 0 LU A 10 DI10
71. EO Stop MC move on key release GO GTI Return to main program EB EB End loop block Non Volatile Variables The non volatile variables 1 50 are fifty user accessible variables that retain their values through power cycles warm boots and system resets Standard user variable are reset at power down or reset Every time one of these variables is changed i e used on the left side of a equal 2 sign the new value is written to and stored in the user non volatile FLASH CAUTION Caution must be used when using these variables Since FLASH have a limited read write lifetime 100 000 writes before failure variable values that change frequently should not be stored as FLASH system variables Examples include loop count variables and POS1 and POS 2 variables The SmartStep will allow only 1 000 FLASH writes between power cycles This limit has been set to prevent a simple programming mistake or misunderstanding from permanently damaging the SmartStep s non volatile memory When this write limit has been exceeded all programs will stop running an error message will be displayed and the appropriate status bits will be set The FLASH system variables were originally developed for use in batch manufacturing applications where a number of variable setup parameters must be entered at the start of each part run These same setup parameters can then be used through any number of power cycles or machine resets Example A progr
72. ETUP gt I O gt OUTSTS gt ST K EGC AE Default CHANGE Range n a This option sets the desired states of the outputs on a Stop or Kill 1 Use lt keys to scroll through outputs 1 8 and any positions configured as outputs 2 Use the f and keys to set the output state as OFF ON or NO CHANGE and press ESC to save Configuring Your End of Travel Switch Polarity Configuring E O T Switch Polarity ET ed ETUP EDIT gt SETUP gt I O gt LIMITS Default CLOSED Range n a This option allows configuration of the EOT switch polarity as NORM OPEN or NORM CLOSED to accommodate the use of either type of switch Use the 1 keys to select NORM or NORM Axis one EOT Pol CLOSED and press ESC to save your choice lt NORM CLOSED gt 5 31 Chapter 5 Configuring Your System Configuring Your Jog Parameters 5 32 Your SmartStep s keypad gives the programmer and the machine operator if desired a convenient way to jog the motor The parameters which control your jog operation are configured using the JOG SETUP menu JOGSETUP ACCEL LO VEL HI VEL JOGSETUP ENABLE Note The Units used by the Jog parameters are configured from the SETUP MECH menu Configuring Jog Acceleration JAr DN gt SETUP gt JOG gt ACCEL Default 0 3 Accel Units Axis One Jog Accel 0 3 s
73. GO A A 1 EB In this example the loop is executed 0 times with a final position 110 distance units Example 2 A 10 LU A lt 20 DI10 GO EB In this example the loop is executed once since the A lt 20 condition is true on the first iteration Example 3 LUXX1X1 MS1 Inputs 3 amp 5 are off EB GT Inputs On In this example the loop will continue to execute as long as inputs 3 and 5 are off Example 4 LU4 1 MS1 Input 4 is off EB GT Input On In this example the loop will continue to execute as long as input 4 is off LW Chapter 6 Programming Commands Loop While Condition True syntax LW See Below v1 00 Units n a Range n a Default n a The Loop While LW command defines a loop block in which loop iterations are based on a conditional result The syntax for LW which is identical to the IF command is as follows Syntax LWixx LWxx LW Mathematical expression or expressions 2 where 1 starting input number 1 8 SmartStep 1 16 SmartDrive X 0 Input Off x 1 Input On x anything else ignore input changes Mathematical expression Any valid conditional or logical expression Note An End of Block EB command must be used with every LW command LW will continue to iterate while the specified condition is true LW checks the condition at the beginning of the loop block therefore if the condition is false on the first iteration the block is immediately
74. IDC Smartstep Microstepping SmartDrive User s Manual any P N PCW 5008 Ver 2 07 03 I Revision History Version 1 0 May 2003 IDC strives to maintain effective communication with all users and potential users of our products If you have any questions or concerns regarding this technical manual or the product it covers please contact Danaher Motion 7C Raymond Avenue Salem NH 03079 TEL 800 277 1066 FAX 603 893 8280 OUTSIDE THE U S CALL 603 893 0588 WEB SITE www idcmotion com EMAIL sales idcmotion com Table of Contents Table of Contents COVE RV I DA Y e A 1 1 SHIPPING CONVFEN TS 2 esoeexeuctve esee eae Fes Fees e terea eve pets eot epo ae Pos aves ee dc asse Ye us deus Le ee dc TN ea VET EN Y 2 1 er 3 1 CHAPTER 4 USING THE KEYPAD cec eee c eoe evene eee een an Cro a ee eee isossa ne eo Sra vasa ae evt eos a an eV eor 4 1 KEYPAD HARDWARE FEATURES e etae eot e te vba eni Peek SEE EROR CHER 4 2 KEYPAD MENU STRUCTURE 6 eie ete e teta o Eee ere eee vu tad ove e te ees eset sete eo eo ve eese ee eue i 4 4 USING THE RUN MENUS av lite bte ee ete desees 4 5 USING THE EDIT lc c 4 9 USING plz 4 16 USING COPY A
75. IO accurately represents the Distance Unit DU 1 Use the numeric keys to enter a ratio expressed as two integers Ex when entering output shaft revolutions of a 5 1 gearbox enter 5 to 1 rather than 1 to 0 2 Notes You can change DIST or RATIO at any time Changing them will not change the associated DIor DA values in a program so all moves will change by the same factor that RATIO was changed If using an IDC supplied actuator the proper Gear Ratios for entering units of Inches and mm can be found in Appendix A Units Example Lead Screw System Desired distance units inches Leadscrew 4 revs inch DIST inch e RATIO 4 to 1 Units Example Rotary Index Table ys Desired distance units 1 8 of a revolution DIST index e RATIO 1 to 8 Units Example Gear Reduced Tangential Drive System Desired distance units mm Reducer 5 1 reduction e Drive pulley 6 inch circumference 0 e DIST mm 50 1524 5 revolutions of motor travel results in 152 4 mm of linear load travel This ratio must be expressed as an integer to be used in the Gear Ratio command Multiply each side by 10 to get a Gear Ratio of 50 to 1524 5 19 Chapter 5 Configuring Your System 5 20 Configuring the Units of Velocity VUi gt SETUP gt MECH gt VEL esl dime Default rps motor revolutions per second Use this option to select your velocity units All velo
76. ND P N QF3 12 Red w Yellow A Red A Gray colored Quick Disconnect Cables are shielded connect shield to GND 9 19 Chapter 9 Hardware Reference 542 Hybrid Step Motor Specifications 7 82 198 6 4 iu 28 THRU 2 a 1 2 14NPS WIRE ENTRY i EO PAD OW _ 0 1875 0 1850 fH re 1 010 0 990 1 i i e e cB E ES i Et ce Hae nnm cr 90 6250 0 6245 0 705 0 688 1 e LA 0 2494 PILOT 22 188 2 184 o ums vanam e sera 1 41 1 35 9 4 22 SQ T Series V Parallel Electrical Specs S42T S42V Continuous Stall Torque oz in N m 1000 7 1 725 5 1 Recommended Current Phase Amps 6 0 7 9 Winding Resistance Ambient Ohms 36 09 Notes Inductance mH 7 1 75 Parallel V wiring 5096 duty cycle Max Winding Temperature 212 100 max above 5 rps 300 rpm Mechanical Specs 542 S42V IDC step motors require a torque i 0 Rotor Inertia ozin s kg m 114 107 80 5 10 5 margin grat lagt aN Axial Shaft Load Ibs N 65 289 Radial Shaft Load 0 5 inches Ibs N 23 6 105 Motor Weight Ibs kg 19 1 8 66 Step Angle full step degrees 1 8 IDC Motor Wiring SERIES CONNECTION PARALLEL CONNECTION YELLOW WHT YEL WHT BLK
77. NG AN ANALOG INPUT 5 er cetero epe eret eere steer eee tese Ee nc vesti 7 10 CHAPTER 8 PROGRAMMING WITH SERIAL COMMUNICATION ccccsssssssssssscscsccccccccceseeees 8 1 SECTION 1 INSTALLING APPLICATION DEVELOPER SOFTWARE sssssseeeeessscsesccceeeceecsceeeeceeeeeseseeeseeereeeeas 8 3 SECTION 2 USING APPLICATION DEVELPER cccscscssccscccccecsccceeceseseseseeseeseuencceaceeseeeecsceeeseeeeseseseseeeeerereeas 8 4 USING THE SETUP 2 08 Eee ete vea be Ee tee De ee e E EE Cue 8 4 AFTER USING THE SETUP WIZARD MORE CONFIGURATION PARAMETERS eeenm eene 8 8 SECTION 3 RS 232C PROTOCOL rere etn eve eese oet ve sees We eue sien ve NDANE 8 19 MAKING RS 232C CONNECTIONS TO THE SMARTSTEP eeeeeeeeeeeeeeeeeeeeee eene nnn nn nnne nnne 8 19 TROUBLESHOOTING SERIAL COMMUNICATION PROBLEMS 8 19 DAISY CHAINING SMARTS veo eoe teet ete ERA eee eU EU ove 8 20 SMARTSTEP MUETEDROPPING euet o epe ette ree este ed ei o Ud ON ve eeu regt 8 21 SECTION 4 RS 232C RS 485 IDEAL COMMAND REFERENCE v sssesscssssessessessesecsessessessessesessessesseaeeseeseene 8 23 COMMAND SYNTAX ii e Lom PI uU Dee Eie 8 26 SERIAL SETUP COMMANDS ient UE I ra ER NEU NE E 8 27 SERIAL PROGRAMMING
78. OR M 3 16 CLEARANCEHOLES 4 M 3 5 CAPTIVE MOUNTING z CUT THESE HOLES FOR B S 32 CLEARANCEHOLES 3 BALL HEAD REMOVABLE MOUNTING 3 250 2 040 750 x D M ML LC ee N E a i E i a a a ci 1 B B A M H i pue RECOMMENDED CUT OUT i i SIZE1 5 i i 0084 406 531 i I i X 406 X 1 138 7 1 i ME MEN LLL P s 4 838 4 380 i 2 4 154 v RECOMMENDED CUT OUT 3 184 090 SIZE 5 gem 230 1 i ru Y B i i i Chapter 9 Hardware Reference SmartStep Specifications Input Power SmartStep 90 120 VAC single phase 50 60 Hz Requirements 500 VA max 7 9 amp setting SmartStep 240 190 240 VAC single phase 50 60 Hz 500 VA max 3 9 amp setting SmartStep 23 90 120 VAC single phase 50 60 Hz 250 VA max 3 0 amp setting Output Power 12 VDC internal power supply 250 mA maximum output current Available 5 VDC at 200 mA available for encoder Environmental Ambient 0 50 C Requirements Temperature Humidity 096 90 non condensing Drive Signals Position Range to 2 147 483 647 steps absolute and incremental Velocity Range 0002 70 rps Acceleration Range 1 to 20 000 000 steps sec Encoder Interface Optically isolated differential 5b
79. S 1 Drive Enabled EB The 16 corresponds to an integer weight of bit 5 10000 since you wish to mask out the enable bit Logical Operations on Expressions amp amp Conditional commands IF WT LU LW support logical operations of AND amp amp OR Two expressions may be logically AND d or OR d within one conditional command For example 5 B 2 5 IF A gt 2 amp amp B 2 5 MS1 True Statement EB In the above program the message True Statement would appear since BOTH conditional statements are true thus making the entire IF conditional true Incrementing and Decrementing Variables There are four syntaxes supported by variables Single Increment Value Increment Single Decrement Value Decrement These operators will initialize any uninitialized variable to zero before incrementing or decrementing it for the first time Variable Name Increments a variable value by 1 Variable Name n Increments a variable value by n Variable Name Decrements a variable value by 1 Variable Name n Decrements a variable value by n Expressions The SmartStep supports five conditional expressions less than equal to greater than gt less than or equal to lt and greater than or equal to gt The IF and WT commands can use these expressions to direct program flow or wait for an analog input to meet a condition The gt and symbols are enter
80. S Displays SS serial command response TEXT Display user defined text in a quadrant 3 Use the and key to scroll through the data types Press ESC to save all data types except TEXT see step 4 4 In order to define a text field scroll to the TEXT data type and then press the ALPHA key or a number key A cursor will appear allowing up to 10 characters to be entered Type the desired text press the ENTER key and then press ESC to register Chapter 5 Configuring Your System Configuring Stop Decel Rate SRi C gt SETUP gt MISC gt STOP RATE el Default 100 rps units fixed at motor rps This option is used to set the deceleration rate whenever a configurable stop input is activated or when the ESC key is pressed while moving This is usually set to the fastest controllable deceleration rate possible with mechanics in your application or whenever a limit switch is hit 1 Use the numeric keys to enter a stop deceleration Configuring Enable Line Polarity ELO Axis One EnablePol EDIT SETUP MISC ENABLE ACTIVE LOW Default ACTIVE LOW Fixed Low on SmartStep This parameter is fixed in the SmartStep Configuring Fault Line Polarity FL 1 gt SETUP gt MISC gt FAULT j Default ACTIVE HIGH Fixed High on SmartStep This parameter is fixed in the SmartStep 5 41 Chapter 5 Configuring Your System 5 42
81. SmartStep Output Characters and Keypad Display Character Keypad Display A Amp Fault B Brake 1 C Over Current not yet implemented D Direction 1 F Fault H At Home 1 K At CI Limit 1 L Limit Error M Move Done 1 P Programmable S Stall T Torque Mode B8961 2 only 5 27 Chapter 5 Configuring Your System 5 28 Output Character Descriptions A Amplifier Fault Output goes low on any amplifier fault An amplifier fault may be due to temperature motor short circuits excessive following error over voltage and excessive regeneration conditions Note This is not an all inclusive fault output Use F Fault for this B Brake B specifies axis 1 EE EE PP ES EE Y CAUTION 4 IDC offers brakes for the actuator screw or as an integral part of some A motors Though both types of brakes are highly effective there are specific trade offs that the user should be aware of regarding each type of brake 4 Please discuss the issue of brakes with IDC Applications Engineer or with s your distributor Note Brake Output connection examples be found on 4 page 9 13 of the Hardware Reference chapter A CELLE KEEKEEKE ad It is often advisable that applications using a ballscrew type actuator with a vertical load use a brake to prevent the load from falling in the event of a fault The Brake output is normally disengaged which is actually an ON condition Wh
82. VDC 2 MHz maximum post quadrature Outputs 8 programmable outputs Open collector sink current 100 mA maximum Inputs 8 programmable inputs 2 Limits Home 24 VDC maximum optically isolated 3 mA current sinking is required at voltage no greater than 0 7 volts Programming IDeal programming language Program from the keypad operator panel or via your PC using IDC s Application Developer software included 9 5 Chapter 9 Hardware Reference SmartStep Hardware Connections FRONT 5 Microstepping SmartDrive Keypad Connection See pages 5 3 and 9 2 TOP CN S CN 0S Power Connection See page 5 5 L2 LJ U Connection pialeleelelelr See pages 9 6and C JC JC UJ COGO 9 9 thru 9 15 DISCRETE 1 8 Inputs 1 8 9 13 Common 14 21 Outputs 1 8 22 23 Common 24 25 OPTO 44 88 50 60 Hz CAUTION High Voltage BOTTOM Limits Connection See pages 9 6 and 9 7 Motor Connection See page 5 2 Encoder Connection See page 5 2 SmartStep Schematics Discrete Inputs 5V isolated 5V local Input isolated COM local COM isolated Chapter 9 Hardware Reference Home amp End of Travel Inputs 1 1 1 1 5V local 5V isolated EOT Home isolated COM COM isolate
83. ad command These run time RS 232C commands are listed in the RS 232C Command Reference but the full definition and examples are listed in Chapter 6 Programming Commands The third category of Serial commands is Serial Immediate Status Commands These commands bypass the normal command buffer and are executed immediately regardless of what else the SmartStep has been asked to do These commands include instantaneous position reporting drive status and emergency kill and stop commands The final category is Serial Supervisory Commands These are the actual uploading and downloading of the setup and program parameters Once an application with setup parameters and command has been created these commands are used to download and upload the file to and from the SmartStep 8 23 Chapter 8 Programming With Serial Communication Sample idc File To familiarize yourself with Deal RS 232C programming commands review the following example of a typical file created in Application Developer for download to a SmartStep You will need to generate a similar file to configure your SmartStep Individual programs can be downloaded in such a configuration file or downloaded separately at run time the SmartStep can also execute run time commands in an immediate mode outside of any program See the Command Syntax section of this chapter for more details 8 24 IIIIIIII UUUUUUUU gt PPPPPPPP SN 1111111 Y l100 Input O
84. am called Set up is run at the start of each part run to initialize a number of variable part parameters During production the program called PARTS is run This program reads from the FLASH variables but does not generate any writes to the FLASH so the lifetime of the FLASH is not compromised Set up MS1 Feed length Writes string beginning at character 1 top line IVI2 LENGTH 1 15 Loads the part length into volatile user variable LENGTH MS1 Feed Speed Writes string beginning at character 1 top line IV12 SPEED 05 5 Loads the speed into volatile user variable SPEED F1 LENGTH Loads the length into non volatile system variable F1 F2 SPEED Loads the speed into non volatile system variable F2 EN 7 5 Chapter 7 Programming Your Application PARTS PARTS runs on power up unless new parameters are entered LENGTH F 1 Load the part specific variable from the non volatile variables SPEED 4F2 LP NUMBER Loop NUMBER of times DI LENGTH Move LENGTH VE SPEED at SPEED velocity GO OTI TD 1 Toggle output to indicate part done EB End the loop Block Arithmetic Operands and Equations The SmartStep supports addition subtraction multiplication and division Expressions may only contain one operand Complex equations require multiple statements Variables and fixed point numbers may be mixed in arithmetic equations AII user arithmetic and variable storage us
85. amp __ _ 0 08 10 0 9 9 2 0 1 59 40 4 SQ T 2Series X V Parallel Electrical Specs S12T S12V Continuous Stall Torque oz in N m 35 0 25 Recommended Current Phase Amps 1 0 2 0 Winding Resistance Ambient Ohms 5 52 1 38 Notes T mH 88 22 Parallel V wiring 50 m I duty cycle max above 5 Max Winding Temperature 212 100 rps 300 rpm Mechanical Specs 12T S12V C gt F IDC step motors require a Rotor Inertia OZ In S kg m 5 1 10 torque safety margin of at Axial Shaft Load Ibs N 10 45 least 3096 Radial Shaft Load 0 5 inches Ibs N 5 22 Motor Weight Ibs kg 0 66 0 3 Step Angle full step degrees IDC Motor Wiring SERIES CONNECTION PARALLEL CONNECTION YELLOW WHT YEL WHT RED RED Chapter 9 Hardware Reference 21 522 523 Hybrid Step Motor Specifications 521 2 02 22 3 02 523 402 0 84 0 78 id N 0 19 0 195 0 215 THRU 4 8 24 AWG LEADS ONA 2 625B C jo 12FEETLONG 0 70 FULL FLAT 0 2500 0 2495 0 2500 0 2495 0 219 m B 002 aly 4 UD ee ee 1 502 1 498 zz SEED Mass s s 1j 4 40UNC 2B THRU 0 79 0 71 0 06 e 1 856 SQ rer um ON 1 812 B C 2 2 27 SQ MAX p
86. anslates directly to the SmartStep inductance setting To determine the 6 lead unipolar motor inductance setting we normally use 4X the manufacturer s rating For 8 lead bi filar wound motors in series set the inductance to 4X the manufacturer s rating In parallel use the manufacturer s rating Again please check with the motor manufacturer to be sure Bi filar wound 8 lead non IDC motors can be wired in series or parallel as shown in the drawing though the color code will probably be different When using a 6 lead unipolar motor the center taps are left unconnected from the drive and insulated from each other and ground Motor Wiring SERIES CONNECTION PARALLEL CONNECTION pu Chapter 9 Hardware Reference Calculating ARunloadea for Non IDC Motors An Unloaded Anti Resonance value is required for Configuring Anti Resonance in Chapter 5 Configuring Your System The following formula is required to calculate Unloaded Anti Resonance ARynjoaded ARu nloaded 12 987 LOG 9 3 Vb SQRT Tm Jr Vb Break Velocity of Knee of Speed Torque Curve in RPS Tm Low Speed Torque of Motor in Nm Jr Unloaded Rotor Inertia in Kg m 2 ARu nloaded 15 also required to calculate your exact Anti Resonance value AR AR AR System unloaded K see Configuring Anti Resonance in Chapter 5 Configuring Your Note ARynioaded Will be different for series and parallel motors because the speed torque curve is a component of V
87. anual has been designed to help you successfully install program and operate your SmartStep If you have any questions that are not adequately answered in this manual please call our factory application engineers at 1 800 544 8466 Use Chapter 2 Shipping Contents to help verify that you have received everything you ordered Quick Start Chapter 3 will help you quickly confirm basic system operation Chapter 4 Using the Keypad describes IDC s keypad operator interface Chapter 5 Configuring Your System covers software and hardware configuration of your application It includes step by step keypad instructions on entering setup parameters This chapter covers initial motor settings I O configuration mechanical setup and other special parameters of your system IDC s Application Developer also follows the same menu structure described in Chapter 5 In Chapter 6 Programming Commands provides an alphabetical list of SmartDrive commands including syntax ranges defaults and programming examples for each command Chapter 7 Programming Your Application provides detailed program and application examples and strategies Other topics include variable usage user menus math functions and analog I O Our Deal command language is generally regarded as the easiest motion control language in the industry It is both easy to remember and intuitive without sacrificing flexibility or power Chapter 8 Programming with Serial Communicat
88. ars the terminal input buffer and buffered command buffer D Lock Disable Keypad When activated the keypad is disabled allowing NO user access The keypad resumes normal operation subject to the DIP switch pattern when the input is released E Extend Jog E specifies axis 1 When activated the motor will Jog in the Extend direction When the input is released motion stops at the Jog Accel rate If an End of Travel limit is hit while jogging the motor will stop at the Stop Rate see Edit Setup Misc Before the motor can be moved back off the limit a Stop or Kill input must be activated to clear the fault generated by hitting an End of Limit switch Alternatively an S or K command sent over RS 232C will also clear the fault as will pressing the ESC key on the keypad The velocity is determined by the Jog Speed Input and the Jog Low and High setup parameters When the input is off the speed is low and vice versa If none of the inputs are configured for Jog Speed the motor will jog at the Jog Low setting G Registration For the Registration command to function Input 1 must be configured as a Registration input no other inputs will work See the RG command for more details I Interrupt Run 98 When activated motion on all axes is stopped at the stop rate see Edit Setup Misc Stop Rate The current program is stopped and processing continues with the first command in program 98 If no program is running when the in
89. atios R2A Smart Drive Mechanical Ratio Setting Motor Screw Overall Ratio EDIT SETUP MECH RATIO menu Series Reduction Pitch Mtr Turns Inch Ratio for Inches Ratio for mm R2A 10T 1 0 33333 0 33333 1 to 3 10 to 762 R2A 15T 1 5 0 33333 0 5 1 to 2 10 to 508 R2A 20T 2 0 33333 0 66667 2 to 3 20 to 762 R2A 31T 3 125 0 33333 1 04167 50 to 48 500 to 12192 R2A 35T 3 571 0 33333 1 19048 50 to 42 500 to 10668 R2A 120T 12 0 33333 4 4 to 1 40 to 254 R2A 102 1 2 2 2 to 1 20 to 254 R2A 152 1 5 2 3 3 to 1 30 to 254 R2A 202 2 2 4 4 to 1 40 to 254 R2A 312 3 125 2 6 25 50 to 8 500 to 2032 R2A 352 3 571 2 7 14286 50 to 7 500 to 1778 R2A 1202 12 2 24 24 to 1 240 to 254 R2A 105 1 5 5 5 to 1 50 to 254 R2A 155 1 5 5 7 5 7 5 to 1 75 to 254 R2A 205 2 5 10 10 to 1 100 to 254 R2A 315 3 125 5 15 625 250 to 16 2500 to 4064 R2A 355 3 571 5 17 8571 250 to 14 2500 to 3556 R2A 1205 12 5 60 60 to 1 600 to 254 R2A 108 1 8 8 8 to 1 80 to 254 R2A 158 1 5 8 12 12 to 1 120 to 254 R2A 208 2 8 16 16 to 1 160 to 254 R2A 318 3 125 8 25 25 to 1 250 to 254 R2A 358 3 571 8 28 5714 200 to 7 2000 to 1778 R2A 1208 12 8 96 96 to 1 960 to 254 Appendix A IDC Actuator Ratios R3 Smart Drive Mechanical Ratio Setting a Motor Screw Overall Ratio EDIT SETUP MECH RATIO menu Series Reduction Pitch Mtr Tums Inch Ratio for Inches Ratio for mm R3 10T 1 0 1666667 0 16667 1 to 6 10 to 1524 R3 15T
90. b and Tm 9 25 Chapter 10 SmartStep Troubleshooting Chapter 10 SmartStep Troubleshooting Symptom Possible Causes Possible Remedies Motor moves the wrong Wrong Gear Ratio Check distance units distance Motor stalled Check motor current induc tance anti resonance settings Check Speed Torque require ments of move lower accelera tion Motor stalls Acceleration and or velocity Reduce acceleration and or are too high velocity Motor configured incorrectly Check motor current induc tance anti resonance settings Motor moves the wrong The motor phases are mis Check per manual or swap A direction wired with A The system s direction is intu Change the control s direction itively opposite to yours parameter The controller does not The keypad has been dis Check the dip switch settings respond to keypad input abled on the back of the keypad The keypad is blank but You have an older keypad that Call IDC for a free firmware up the backlight is on requires new firmware The grade to your keypad SmartStep requires a keypad with Version 2 10 firmware or higher The DF parameter is set to See page 5 38 or 8 27 DFO 0 0 0 The keypad is blank and The keypad is not receiving a Check wiring verify that the the backlight is off good 5VDC signal 5VDC is between 4 8 and 5 2V It is difficult to read the The Contrast needs adjust Adjust the contrast with the pot display ment on the back of the keypad
91. boots the control software to its power up state The initialization process takes about 10 seconds to complete Programs and config uration settings are not erased This command is the equivalent of cycling power S Stop lt n gt S Terminates program execution and immediately decelerates each motor to a halt at a rate set by the SR command Functions the same as the pressing ESC key on the IDC keypad or activating an input defined as a Stop input 8 36 Chapter 8 Programming With Serial Communication Serial Immediate Status Commands Note but the S and commands require an address Command Command Description and Application Examples Syntax SA Tell Axis Status Returns the current axis status as a four digit hexadecimal number preceded by an asterisk Your controller program will decode the hexadecimal number to determine the axis status Example SAI returns 002A cr This means Axis 1 is not moving the last move completed successfully and the home switch is on Status Fs ss a s a a 8 3 8 T2 T8 T5 T4 8 2 pot ot or por ot or or of or of on on ot on _ NUNT Not Moving Moving 1 1 Steps being sent to the amplifier 0 No steps being sent At Velocity 2 1 Stepping at a constant rate includes zero velocity 0 Step rate is changing 3 Move Command 4 1 The correct number of steps were sent without an Complete Same as amp fault follow
92. calculated as displacement correction gain in units of steps sec Therefore the larger the displacement the faster position maintenance will attempt to correct position For example if the correction gain is set to 3 and an active displacement of 3200 steps occurs the correction velocity will be 3 3200 9600 steps sec Configuring Position Maintenance Max Velocity PVi Axis One PM MaxVel lt 1 0 rps SEI gt SETUP gt ENC gt PMMAX Default 1 0 rps Range 0 005 9 999 999 PMMAX limits the velocity of a position maintenance correction Regardless of the magnitude of displacement or correction gain the correction velocity will never exceed the maximum velocity setting 5 17 Chapter 5 Configuring Your System Configuring Your Mechanics Through the MECH SETUP menu your SmartStep 5 18 allows you to program distance velocity and acceleration units convenient for your application Once configured your keypad will use these units in all display and position reporting modes This menu also allows you to compensate for a known amount of backlash in your mechanical system and to set a maximum allowable speed for each axis Pressing MECH displays three menu choices Pressing orf reveals four additional menu choices EM gt SETUP gt MECH gt DIST Default revs Configuring the Distance Unit DUi lt MECH SETUP DIST RATIO BKLASH MECH SETUP
93. can be found in Chapter 5 Configuring Your System Applications programs and configuration files may be created saved edited and downloaded sent to your control Application Developer will also upload receive an entire setup and program memory from a control Using the Setup Wizard The Setup Wizard allows the quickest and most accurate initial selection of drive encoder mechanics and motion units This chapter contains information to help you get started using Application Developer Open an Existing File The window shown below appears immediately after starting the Application Developer program If you Open an Existing Project Application Developer will bypass the Setup Wizard and allow you to select a file in the Open File window see below After you have opened an existing file it is still possible to use the Setup Wizard at any time by simply clicking on the Wizard tool bar button iy IDC Application Developer Startup 3 IDC Application Developer EN 8 4 Chapter 8 Programming With Serial Communication New Project Using the Setup Wizard 1 Click on the New Project button to start the Setup Wizard iy IDC Application Developer Startup gt Application Developer 8 0 2 Select the product you are configuring SmartStep in this case and click on the Next button The Wizard Navigator left of photo allows you to quickly locate your current position at any time during the setup
94. can easily be manually rotated RESET is applicable only to the B8961 2 1 Press RUN gt TEST 2 Press or until SHUTDN appears above 3 Press SHUTDN 4 Press ENABLE or DISABLE RS232 lt Drive 1 Disabled ENABLE DISABLE RESET The RS232 feature allows for testing and debugging of daisy chain terminal communications through the keypad thus eliminating the need for a PC terminal connection Testing Serial Transmit 1 Press RUN gt TEST 2 Press or until RS232 appears above F2 3 Press RS232 4 Inthe Test Connection menu press TRANSMIT The SmartDrive will now transmit the string ABC123 every 5 seconds Testing Serial Receive 1 Inthe Test Connection menu press RECEIVE 2 Any character received on the terminal port will be displayed on the keypad SHUTDN RS232 ENCODER Test Connection TRANSMIT RECEIVE Idle Data Received Test String ABC123 4 7 Chapter 4 Using the Keypad 4 8 ENCODER The ENCODER sub menu allows you to perform three differ ent tests to determine 1f encoders are working properly Refer to page 5 13 1f your encoder has not yet been configured Press RUN gt TEST Press 1 or until ENCODER appears above Press ENCODER Press desired encoder test described below pco qs SHUTDN RS232 ENCODER Use the lt or arrows to select the axis of the encoder to be tested Note the encoder
95. ce lt n gt ARi AU Acceleration Units lt n gt AUi i 0 units s where units is a string defined by the DU command 1 rps 2 seconds Example AUO units s on axis one DF Display Format lt n gt DFi i i i Configures the four keypad run time display quadrants DF takes four param lt N gt DF Text i i i eters where i is an integer representing a display data type per quadrant User defined text is limited to 10 characters per field i 0 Blank i 8 CUR2 i 1 POS1 i 9 INPUTS i 2 POS2 i 10 OUTPUTS i23 POS1 UNIT 11 OPTOS i 4 POS2 UNIT i 12 SA_STATUS1 i 5 VEL1 i 13 SA_STATUS2 i 6 VEL2 i 14 SS_STATUS i 7 CUR1 User defined text in quotes Not available DU Distance Unit Label lt n gt DUi i 0 steps fixes GR 1 1 1 rev 5 cm 9 deg 13 2 inch 6mm 10 radian 14 3 mil 7 yard 11 grad 15 index 4 meter 8 foot 12 16 um DY Scan Delay lt n gt DYi Where i is the number of milliseconds Example DY500 500 ms Default is 100ms EL Enable Line Polarity lt n gt EL1 Fixed in SmartStep EM Encoder Mode lt n gt EMi 0 Open Loop 1 Open Loop with stall detect 2 Closed Loop 3 Servo Closed Loop 4 Closed Loop Position maintenance Example EM2 closed loop 8 27 Chapter 8 Programming With Serial Communication Serial Setup Commands These are the commands that the Application Developer program uses to configure the SmartStep accordin
96. ce units 5 18 drive signals 9 5 E echo enable 5 39 editing an existing program 4 11 enable disable amplifier command 6 6 encoder following error 5 16 resolution 5 16 encoder color code 5 4 encoder input schematic 9 8 encoder interface 9 5 encoder mode 5 15 end of block command 6 7 end of routine command 6 7 end of travel switch polarity 5 31 entering a new program 4 10 entering characters with ALPHA key 4 12 entering commands with number keys 4 10 environmental requirements specs 9 5 equations 7 6 expressions conditional 7 7 extend jog input 5 23 F factory authorized distributors 11 11 fault line polarity 5 41 fault output 5 28 FLASH system variables 7 5 following error 5 16 following error limit 5 16 function key command 6 8 G gear ratio 5 19 go start a move command 6 13 go home command 6 10 go immediate command 6 11 go to program command 6 14 gosub command 6 14 grounding your machine 5 2 H hardware 9 1 limit switches 9 8 OPTO rack connections 9 11 screw terminal breakout board 9 15 SmartStep Connections 9 6 SmartStep schematics 9 7 HELP keypad 4 16 home parameters 5 34 home edge 5 34 home final direction 5 35 home offset 5 35 home switch 5 34 homing mode 5 36 T O setup 5 22 IDC web site 11 11 IDeal Commands Acceleration AC 6 2 Break BR 6 2 Deceleration DE 6 6 Distance Absolute DA 6 3 6 23 Distance Incremental DI 6 6 Distance to a Change DC 6
97. celeration units 5 20 anti resonance 5 11 display format 5 40 drive resolution 5 14 echo enable 5 39 enable line polarity 5 41 encoder mode 5 15 Index encoder resolution 5 16 end of travel switch polarity 5 31 fault line polarity 5 41 gear ratio 5 19 home offset 5 35 home switch 5 34 homing mode 5 36 idle mode 5 14 inputs 5 22 jog acceleration 5 32 jog enable 5 33 jog high velocity 5 32 jog low velocity 5 32 maximum velocity 5 20 mechanical parameters 5 18 motor direction 5 14 motor inductance 5 12 motor type 5 9 offsets 5 13 OPTO modules 5 30 output definition 5 27 output states on fault 5 30 output states on power up 5 30 output states on power up 5 30 output states on Stop Kill 5 31 passwords 5 42 position maintenance gain 5 17 position maintenance in range deadband 5 17 position maintenance max velocity 5 17 power up program 5 37 rest mode 5 13 scan conditions 5 37 scan delay 5 38 serial communications 5 38 5 39 stop decel rate 5 41 unit number 5 39 velocity units 5 20 waveform 5 12 connecting hardware 9 6 AC power connection 5 7 connecting the keypad 5 5 encoder wiring 5 4 motor wiring 5 3 connection to SmartStep 8 19 COPY keypad 4 17 D daisy chaining SmartDrives 8 20 data valid input 5 26 deceleration command 6 6 decrementing variables 7 7 DELETE keypad 4 19 DI 6 6 direction output 5 28 Index display format 5 40 distance absolute command 6 3 distance to a change command 6 4 distan
98. city values specified in the system will be expressed in these units 1 Use the 1 and ENTER keys to select velocity units from the list e rps motor velocity not affected by Gear Ratio e rpm motor velocity not affected by Gear Ratio e DIST units sec see SETUP gt MECH gt DIST e DIST units min see SETUP gt MECH gt DIST Configuring Maximum Velocity MVr cot gt SETUP gt MECH gt VMAX Default 50 velocity units This parameter limits the top speed of your motor Depending on the application you may want to limit the speed of your control to prevent accidental damage to your mechanics For example in a leadscrew driven system exceeding the critical speed will damage the leadscrew 1 Use the numeric keys to set the maximum velocity in VEL units Configuring Acceleration Units AUi C gt SETUP gt MECH gt ACCEL 2i See i oe Default sec This option is used to select acceleration and deceleration units All acceleration and deceleration values specified in the system will be expressed in these units You may specify acceleration as a rate or in time to accelerate to full speed Motor shaft acceleration is not affected by Gear Ratio 1 Use the 1 and ENTER keys to select acceleration units from the list e time to reach top speed DIST units sec rps motor revolutions sec Chapter 5 Configuring Your System Configuri
99. coders are also used to position to the actual load position rather than a motor position IDC recommends an encoder resolution of 8000 pulses per revolution or less with the SmartStep to prevent the possibility of end of move dither which is caused by encoder positioning that falls between two motor step positions Red Green Blue Yellow Orange SUI Shield The color codes shown to the right apply to IDC supplied encoders only Use the signal names to connect other manufacturer s encoders Pink or Purple Connecting an Encoder to a SmartStep Color codes are for IDC encoders only Use signal names for other manu facturer s encoders Chapter 5 Configuring Your System 4 Connecting Your Keypad Your FP220 Keypad will work normally with the standard SmartStep as shown to the right Smart St ep Connect the keypad to the RS232 or KEYPAD Microstepping Smart Drive connector on the front of the SmartStep ON i a a ha le WARNING Your keypad will not RS232 work with the RS 485 version of the SmartStep KEYPAD ann 4 Do Not Plug Your Keypad into the f RS 485 SmartStep shown below ba TTTTTTTTTTTTTTTEAA anun SmartStep Microstepping Smart Drive DISCRETE I O ON 1 8 Inputs 1 8 9 13 Common 14 21 Outputs 1 8 22 23 Common 24 25 OPTO 44 88 LJ DISCRETE I O 1 8 Inputs 1 8 9 13 Common 14 21 Outpu
100. cts alphabet characters and other special characters see page 4 13 Selects the direction of motion in programs and may be used in math programs Pressing ESC ALPHA 1 enters A Stops a program or moves back ALPHA 1 1 1 1 enters a one menu level Exits and saves a ALPHA or enters program in the program editor H96 amp V 4 3 Chapter 4 Using the Keypad Keypad Menu Structure Most operations from the Keypad are menu driven A menu consists of a title bar on the top display line and as many as three options or sub menus at a time on the bottom display line Each option is displayed above one of the function keys F1 F2 or Press a function key to select the corresponding option The following table shows the Menus which are accessible from the Main Display by pressing the RUN EDIT HELP COPY and DEL keys Main Menu Keys and Associated Menus Press Once to Begin PROG F1 Run programs by name or number PROG F1 Edit or write pro grams In Main Menu Provides help on the functions of RUN EDIT and COPY Gives SmartStep keypad firmware and FPGA versions PROGRAM F1 To copy programs within a control PROGRAM Deletes an entire program or charac ters in the editor Menu Options JOG F2 Jog either axis at low or high speeds Press F1 or F2 and any arrow key SETUP F2 Configure system components and operating l
101. current drive status as a four digit hexadecimal number preceded by an asterisk Your controller program decodes the hexadecimal number to deter mine the drive status Example SD1 returns 0010 cr This means Axis 1 is enabled in position mode and is not faulted Status e 7 eee 1 Following Error 1 Following error occurred O At power up and reset Set to zero at the start of the next move Over current 2 1 Over Current requires reset to clear 0 At power up and after reset Thermal Fault 3 1 Thermal fault in the motor or drive requires reset to clear 0 At power up and after reset RMS Over current B6961 2 only Drive Enabled 5 1 Enable Drive see also EA1 0 Disable Drive see also EAO RESERVED State undefined should be masked Amplifier Fault 12 The amplifier is faulted Requires a power cycle to reset 0 At power up or reset RESERVED 7 State undefined should be masked Torque Position 8 8896172 only lt n gt SD1 8 38 Chapter 8 Programming With Serial Communication Serial Immediate Status Commands Note but the S and commands require an address Command Command Description and Application Examples Syntax SS Tell System Status lt n gt SS Returns the current system status as a four digit hexadecimal number preceded by an asterisk Your controller program decodes the hexadecimal number to determine the system status
102. d Programmable Outputs Factory installed jumper between 12V and Pull Up terminals See drawing on the right for 24V operation Programmable Outputs 1 8 InsideSmartStep Max sink current 100 mA per output Total 350 mA available from 12VDC supply Connecting a 24V Power Supply 1 Remove factory installed jumper between 12V and Pull Up SmartStep 2 Connect Limits Connector co EXTERNAL Hom 24 VDC 12V POWER SUPPLY P Up rage 24 VDC L Remove Jumper Chapter 9 Hardware Reference Connecting IDC Limit Switches to the SmartStep IDC Limit Switches Switch Type Comments Connections RPS 1 Normally Open Reed Switch less wiring Home only and lower cost LIMITS RPS 2 Normally Closed Mounts to N T R2 Shield Connector and R4 Actuators RP 1 Normally Open Hall Effect Switch has T Home only longer life and uses Red LEDs niine RP 2 Normally Closed Switch Connector Mounts to N T R2 R3 Shield and R4 Actuators PSR 1 Normally Open Reed Switch Hom ET or ET Smartsiep PSR 1Q Home Only Q indicates Quick Dis RPS connect Limit LIMITS PSR 2 Normally Closed Switch Shield Connector PSR 2Q Mounts to EC NV PSN 1 Normally Open NPN Hall Effect PSN 1Q Home Only Q indicates Quick Dis mE 12V SmartStep connect PSN 2 Norma
103. d in the math and variables section Default n a Syntax WTi xx WTxx assumes first input is input 1 W Texpression WT 1 used with GI moves This command waits for the specified condition to be true before continuing execution of a program Either digital or analog input conditions may be used To increase flexibility the WT command allows you to use configured inputs in the expression To help prevent this added flexibility from causing programming confusion you can specify any character as an input x This allows you to self document your WT statements For example assume you configured input 3 as a JOG SPEED input Programming like WTO1J10 can help remind you that you are already using input 3 Example WT4 1 GO Wait for input 4 to equal 1 before moving WT2 010 GO Wait for inputs 2 4 to equal 010 before moving WT110 GO Wait for inputs 1 3 to equal 110 before moving WT 1 Causes program execution to halt until GI move is complete Note In order to synchronize program execution with the end of a GI move there is new syntax associated with the WT command WT 1 2 will halt program execution until the respective axis has completed its move WT 1 will wait for only axis 1 WT 2 will wait only for axis 2 WT 1 2 will wait until both axes have stopped 6 29 Chapter 6 Programming Commands Summary of Operators Functions and Expressions
104. defined ST 1 TDI ST 2 Stop motion on axis 1 wait 1 sec then stop axis 2 EB ST 1 2 Stop motion on both axes Time Delay aiieieo syntax TDr v1 00 Units seconds Range r 01 to 99999 99 seconds Default Delay r seconds before executing the next command Example 50 DI4 GO OT11 TD 5 Move 4 units turn outputs 1 and 2 on delay 0 5 seconds and turn outputs 1 and 2 off See also System variable TIME in Chapter 7 Programming Your Application 6 27 Chapter 6 Programming Commands 6 28 VE Lii TI syntax VEr v1 00 Units selected from the EDIT SETUP MECH menu Range 002 50 rps Range is scaled to velocity units Default motor rev per sec rps VE sets the maximum velocity during a move profile If the acceleration rate is not high enough or the move distance is not long enough the motor may end up making a triangular velocity vs time move and the motor may never reach the specified speed Once VE is specified the value is used in all subsequent moves until re defined Example AC 1 DE 2 50 DA4 GO Move to absolute position 4 units with a top speed of 50 units sec WT Chapter 6 Programming Commands ri syntax see below v1 00 Units n a Range 1 starting input number 1 16 x 0 input high x 1 input low grounded x anything but 1 or 0 ignore the input level expression any valid expression as define
105. ditor 14 sme Bm _ st iew Configurati Communications 8 16 Communications functions may be accessed from the main menu bar Send All Receive All 3 2 amp IDC Terminal are selectable on the Toolbar Send Terminal as shown here All Receive All Send All Use Send All to download the application you have developed In addition to motion programs your application file will include the setup commands derived from the choices you made in the Setup dialog boxes Send All completely configures the SmartStep control and will overwrite any existing programs or configurations in the control The feature allows easy configuration of repeat machines Program comments will be stripped off before being sent to the SmartStep IDC recommends saving the commented version of your application before downloading Retrieve All Use Retrieve All to upload the entire contents of a SmartStep control to a new file that can then be edited downloaded to another SmartStep or saved to a PC file for documentation purposes This file contains the complete contents of the SmartStep including all the programs defined I O definition and mechanical scaling parameters Please note that this version of your application does not contain any comments as they are stripped off during download to conserve memory in the SmartStep Run Menu Chapter 8 Programming With Serial Communication Change Unit Number Cha
106. e Either the motion commanded was not correct or the EOT Switch is incorrectly positioned on your system Check the cause of the faults RS 232 SS SA and SD com mands Symptom Over Temperature Fault Over Current Fault Over Voltage Fault Interlock Fault Chapter 10 SmartStep Troubleshooting Possible Causes Possible Remedies Internal Fan or Heatsink Tun nel is clogged or restricted Ambient air in cabinet is too hot The fan is not turning The motor is mis wired or inter nally shorted The SmartStep is protected against such shorts but you will need to cor rect the problem to clear the fault Too high a bus voltage is present This is usually caused by a regeneration event that overwhelms our internal power dump circuit It can also be caused by high line voltage or voltage spikes Motor connector does not con tain an interlock wire connec tion or motor has been disconnected Remove obstruction or clean tunnel by removing unit use screwdriver to prevent the fan from turning and blow shop air through the tunnel Return unit to installation The SmartStep can produce significant heat If multiple units are installed next to each other the cabinet must be adequately ventilated to remove heat With power off confirm the in ternal fan connection If con nected the fan bearings have probably worn Contact IDC to obtain a replacement fan With power off
107. e SmartStep via program select lines for motion 3 Ina hosted mode the PC sends serial commands to the SmartStep for execution The SmartStep uses a sequential interpretive command processor This means that commands in a program are executed one at a time and that one command must be completed before the next command is processed The following example shows this type of program Program Move VE4 DI10 OT01 GO OT10 In the program Move the maximum move velocity is set to 4 the command incremental distance is set to 10 output 1 and output 2 are turned off and on simultaneously axis one then moves 10 units After axis one stops moving output 1 is turned on and output 2 is turned off These changes of outputs 1 and 2 occur at the same time The programmer can control the flow of the program with WT wait for an event or condition to occur TD wait for a pre set amount of time to elapse and IF if a certain condition is true at this instant then execute a block of commands statements External controllers such as PLC and computers can be coordinated via digital outputs and ASCII strings sent out the serial port Creating or Editing Programs with the Keypad IDC s IDeal Command language is easy to remember and powerful Command descriptions are available on line using the HELP key within the editor If you need help with basic keypad operation please refer to Chapter 1 Using the Keypad and Chapter 2 Configuring Your Sys
108. e and can be used in OT commands S Stall The output goes low if the control detects a motor stall T Torque Mode n a on SmartStep 5 29 Chapter 5 Configuring Your System Configuring Your Optional OPTO Modules Opto Definition OP co gt SETUP gt 1 0 gt OPTOS A tae The SmartStep does not have onboard I O Use OPTO44 or OPTO88 module to condition your I O The I O on these racks is not bidirectional so configuration is not necessary Configuring Your Output States 5 30 Configuring Output States on Power Up gt SETUP gt gt OUTSTS gt PWR UP Default OFF Range n a This option sets the desired states of the outputs on power up 1 Use lt keys to scroll through outputs 1 8 and positions configured as outputs 2 Use the and keys to set the output state as OFF or ON and press ESC to save Configuring Output States on Fault OEF gt SETUP gt I O gt OUTSTS gt FAULT c Default CHANGE Range n a This option sets the desired states of the outputs on a fault 1 Use lt and keys to scroll through outputs 1 8 and positions configured as outputs 2 Use the f and keys to set the output state as OFF ON or NO CHANGE and press ESC to save Chapter 5 Configuring Your System Configuring Output States on Stop Kill OES EDIT gt S
109. e color of the command you wish to enter 2 Press the number key that contains the desired command 3 Press the ENTER key to insert a space before entering the next command Note All commands that may be used by the SmartDrive are not on keypad keys See Chapter 6 Programming Commands for a listing of all available commands Step by Step Example of Entering a New Program 4 10 You must be inside the program editor as accomplished in steps 1 through 5 on the previous page To enter the program AC 3 VE2 GO 1 Press F2 2 Press the 2 key This will enter the AC command 3 Press the decimal or period key adjacent to the 9 key 4 Press the 3 key 5 Press ENTER 6 Press Fl 7 Pressthe 2 key This will enter the VE command 8 Press the 2 key 9 Press ENTER 10 Press F2 11 Press the 1 key This will enter the DI command 12 Press the 1 key 13 Press ENTER 14 Press F1 15 Press the 3 key This will enter the GO command You AC 5 vE2 GO will see the display shown here Chapter 4 Using the Keypad To Save the Program 1 Press ESC red octagon in lower left corner or keypad You will see a Save Program query as shown to the right 2 Press Fl YES or F3 NO Save Program _ YES NO To Edit an Existing Program Follow the same steps as in Create a New Program and remember that e Inside the editor pressing ENTER inserts spaces which a
110. e control to abruptly stop commanding further motion and terminates program execution No deceleration ramp is used Caution instantaneous deceleration could cause damage to mechanics The Stop input provides a more controlled halt Chapter 5 Configuring Your System M Motor Shutdown M specifies axis 1 Disables amplifier May be activated when the control is not running a program and the motor is idle Selecting shutdown M m will disconnect power to the motor which removes current torque and allows the motor to spin freely N Analog The SmartStep has analog input capabilities when used in conjunction with an OPTO 44 or 88 rack Analog input configuration is limited to inputs 1 6 only Analog input values AIx the Built In Variable are updated every 16ms P Pause Continue When this input is grounded program execution is stopped Moves are not interrupted when the Pause input goes active Command execution will Pause at the end of the move and Continue when the input goes high See the ST and RG commands in Chapter 3 for interrupting moves in progress R Retract Jog R specifies axis 1 When activated the motor will Jog in the Retract direction When the input is released motion stops at the Jog Accel rate If an End of Travel limit is hit while jogging the motor will stop at the Stop Rate see Edit Setup Misc Before the motor can be moved back off the limit a Stop or Kill input must be activated to clea
111. e for your motor Press ESC until you return to the main display Your motor should now have torque If your mechanical system allows it check for 3 1 Chapter 3 Quick Start torque by trying to turn the motor shaft by hand 11 Press RUN gt JOG F2 JOG AXIS 1 0 0000 LO HIGH 12 Jog the motor by selecting LO or HIGH Confirm that the motor turns in both directions by pressing lt gt 13 If your motor is moving when you press the arrow keys your system is set up correctly If your motor does not move see Chapter 10 SmartStep Troubleshooting 14 For complete setup instructions see Chapter 5 Configuring Your System or use the Setup Wizard in the Application Developer software Motor Reference 1 ERGIBT Inductance Unloaded COANE Inductance MOTOR MOTOR Anti Res SERIES T 9120 9240 Setting Anti Res PARALLEL V 120 Q240 Setting 12 1 0 1 0 LOW 29 12 2 0 LOW 29 21 1 2 1 2 HIGH 30 21 2 3 LOW 27 22 1 5 1 5 HIGH 28 22 3 0 LOW 24 23 qax 1 7 HIGH 25 S23 3 4 LOW 22 S32 2 8 2 8 HIGH 22 S32 5 6 LOW 18 S33 3 5 3 5 HIGH 21 S33 7 0 LOW 17 S42 6 0 4 0 LOW 16 42 7 9 LOW 12 P21 0 7 HIGH 30 P21 1 3 LOW 27 P22 1 0 HIGH 28 P22 2 0 LOW 24 P31 1 5 HIGH 27 P31 2 9 HIGH 23 P32 1 6 HIGH 24 P32 3 3 HIGH 20 P33 2 0 HIGH 22 P33 4 0 HIGH 18 P41 2 8 HIGH 21 P41 5 7 HIGH 17 P42 3 3 HIGH 18 P42 6 6 HIGH 17
112. ec gt This option sets the acceleration and deceleration used during a jog move 1 Use the numeric keys to enter a new Jog Accel Decel value in the same units you selected in the SETUP MECH ACCEL menu Configuring Jog Low Velocity JLr EDIT gt SETUP gt JOG gt LO VEL Default 0 5 Velocity Units Axis One Jog Lo Vel 4 0 5 in sec This option sets the low speed jog velocity used during a jog move 1 Use the numeric keys to enter new low jog velocity value in the same units you selected in the SETUP MECH VEL menu Configuring Jog High Velocity JHr EDIT gt SETUP gt JOG gt HI VEL Default 2 0 Velocity Units Axis One Jog Hi Vel lt 2 0 in sec This option sets the high speed jog velocity used during a jog move 1 Use the numeric keys to enter new high jog velocity value in the same units you selected in the SETUP MECH VEL menu Chapter 5 Configuring Your System Configuring Jog Enable JEi gt SETUP gt JOG gt ENABLE Default Enabled This option enables or disables the jogging features of the control When disabled an error message is displayed when the jog buttons are pressed Jogging functions are often disabled once a machine is installed to prevent an operator from accessing them Use keys to enable and disable the function 5 33 Chapter 5 Configuring Your System Conf
113. ed into the keypad editor with the ALPHA 1 41 7 Examples IF X gt 10 GS20 EB If X is greater than 10 gosub to program 20 WT AI12 lt MAX TEMP Wait for the temperature to go below the maximum before continuing command processing 7 7 Chapter 7 Programming Your Application Other Typical Programming Examples 7 8 The following example programs will give you an idea of how the IDeal command language can be used to solve simple tasks More extensive and elaborate example programs can be found in the DEMOS idc file that came with your IDC CD rom This file can be accessed from application developer To aid your program documentation comments can be placed in brackets These comments are stripped from the program as it is downloaded to help conserve memory in the control Files should be saved BEFORE downloading for documentation purposes Example DI10 2 GO Moves to load position DI15 15 GO Moves to unload position To create a Message and input a Variable GET PARTS Name the subroutine MS1 Clears the Display MS1 How many Writes string beginning at character 1 top line IV12 PIECES Waits at 12th character for the of pieces MS1 Clears the Display MS1 How long Writes string beginning at character 1 top line IV12 LENGTH Waits at 12th character for the length LP PIECES Loops the number of pieces entered DI LENGTH Moves the length entered GO EB Creating an Operator Menu see t
114. ed later Quick Start 1 10 Connect your keypad and motor to the SmartStep If you have questions about connecting your motor refer to Chapter 9 Hardware Reference Connect the power cord to the AC connection on top of the SmartStep Power is applied to the SmartStep when the power cord is plugged into the AC power source Apply power The ON LED on front of the SmartStep 0 0000 will be green The keypad LCD display briefly shows Model and Firmware Revision then changes to the main 01000000025200800000 diagnostic display as shown to the right Note The LCD display may require adjustment for better viewing If so please refer to Adjusting Contrast in Chapter 4 Using the Keypad On the keypad press EDIT gt SETUP F2 gt MOTOR F1 gt TYPE F1 gt STEPER F1 The display should read as shown to the right STEPPER SETUP CURRENT A RES INDUCT For steps 5 through 12 use Motor Reference 1 on the following page for current unloaded anti res and inductance settings Select CURRENT F1 SmartStep is shipped from the Axis One Motor Curnt factory with motor current set at zero Amps Enter the appropriate current setting for your motor Press ESC FRISOU ARES 4 Axis One Anti Res 0 Enter the Unloaded Anti Res setting for your motor Press ESC Select INDUCT F3 Axis One Inductance f e HIGH Select HIGH or LOW inductanc
115. ee Data Valid Input Configuration for an alternate approach 5 38 Chapter 5 Configuring Your System Configuring Your Serial Communications If you plan to use the serial communications port on your RS 232C SETUP SmartStep you can use your keypad to turn the auto echo on ECHO UNIT and off and set the unit s daisy chain address The baud rate of 9600 is fixed on the SmartStep Fixed RS 232C parameters e Baud rate 9600 e Data bits 8 e Stop bits 1 e Parity none Configuring Echo Enable ECi eor gt SETUP gt RS232 gt ECHO dA cris 1 ENABLED Default ENABLED This option is used to enable or disable the RS 232C ECHO If ECHO is disabled characters received by the control s serial port will not be re transmitted ECHO must be enabled in daisy chaining applications Note when a SmartStep is used to control a daisy chain as a master to several slave units the ECHO must be disabled on the master unit 1 Use the f keys to enable or disable ECHO Configuring Unit Number UNI gt SETUP gt RS232 gt UNIT ME Range 1 99 Default 1 This option is used to set the unit address Each unit in an RS 232C serial daisy chain of multiple units must have a unique Unit Address Refer to the section on daisy chain operation in the RS 232 Operation chapter more information on this type of application 1 Use the numeric keys to enter the unit addre
116. eger portion of the variable For example COUNT 25 2 LP COUNT will only loop 4 times because COUNT 4 9999 A small offset can be added to variables used in LP statements to avoid this problem COUNT COUNT 1 will guarantee that COUNT will be greater than 5 so the program will loop 5 times Example MS1 Clears the Display MS1 How many Writes string beginning at character 1 top line IV12 PIECES 1 15 Waits at 12th character for the of pieces in the range 1 15 MS1 Clears the Display MS1 How long Writes string beginning at character 1 top line IV12 LENGTH Waits at 12th character for the of pieces LP PIECES Loops the number of pieces entered DI LENGTH Defines the desired move length distance GO Moves the length commanded EB Ends the loop 6 16 LP Chapter 6 Programming Commands LOOP 2 2 syntax LPi v1 00 Units n a Range n a Default 0 LP will cause all commands between LP and EB to be repeated 1 times If LP is followed by a 0 or no number the loop will repeat continuously Note An End of Block EB command must be used with every LP command The standard software allows up to 16 nested loops one inside the other Each LP command must have a corresponding EB command to end the block loop A GT command within a loop will terminate the loop clear the loop stack and jump to a new program Example AC 09 DE 09 LP3 VE30 GO
117. en a fault occurs power to the brake is removed and the brake is engaged This is a fail safe type of brake controlled by an OPTO module and it requires a customer supplied 120VAC power supply or 24 VDC with B Motors C Over Current not yet implemented D Direction D specifies axis 1 The Direction Output indicates the direction of motion for a given axis The output remains set until motion is commanded in the reverse direction F Fault The fault output acts as an all inclusive fail safe output Under normal operation the output is grounded ON and goes high OFF when any type of fault occurs A fault can occur from any amplifier fault condition as well as for the following general faults e BMA Board Monitor Alarm time out e Error finding Home both limits were hit The exact cause of the fault can be determined a number of ways e Keypad display e Over RS 232C using the SS SD and SA status commands see Chapter 8 e Other outputs be configured to show more specific fault states H At Home H specifies axis 1 The output is on as long as an axis is at home L Limit Error The output goes low if a limit switch is hit during a normal move or if both limits are hit during a Go Home move M Move Complete M specifies axis 1 Chapter 5 Configuring Your System The output goes high when an axis move is started and goes low when a move is completed P Programmable Unassigned outputs default to Programmabl
118. ent occurs the current program and move are interrupted and program execution begins at the predefined interrupt program The interrupt program can be defined as a GT or a GS Defining the interrupt as a GS allows program execution to return to the exact point in the original program where the interrupt occurred The ON command supports End of Travel EOT as an event conditional The syntax for defining an event interrupt program number and type is ONn GTx or ONn GSx where n is the event type and x is the interrupt program number or name n L On EOT Limit The syntax for clearing a previously defined event conditional is ONn 0 where n is the event type as listed above and 0 zero is the clear event designator Once an ON event has been defined it is active in all user programs and need not be redefined The ON event should be redefined if the user wishes to change the interrupt program type number or name or clear the event condition Example Using ON to handle an EOT event POWERUP ONL GT ON EOT Goto ON EOT on an End of Travel input GT HOME Home the machine MAIN LP Loop infinitely 5 DA20 GO Define move DAO GO Define move EB ON EOT IF SA1 amp 256 Check if EOT switch was hit bit 9 in SA VEI DAO 5 GO Move off EOT switch GT HOME Home the machine EB VEI DA 0 5 GO Move off EOT switch GT HOME Home the machine HOME GH3 Home GT MAIN Jump to main loop 6 23 Chapter 6 Program
119. equipped PLC or some other type of intelligent device 8 1 Chapter 8 Programming With Serial Communication This page intentionally left blank 8 2 Chapter 8 Programming With Serial Communication Section 1 Application Developer Software of IDC s SmartSteps come with Application Developer software The programs and data files are automatically installed with a setup utility included on the CD Installing Application Developer in Windows 95 98 or NT 1 2 3 4 nM Insert the Application Developer CD in your CD ROM drive Click on Start Click on Run Type the following in the Command Line box that appears replace d with your CD drive letter if different d App_Dev Setupex exe Click OK Follow the installation instructions on the screen Restart Windows required If You Need Help Installing Application Developer There are no known installation problems with Application Developer Please call the IDC Electric Applications Department at 800 544 8466 or 704 588 5693 from outside U S if you need assistance installing this software 8 3 Chapter 8 Programming With Serial Communication Section 2 Using Application Developer Application Developer s graphical environment helps you setup and program your SmartStep from your computer It guides you through configuring your control following the same steps and menus as the keypad configuration Complete details on setup menus and choices
120. er TARGET PROGRAM 2 Press ENTER gt 5 Remember to change the name of the copied programs to avoid subroutine call conflicts Note regarding keypad and SmartDrive memory standard memory on both the keypad and SmartDrive is 6K The keypad cannot copy more than 6K of programs from a SmartDrive equipped with the 30K memory option TO PAD Allows you to copy programs from the SmartDrive tothe COPY keypad or from a PC to the keypad PROG TOPAD FROM To copy programs from the SmartDrive to the keypad 1 Press F2 TO PAD The two messages to the right will appear sequentially on the keypad display Receiving From Drive When the messages disappear the programs have been downloaded to the keypad Saving to EEPROM To copy programs from a PC to the keypad 1 Connect keypad to Computer using RS232 cable IDC P N PCS 5004 2 In Application Developer Communications menu click on Send and choose To Keypad The keypad will display the message Receiving From PC and a few more messages will quickly appear then disappear from the screen When the keypad display goes completely blank the PC to keypad download is complete Chapter 4 Using the Keypad FROM Provides a means of copying sending programs from the keypad to a SmartDrive or from the keypad to a PC To copy programs from keypad to SmartDrive Reading From EEPROM 1 Press FROM The four me
121. eration is specified The value set will be used on subsequent moves unless it is re specified by either an acceleration AC or deceleration DE command Examples AC2 VE12 DA3 GO Sets acceleration and deceleration to 2 DE 5 VE12 DA6 GO Accel stays at 2 and decel changes to 0 5 VE20 DAO GO Acceleration and deceleration remain at 2 and 0 5 AC4 DA2 GO Both acceleration and deceleration become 4 DE3 ACI DI3 GO AC1 sets both the accel and decel to 1 Distance Incremental syntax DI r v1 00 Units selected from the EDIT SETUP MECH menu Range unit scaling dependent Default n a DI specifies a move distance relative to the current position Such moves are called incremental moves as opposed to the absolute zero reference used in DA Incremental moves are typically used in applications where there is no concern for origin such as feed to length applications Incremental moves are also often used inside a loop to shorten a program Incremental and absolute moves may be mixed the control always keeps track of the absolute position Example AC 1 VE60 DI2 GO GO DI 4 GO Move 2 units in the direction Move 1 more unit in the positive direction Move 4 units in the negative direction The final absolute position is 1 0000 Enable Disable Amplifier syntax EAi v1 00 Units n a Range 0 disable 1 enable 2 standby Defau
122. es 32 bit integer and fractional representation The and symbols have a dedicated button on the keypad Pressing the button will toggle between the two The and are accessed from the Alpha 0 keystrokes Examples e X Y 10 e AO15 VOLTAGE ERROR You can not enter e X 2142 3 This statement is not legal because it has more than one operand e Length Total 03125 The SmartStep fixed point variable storage only supports 4 places to the right of the decimal place 32 bit storage of fractional decimal number Instead enter X 1 X X 2 or X 2 X X 3 or X 3 and e Length Total 3 125 Multiply by the significant figures e Length Length 01 Then move the decimal place or Length Total 32 The SmartStep fixed point variable storage supports 4 characters to the right of the decimal place 32 bit storage of fractional decimal number 7 6 Chapter 7 Programming Your Application Boolean Operators amp And Or The operators amp and will perform the respective bitwise Boolean functions on immediate or variable parameters An application example of the Boolean operators would be isolating a specific bit from an SD response Suppose you want to determine if axis 1 drive was enabled from a program This corresponds to a bit 5 10000 Binary 16 Integer in the SD response The program segment would look as follows DRIVE STAT SD1 amp 16 IF DRIVE STAT 16 M
123. etic character h Hexadecimal number i Decimal integer number r Decimal real number up to 4 places to the right of the decimal A colon is a neutral character It can be used in a command to make it more readable to the programmer For example OP OOOOQ III is easier to understand than OPOOOOIIII Note The colon is required in GR command and is not neutral Unit Ratio Lxamp le GR4 1 Some Deal commands request a response from the control Responses will always be preceded by an asterisk which notifies the other controls on a daisy chain to ignore the subsequent response characters preceding the next command delimiter For example the Input State IS command might return AF09 cr Your computer program will need to mask the asterisk before decoding the value returned You can document your programs by placing comments between brackets For example this is a comment To maximize program storage space the control strips off these comments when a program file is downloaded Chapter 8 Programming With Serial Communication These are the commands that the Application Developer program uses to configure the SmartStep according Serial Setup Commands to the choices made in the SETUP dialog boxes Command Command Description and Application Examples Syntax AM Acceleration Maximum lt n gt AMr AR Anti Resonan
124. eturn character ASCII 13 Variable values may be transmitted over a serial interface with the TERM variable see page 7 3 Example Move Complete 6609 Transmits string only out serial interface Transmits a carriage return only Chapter 6 Programming Commands 5 Tm syntax RGr v1 00 Units n a Range n a Default n a The Registration Command RG specifies a distance to be indexed from the current position as commanded by a specific input trigger For example in the following program of 10 user units on axis 1 the input trigger is received at user unit 4 to move 3 user units from the point where the input trigger was received VE2 AC 1 DA10 GO In the program above assume the input was an optical sensor which triggered on a registration mark at a position of 4 user units The figure below shows the commanded move related to the registration move V RG Input RG Trigger End of Move 4 7 10 t RG index distance Ends at Commanded Position Accompanying the programmable Registration Command is the configurable Registration Input G also G in Serial Setup Commands To configure a Registration input from the keypad choose EDIT SETUP I O INPUTS An input configured as a Registration Input will be designated by a G on the keypad input status display The RG Command will only function if the corresponding input has been configured as a Registration Input
125. exceeds 16 nested IF Reduce number of nested IF blocks blocks Bad Variable Name A variable used as a command Verify variable name or define parameter is undefined or mis variable with an initial value spelled No Free Variables Attempted to define more than Reduce number of user vari 100 user variables ables B8961 2 Command Command is available on ser Delete the command or pur Only vo SmartDrives only chase a B8961 2 10 5 Product Support amp Warranty Product Support Factory Authorized Distributors IDC has factory trained and authorized automation technology distributors located throughout North America Western Europe and the Pacific Rim Each has been selected for their technical expertise their local market knowledge and exemplary business practices They are ready to assist you in applying IDC s systems as well as other complementary equipment Contact us at 800 227 1066 or 603 893 0588 from outside the U S for the name of the distributor in your area Regional Offices IDC Distributors are supported by local direct Danaher Motion Field Sales Engineers FSE s Danaher Motion FSE s are available to assist with unusually demanding applications present on site customer seminars determine custom product needs or respond to high volume requirements Toll Free Technical Support CAD Library Web Site IDC employs a full staff of Applications Engineers whose full time responsibility i
126. f ten becomes the denominator 10 10000 Enter Ratio into Smart Drive A Press EDIT SETUP MECH RATIO to get to the Mechanical 24606 to 10000 Ratio menu The numbers from step 4 can now be entered B Press Enter after entering the ratio numerator then to move right and enter the ratio denominator Press Enter after entering the denominator then ESC to move back one menu Program Smart Drive The Smart Drive is now ready to program in your own User Units DI10 0 GO Distances will match the units gured above moves 10 0 cm A 7 Index A acceleration maximum 5 21 units 5 20 accessories input and output 9 9 amplifier fault 5 28 analog input 5 25 7 10 anti resonance 5 11 calculating anti resonance 9 25 Application Developer software axis setup 8 9 communications 8 16 file menu 8 14 I O setup 8 12 installation 8 3 misc setup 8 13 program editor 8 15 Run menu 8 17 Setup Wizard 8 4 view configuration 8 16 applications typical SmartStep 5 1 arithmetic operands and equations 7 6 arrow keys 4 12 at home output 5 28 B BCD inputs 7 9 BCD program select input 5 23 binary program select 5 23 Boolean operators 7 7 brake output 5 28 break command 6 2 breakout board 25 pin 9 15 breakout board PNP 9 16 built in variables 7 3 examples 7 4 C clear command buffer input 5 23 commands programming 6 1 configuring software acceleration maximum 5 21 ac
127. g Scanning enabled 0 A Stop Scan condition has occurred or no inputs are configured as program select lines Data Download Status 13 1 Data Transfer failed program memory overflow O Data successfully received RESERVED State undefined should be masked 8 39 Chapter 8 Programming With Serial Communication Serial Supervisory Commands The following commands control program uploading downloading deleting execution etc All of these commands are fully defined in this section Command Command Description and Application Examples Syntax AA Auto Address The AA command automatically addresses SmartStep units in a daisy chain It assigns an address to each unit on the daisy chain This allows the units to be wired in a daisy chain without setting each unit s address manually The AA command parameter n indicates the value in which the addressing sequence will begin 19 Unit 2 Unit 3 Unit 4 Unit assigned assigned assigned assigned 4 7 5 6 RX TX RX TX RX TX In the example above the Host issues an AA4 and the units are addressed 4 5 6 7 This offers the convenience of adding a new unit anywhere in the daisy chain without manually re addressing all the other units Just connect the new unit issue an AA command from the new unit with the address of the new unit as the AA parameter i e AAi lt gt or AAi DP Delete Program Erases a program from memory where
128. g to the choices made in the SETUP dialog boxes Command Command Description and Application Examples Syntax ER Encoder Resolution lt n gt ERi Where i is an even integer Example ER2000 2000 counts rev ET End of Travel Switch Polarity lt n gt ETi Selects the polarity of the EOT End of Travel switches i 0 NORM OPEN i 1 NORM CLOSED FE Following Error Limit lt n gt FEi Example FE1000 axis one 1000 counts FL Fault Line Polarity lt n gt FLO Fixed in SmartStep GR Units Ratio lt n gt GRi i Example GR4 1 4 motor revolutions per distance DU unit HE Home Edge lt n gt HEi 0 Negative Edge 1 Positive Edge Example HEO positive HF Home Final Direction lt n gt HFi 0 Negative direction 1 Positive direction Example HF1 one positive HM Homing Mode lt n gt HMi i 0 Switch Only i 1 Switch Then Z Channel i 2 Z Channel Only HO Home Offset lt gt Example HO1 0 axis 1 0 distance unit HS Home Switch lt n gt HSi 0 Normally Closed 1 Normally Open Example HS1 uses a normally open home switch this is the default setting ID Input Definition lt n gt IDaaaaaaaa Example ID UUUUUUUU The first 8 inputs are unassigned All 8 input states must be specified See also OD Note The G Registration Command is only valid for Input 1 IL Idle n lLi 1 1 Enables Idle Mode 1 0 Disables Idle Mode IR Position Maintenance Deadband n lRi Sets
129. hapter 4 Using the Keypad Entering Characters Using The ALPHA Key The ALPHA key allows you to enter almost any character into a program from the keypad You will find this desirable if you want to Name your programs or subroutines Call your subroutines by name Make variable names more descriptive Use operator messages or prompts Send messages over RS 232C Use commands not on the keypad such as EA or 6699 General Rules for Using the ALPHA key Any letter and character located above a number on a numeric key may be inserted into a program i e the A B or C above 1 on the 1 key Press a numeric key 4 5 and 6 times to access the lower case letters You must press ALPHA prior to each character you wish to enter Press the or arrow key to move the cursor to the next space Press ALPHA to move the cursor more than one space For example if you want to leave more than one space between words in a message to an operator Entering a Character those found above numbers on Keypad Example to insert the A B or C on the 1 key l Press ALPHA 2 Pressthe 1 key once to enter A press it twice to enter B or press it three times to enter the C Using 1 Arrow Keys for Additional ALPHA Characters 4 12 The 19 special characters shown to the right are available by pressing ALPHA and scrolling through 125 the list using the arrow keys ZEN 114 1 Press ALPHA Pres
130. he FK command description for details MS1 Clears keypad screen MS21 PARTI PART2 PART3 Writes a message above function keys FK1 2 3 Waits for a Function Key to be pressed FKEY FKEY 50 Add an offset to FKEY GT FKEY Goto program 51 52 or 53 50 1 2 or 3 Chapter 7 Programming Your Application Fast In Slow Feed Move Using the Distance to Change DC command AC 05 DE 09 50 DA6 DC5 5 VES GO 50 5 0 17 Turning On an Output on the fly Set acceleration Set deceleration Set first velocity Set total move distance Set point where you want to change speed Set second speed Start the move profile 55 60 AC 05 Set acceleration VEIO Set velocity DA4 Set total move distance DCI Set point to turn on OTI Output 1 DC2 Set point to turn on OT2 1 Output 2 DC3 Set point to turn on OT3 1 Output 3 GO OT1 1 2 1 OT3 1 To input a 4 Digit BCD number reading 2 Digits at a time GET 4 BCDS OTO1 4 DIGIT BCD 2TW 100 OT10 4 DIGIT BCD 4 DIGIT BCD 2TW Returns value of 4 digit BCD number Connect ground of first two BCD digits Make value of first two digits the MSB Connect ground of 2nd two BCD digits Add value of 2nd two to Ist two 100 7 9 Chapter 7 Programming Your Application 7 10 Reading an Analog Input The value of the analog system variables AI1 AI6 are scaled from 14 400 to 72 000 Hz This value is actually a scaled frequency read f
131. he unit addresses are not required to be numerically sequential but must be in ascending order Example 1 2 4 6 8 is valid addressing 6 3 10 8 2 is not valid 2 Do not duplicate unit numbers or addresses 3 RS 232C Echo should be enabled for each unit on the daisy chain Disabling RS 232C Echo will prevent the daisy chain from functioning properly 4 loose RS 232C connections or miswiring along the daisy chain will cause communication to fail Please double check wiring if communication problems arise 5 Device Addressing RS 232C commands using the specific unit number in front of the command is necessary if the user wants only one specific unit to perform an operation 6 Status commands require addressing Please call IDC if you need to daisy chain more than 99 drives The hardware diagram below shows how to connect the daisy chain PC Host SmartStep SmartStep SmartStep RS 232C Unit 1 Unit 2 Unit 3 Device RX TX COM RX TX COM RX TX COM RX TX COM Chapter 8 Programming With Serial Communication RS 485 Protocol SmartStep Multi Dropping LIL Important Modification for RS 485 Users If you are multi dropping SmartSteps add ter mination resistors 120 ohms each across RX and TX connections of the as unitas shown to the right Note On early RS485 SmartSteps Com may have been labeled as Sh
132. i is the program number This is equiva lent to pressing the delete key on the keypad and entering the program number Range 1 199 1 400 with 30K memory option Example DP99 deletes program number 99 lt n gt DPi DR Download Program to RAM Begins downloading a program from the host to the control s RAM rather than non volatile memory Also see the PR command description These programs will be lost after a reset or power cycle The program string must end in EP The commands between DR and EP do not need a device address The DR command is typically used when the control is operated exclusively via a host controller which constantly downloads and executes programs This increases the usable life of the FLASH Range 1 199 1 400 with 30K memory option Example 1DR50 AC4 DE4 VE30 LP6 DI10 5 GO EN LEP RN50 Downloads program 50 to Unit 1 s RAM then runs program 50 lt n gt DRi EC RS 232C Echo Enable Disable 0 2 echo Disabled 1 echo Enabled Example ECO echo off The RS 232C Echo must be enabled for daisy chain operation lt n gt ECi EP End Program Definition Denotes the end of a program definition All program definitions must begin with nPRi or nDRi and end with EP Example PR15 part A AC4 VE30 DI10 5 GO EP lt n gt EP 8 40 Chapter 8 Programming With Serial Communication Serial Supervisory Commands The following commands control program uploading downloading
133. icate Following Error along with an explanation e A fault output will be generated if defined as a Stall or Fault output e The fault must be cleared before motion can occur A Stop or Kill via programmable inputs or serial command the ESC key or a RESET will clear a Following Error fault e Bit 9 of SS response is set to 1 e Bit 1 of SD response is set to 1 Following Error is always set in motor steps not encoder steps Chapter 5 Configuring Your System Configuring Position Maintenance In Range Deadband INFRANGE SETUP EDIT gt SETUP gt ENC gt IN RNGE WINDOW TIME Default 25 encoder steps In Range Window specifies the position maintenance deadband or region surrounding the set point position The window is specified in post quadrature 4 x of lines encoder steps The window is the region surrounding the commanded position in which the motor shaft can reside and not be considered out of position The control will try to correct the position if the motor is outside this window 1 Select WINDOW in the IN RANGE SETUP menu 2 Enter the desired number of encoder steps must be a positive number 3 Press ENTER Configuring Position Maintenance Gain PGi Axis One PM Gain oe gt SETUP gt ENC gt PMGAIN Default 10 Range 1 32 767 PM Gain specifies a gain value used to determine correction velocity The correction velocity is
134. iguring Your HOME Parameters 5 34 Your SmartStep has a built in homing function which 1 HOME SETUP combines the flexibility of a customized homing routine with EDGE LEVEL OFFSET the ease of use of calling a canned program Also see the GH command in the IDeal Command Reference chapter for more details on homing Configuring Home Edge HEi cor gt SETUP gt HOME gt EDGE fe eee Be Default NEGATIVE This option selects which side positive or negative of the home switch active region the Smart Drive must find before searching for the index channel of the encoder 1 Use keys to select the active edge as the positive or negative side of the home switch Configuring Home Switch HSi cor gt SETUP gt HOME gt SWITCH Sere eg ees Default Norm Open This option selects the type of switch used for the home input for each axis A Normally Open switch connects to ground when activated A Normally Closed switch is pulled high when activated 2 Use 1 keys to select the switch type NORM OPEN or NORM CLOSED NOTE To save inventory part numbers you may want to use only N C switches Chapter 5 Configuring Your System Configuring Home Offset HOr sot gt SETUP gt HOME gt OFFSET E Default 0 0 Distance Units This option sets the home offset After a successful homing move the home position the default home position is 0 000
135. ill interrupt the SmartStep and generate a return They do not affect operation of the SmartStep In a typical hosted mode application all machine operations and decisions are performed by a high level device Motion commands are generated and downloaded to the SmartStep by this host device such as a computer or PLC The following commands are provided so the host can verify the status of the SmartStep before commanding motion The System Status SS command returns overall system information and indicates general faults The Axis and Drive SAi and SDi commands can then be used to provide more detailed axis specific information These commands are also an invaluable system troubleshooting aid Since they are immediate commands they will generate a response from the SmartStep even if itis in the middle of move waiting for an input condition to become true etc Checking the System Status and the I O Status will provide enough information to explain what the SmartStep is doing If a fault is indicated the Drive Status and Axis Status commands can give detailed axis specific information Summary of Immediate Status Commands Command Syntax Purpose Clear Command lt n gt CB Clears the terminal input buffer and buffered command Buffer buffer Input States n IS Real time status of discrete and OPTO inputs Kill lt n gt K Issues immediate halt to current and programmed motion Model Number lt n gt MN Returns unit model numbe
136. imits In Menus Provides help on moving about in menus TO PAD F2 To upload a control s memory to the key pad 1 1 TEST F3 POS F3 In Sub Menus FROM F3 Run programs in Reset axis position Explains setup To download keypad 4 4 trace mode amplifier to zero choices memory to a control shutdown and reset YES NO test outputs or F1 F3 moves LIST 1 F1 In the Editor Directory of stored Provides command programs memory descriptions usage and available space If a menu has more than three options arrows will appear on both sides of the display to indicate that more options are available Press the appropriate arrow key to cycle one dis play at a time through all options in that menu To exit a menu without making a selection or to back up one menu level press ESC NOTE ESC backs up one menu in SETUP and returns the user to the Main Display elsewhere Chapter 4 Using the Keypad Using the RUN Menus Pressing the RUN key displays a set of sub menus Access the sub menus by pressing F1 PROG F2 JOG or F3 TEST Following are instructions for various activities within each sub menu Select PROG To Run a Program To run an existing program by program number 1 Press F1 2 Press program number 1 199 using numeric keys 1 400 3 with 30K option Press ENTER To run an existing program by name 1 Press PROG F1 2 P
137. ing error or hitting an End of Travel Move Done Output limit O Reset to zero at the beginning of each move Home Successful 12 The last homing move was successful 0 At power up reset to zero at the start of the next jog GO or GH Home Switch Status 6 Hardware status of home switch O off 1 Limit Switch Status 7 Hardware status of limit switch O off 1 on limits require a NC switch Limit Switch Status Hardware status of limit switch O off 1 on limits require a NC switch Limit Switch Latched 12 Set when a move is terminated by a limit in the direction Cleared at the start of a move in the direction 0 At power up or reset even if on the limit Limit Switch Latched 12 Set when a move is terminated by a limit in the direction Cleared at the start of a move in the direction 0 At power up or reset even if on the limit RESERVED State undefined should be masked 5 10 11 RESERVED State undefined should be masked RESERVED State undefined should be masked RESERVED State undefined should be masked RESERVED State undefined should be masked RESERVED State undefined should be masked lt n gt SA1 8 37 Chapter 8 Programming With Serial Communication Serial Immediate Status Commands Note All but the S and commands require an address Command Command Description and Application Examples Syntax SD Tell Drive Status Returns the
138. input Note e f j m and r lower case are on the keypad but are not used with SmartStep Input Characters and Keypad Display Character Keypad Display B Bin Program C BCD Program Clear Command Buffer D Lock Keypad E Extend Jog 1 F Set Force 1 Interrupt RUN 98 Jog Speed 1 Kill Shutdown 1 Analog Input Pause Continue Retract Jog 1 Registration Stop Unassigned lt 2 lt Data Valid Warm Boot B8961 2 only 5 22 Chapter 5 Configuring Your System Input Character Descriptions B Binary Program Select Allows programs to be run remotely using a PLC switches or outputs from a computer Up to 255 programs may be selected using binary inputs The lowest numbered input becomes the least significant selection bit 1 input 1 is less significant than input 2 The act of configuring an input as a program select input also enables binary program select mode C BCD Program Select Allows programs to be run remotely using a TM99 Thumbwheel module PLC switches or outputs from a computer Up to 99 programs may be selected using BCD inputs The lowest numbered input becomes the least significant selection bit 1 input 1 is less significant than input 2 The act of configuring an input as a program select input also enables the BCD program select mode c Clear Command Buffer Cle
139. ion use the beginning of the decel ramp as the DC in the DC formula A deceleration from 2 5 to 0 requires 1 distance unit in 0 8 seconds s 2 therefore 19 13 35 65 Since the result is positive the DC13 35 VE2 5 is a valid segment Examples of DC move profiles AC 05 DE 05 VE10 DA4 DC1 OT100 DC2 OT010 DC3 OT001 GO While moving to an absolute position of 4 units turn on output 1 at 1 unit output 2 at 2 units and output 3 at 3 units AC 05 DE 09 VE30 DA6 DC3 VE15 GO Move to absolute position 6 units with a starting speed of 30 At 3 units reduce speed to 15 change on fly and complete move DE 5 VE20 DI 8 DC1 OT10 DC3 OTO1 GO Move an incremental distance of negative 8 units After 1 unit turn on output 1 and after 3 additional units of motion turn off output 1 and turn on output 2 AC 05 DE 15 VE50 DI15 DC5 VE10 DCS VE5 GO Ata starting speed of 50 begin moving an incremental distance of 15 units After 5 units ramp down to 10 speed After an additional 5 distance units ramp down to 5 speed and continue until the final position is reached 6 5 Chapter 6 Programming Commands 6 6 EA syntax DEr v1 00 Units sec rps or unit s Range unit scaling dependent Default n a Sets the deceleration ramp on all negative velocity changes The deceleration value will be the same as the acceleration value unless a decel
140. ion is for users who plan to configure and program the SmartStep in an RS 232C or RS 485 hosted mode IDC s Application Developer program follows a standard Windows dialog box structure for straightforward cofiguration and programming of the SmartStep This section also covers RS232C command syntax and definitions for users who are not using Windows Chapter 9 Hardware Reference provides SmartStep mounting information specifications detailed I O schematics and IDC motor data 1 1 Chapter 1 Overview 1 2 Chapter 10 Troubleshooting lists some common application problems along with their symptoms and solutions Included with this manual is the DC Application Developer CD IDC s Application Developer is automatically installed on your hard drive by running the setup program on the IDC Application Developer CD This disk also includes a readme file containing the latest information on software features The readme file also contains a listing of demo program files included with Application Developer Chapter 2 Shipping Contents Chapter 2 Shipping Contents Your SmartStep will arrive equipped as listed below If any parts or accessories are missing please call IDC Customer Support at 800 227 1066 If you ordered a SmartStep with Keypad you will receive 1 SmartStep SmartStep23 or SmartStep240 MD will be added if you ordered a minimum depth mounting e g SmartStep MD Keypad AC power cord for SmartStep Rem
141. ion users should refer to this chapter for detailed explanations of configuration parameters In this chapter the 2 character ASCII command appears in brackets next to the keypad command Application Developer users will find that the Windows dialog boxes follow the keypad menu structure very closely PC non Windows PC or PLC users will find details on using IDC s Application Developer in Chapter 8 Programming with Serial Communication The task of configuring your SmartStep to a specific application consists of customizing a number of software parameters to match the mechanics of the system These parameters include motor setup encoder distance acceleration and velocity scaling I O jog home and serial communication Each SETUP procedure follows the format of the example below possum 1 0 SS SS em iem qnt eim 4 Input Definition ID Keypad display z Keypad IN1 unassigned EDIT o gt SETUP gt I O gt INPUTS BBBBKREJ Default UUUUUUUU Information and steps that apply to configuring this parameter will appear here mper E 5 8 Chapter 5 Configuring Your System Using the SETUP Parameters to Configure Your System Press the EDIT key then the SETUP F2 key to reveal three parameters as shown at top right Press 1 or to access the remaining six parameters
142. ld Functionally they are identical 8 21 Chapter 8 Programming With Serial Communication This page intentionally left blank 8 22 Chapter 8 Programming With Serial Communication Section 4 RS 232C IDeal Command Reference Overview Though we strongly recommend taking advantage of the capabilities and convenience of Application Developer you can configure program and run a SmartStep from any RS 232C terminal or computer If you do not intend to use the Windows software tools we provide you will need to use the IDeal RS 232C command listings that follow Hosted or interactive motion control from a PLC or PC is also a common mode of operation You can write your control programs in your language of choice BASIC C ladder etc RS 232C SmartStep operation is divided into four categories of commands The first category is Serial Setup Commands These are the commands that IDC s Application Developer program uses to configure the SmartStep according to the choices made in the SETUP dialog boxes These Serial Setup Commands include the syntax of the command but the full command definitions and examples are found in Chapter 5 Configuring Your System The second category is Serial Programming Commands These are commands that can be executed over RS 232C or downloaded to the SmartStep s non volatile memory for later execution This category of commands is identical in syntax and functionality to the equivalent keyp
143. lines are the serial signals supported No hardware handshaking is required Note that some RS 232C devices require handshaking such as RTS and CTS It is the responsibility of the user to disable this handshaking via software or hardware Making RS 232C Connections to the SmartStep Make your RS 232C connection as shown below The SmartStep to PC Cable IDC P N PCS 4991 shown below is an ideal choice for making trouble free connections Computer Connectors SmartStep 25 pin 9 pin 2 A S Connector Connector umm N Pin Pin D 5v W PC Cable 2 TX gt Rs 232c P N PCS 4991 3 RX RX O ks 7 GND GND lt a D Shid Comm Port Settings 9600 Parity None 1 XON XOFF Yes 8 Baud Rate Stop Bits Data Bits Troubleshooting Serial Communication Problems If communications between computer and SmartStep are unsuccessful one or more of the following procedures will usually solve the problem T Test your terminal or terminal emulation software Unhook the drive and transmit a character An echoed character should not be received If an echoed character is received you are in half duplex mode Jumper your host s TX and RX connections and transmit another character If you do not receive the echoed character consult the manufacturer of the host s serial interface for proper pin outs Host transmit TX must be
144. ll moves will change by the same factor that RATIO was changed e f using an IDC supplied actuator the proper Gear Ratios for entering units of 7cZes and can be found in the following actuator ration tables A 2 Appendix A IDC Actuator Ratios IDC Actuator Ratios N2 EC2 EC3 ECA EC5 Series N2 Smart Drive Mechanical Ratio Setting Motor Screw Overall Ratio EDIT SETUP MECH RATIO menu Series Reduction Pitch Mtr Turns Inch Ratio for Inches Ratio for mm N2 10 2x 1 2 2 2 tol 20 to 254 N2 15 2x 1 5 2 3 3 tol 30 to 254 N2 20 2X 2 2 4 4 tol 40 to 254 N2 10 5x 1 5 5 5 tol 50 to 254 N2 15 5x 1 5 5 7 5 75 to 10 750 to 2540 N2 20 5x 2 5 10 10 to 1 100 to 254 N2 25 5x 2 5 5 12 5 125 to 10 1250 to 2540 N2 31 5x 3 125 5 15 625 250 to 16 2500 to 4064 N2 120 5x 12 5 60 60 to 1 600 to 254 N2 10 8x 1 8 8 8 to1 80 to 254 N2 15 8x 1 5 8 12 12 to 1 120 to 254 N2 20 8x 2 8 16 16 to 1 160 to 254 N2 31 8x 3 125 8 25 25 tol 250 to 254 N2 120 8x 12 8 96 96 to 1 960 to 254 EC2 Smart Drive Mechanical Ratio Setting Motor Screw Overall Ratio EDIT SETUP MECH RATIO menu Se ries Reduction Pitch Mtr Turns Inch Ratio for Inches Ratio for mm EC2 10 16B 1 1 5875 1 59 254 to 160 1 to 16 EC2 15 16B 1 471 1 5875 2 33 6350 to 2720 25 to 272 EC2 20 16B 2 1 5875 3 18 508 to 160 2 to 16 EC2 50 16B 5 022 1 5875 7 97 242341 to 30400 9541 to 30400 EC2 100 16B 10 005 1 5875 15 88 183487 to 11
145. lly Closed Switch Connector PSN 2Q Mounts to EC NV Shield PSP 1 Normally Open Hall Effect PSP 1Q sedon Control sed on Controls requir PSP 2 Normally Closed ling PNP 3 Will Not Work with IDC Controls PSP 2Q Mounts to EC NV Connecting an Encoder to a SmartStep Color codes are for IDC encoders only Use signal names for other manufacturer s encoders Encoder Wiring Pink or Purple Green Yellow Orange White Brown N C Connector on SmartStep Encoder Input Schematic Outside SmartStep Differential signal from Encoder A B Z Insided SmartStep S To quadrature D decoder d g 2 26LS32 9 8 SmartStep Accessories Chapter 9 Hardware Reference SmartStep I O Accessories Accessory P N Description OPTO44 OPTO Rack accepts up to 8 optional conditioning modules See Opto Module table in this chapter for list of modules available from IDC See the following page for dimensions OPTO88 OPTO Rack accepts up to 16 optional conditioning modules See Opto Module table in this chapter for list of modules available from IDC See the following page for dimensions DB25BO Dimensions 2 0L x 1 0W x 0 8D Screw Terminal Breakout Board See page 9 14 for connection infor mation SS PNP BO Dimensions 2 0L x 1 5W x 1 28D Screw Ter
146. lt n a EA sets the state of the amplifier enable signal The polarity can be changed in EDIT SETUP MISC ENABLE Example Disables the amplifier on axis one Chapter 6 Programming Commands End of Block iecur etri syntax EB v1 00 Units n a Range n a Default n a The EB command designates the End of a Block of loop or IF commands Every LP LW LU and IF statement must have an EB associated with it Examples LP2 DI3 GO EB Performs the move twice IF1 1 DIS GO GO EB GH3 If input 1 is ON make 2 moves before homing If input 1 is OFF jump to the GH command End of Routine ecrire erre nnne ranis syntax EN v1 00 Units n a Range n a Default n a EN marks the end of a program or subroutine It is optional at the end of a program If EN marks the end of a subroutine command execution continues from the command following the gosub GS command which called the subroutine If the routine was not called from another program the EN command simply stops command execution The control continues to monitor the program select inputs if defined The EN command can be used anywhere in a program to stop command execution Example IF2 1 EN EB DI2 GO If input 2 is ON stop the program or returnto the calling program If not move 2 units 6 7 Chapter 6 Programming Commands 6 8 Function tror
147. m Wait for Function Key Go Home Go Immediate IDeal Commands Reference The following commands are available Acceleration Break Loop Current Limit Current Hold Time Distance Absolute Distance to a Change Deceleration Distance Incremental Enable Disable Amplifier End of Block End of Subroutine or Program Wait for Function Key Go Home Go Immediate Go Start a Move Go Point Gosub Go to Program If Input Variable Loop Loop Until Loop While Isle Fert ere BeLa The drop down menu box A in the upper left hand corner shows the number and name of the currently active program plus a list of up to 399 more programs When the entire file is downloaded to the SmartStep these program numbers correspond to the program numbers the controller uses for binary and BCD program selections Program comments are placed between brackets comments These comments are not downloaded to the SmartStep Total program length not including comments is limited to 1k Total program length with comments is 8k 8 15 Chapter 8 Programming With Serial Communication View Configuration Click on the View Configuration button at any time to see your system configuration status configuration parameters are listed and may be viewed by scrolling the list E IDC Application Developer untitled idc The open file has not been downloaded cielo Solis fim e 15 Program E
148. m checksum Read Only VEL1 Cmnd velocity of axis 1 Read Only SA1 Value of axis status Read Only EE1 thru EE50 Non volatile variables Read Ltd SD1 Value of drive status Read Only amp F1 thru F50 Write FKEY Val of Func Key pressed Read Only SS Value of System Status Read Only LASTKEY Val of last function key pressed Read Write INT98CTRL Enable Disable ARM INT98 Read Write TERM Send variable out RS232 Port Write Only INT98 Enable Disable INT98 if Read Write INT98CTRL is enabled
149. minal Breakout Board to Convert to Sourcing Outputs See page 9 15 for connection infor mation 55 0 SS IO 6 I O cables that connect SmartStep to other devices or PLC SS IO is 2 ft SS IO 6 is 6 ft See page 9 13 for wire color codes SS RS232 Cable for connecting SmartStep to PC 9 pin Comm Port PCS 5004 PC Keypad Cable for copying pro grams between keypad and PC 9 9 Chapter 9 Hardware Reference OPTO Racks OPTO88 RACK OPTO44 RACK O O 88 SmartStep RACK PCS 4972 PCA 4973 Rev A OPTO INPUT 1 OPTO INPUT 1 IN1 IN2 COM OPTO INPUT 2 IN3 IN4 or OOOOO0090090 2090O0O9 0O9OOO99 OPTO INPUT 2 IN2 COM IN5 OPTO INPUT 3 ING COM IN7 er OPTO INPUT 3 IN8 z D D OPTO INPUT 4 COM OPTO INPUT 4 d 5 525 0 OUTPUT 1 ouA OPTO INPUT 5 OUT2 0 6 OUT3 7 S OPTO INPUT 6 W OPTO OUTPUT 2 9 5 ours 2 D oe Ol amp E OPTO OUTPUT 3 com 0 OPTO INPUT 7 OUT 10 1 D OPTO INPUT 8 D 2 OPTO OUTPUT 1 7 0 3 6 c OPTO OUTPUT 2 D
150. ming Commands OT 6 24 syntax see below v1 00 Units n a Range 1 starting output number 1 16 x 2 0 output high OFF 1 output low ON x anything but a 1 or 0 the state of the output remains unchanged Default Syntax OTi xx sets output states starting with output OTxx assumes first output is 1 Sets both discrete and digital Opto output states Once an output is turned on it will remain set until changed by another output command a reset input software warm boot or power is cycled outputs are turned off upon power up or during a reset To increase flexibility the OT command allows you to use configured outputs anytime To help prevent this added flexibility from causing programming confusion you can use any character in the don t change section of your output statement This allows you to self document your OT statements For example assume you configured output 3 as a FAULT output Programming like OT0O1F10 can help remind you that you are already using output 3 Example OT4 1 Turn on Output 4 OT2 0D1 Turn Output 2 off leave 3 as is and turn 4 on OT110 Turn Outputs 1 and 2 on and 3 off QUOTE Mes syntax Any ASCII character v1 00 Units n a Range n a Default n a The Quote command transmits a string out the serial communications interface A without any string will transmit a carriage r
151. mmands between the IF and the EB are executed If FALSE execution continues with the command following the EB An IF statement should not be confused with a WT statement An IF statement evaluates true or false based on the conditions that the SmartDrive sees at the instant the command is processed A WT statement pauses command processing until the condition is true Note An End of Block EB command must be used with every IF command IF blocks can be nested up to 16 levels deep To increase flexibility primarily with programmable logic controllers or PLCs the IF command allows you to use configured inputs in the command To help prevent this added flexibility from causing programming confusion you can specify any character as an input x This allows you to self document your IF statements For example assume you configured input 3 as a JOG SPEED input Programming such as IFO1J10 can help remind you that you are already using input 3 as JOG SPEED Example IF14 1 GO EB If input 14 equals 1 Go IF12 010 GO EB If inputs 12 14 equal 010 Go IF110 GO OT3 1 EB If inputs 1 3 equal 110 Go and turn on Output 3 IF A19 lt 5500 OT11 GO EB If analog input 9 is less than 5500 turn on output 1 and 2 then GO IF TEMP gt 50 OT1 EB If temperature variable gt 50 turn on Output 1 IF PARTS 25 GS20 EB If PARTS variable 25 Gosub to Program 20 6 15 Chapter 6 Programming Commands IV Input Variable
152. n of axis 1 Read Only VEL1 Commanded velocity of axis 1 Read Only POS1 POS2 Current Position of axis 1 2 Read Only F1 thru F50 Non volatile limited use user system variables Read Ltd Write FKEY Value of Function Key pressed Read Only LASTKEY Value of last Function key pressed Read Only TERM Sends variable out RS 232 port Write only 1TW Scans inputs 1 4 for BCD Digit Read Only 2TW Scans inputs 1 8 for BCD Digit Read Only TIME Elapsed Time ms since power up or since reset Read Only CRCS Value of the EEPROM setup checksum Read Only CRCP Value of the EEPROM program checksum Read Only SA1 SA2 Integer value of the status of axis 1 2 See RS232 Read Only command SA SD1 SD2 Integer value of the drive status of axis 1 2 See Read Only RS232 command SD SS Integer value of the system status See RS232 Read Only command SS INT98CTRL Enables disables ARM INT98 trigger option Read and Write Refer to Ch 2 Configuring Your Inputs Input De scriptions Input 1 ARM INT98 INT98 input if INT98CTRL is Read and Write enable 7 3 Chapter 7 Programming Your Application 7 4 Examples of Built In Variables PIECES 10 SPEED AI4 VEL SCALE MS21 Enter Length IV32 LENGTH VE SPEED MS1 POS2 TERM POS 1 TEMPERATURE AI6 F1 PIECES Assigns 10 to variable Speed analog input times a scalar Prompts user and gets feed length Se
153. nd can only be used when the motor is moving at constant speed i e not accelerating or decelerating Issuing a DC command or trigger position before a previous DC has finished execution is invalid and can cause unpredictable results For example the following programmed move profile is an incorrect use of the DC command ACI VE5 DA20 DC1 75 VE7 5 GO Since the initial acceleration ramp requires 2 5 units of distance to reach velocity s 5 the DC1 75 is an invalid trigger position and will be ignored The following formula ensures the use of valid DC trigger positions V 17 v Dime Qu ig 2 Where n is the current DC command distance n 19 in this example n is the previous DC command distance e g 10 V is the velocity and t is acceleration time for the first DC specified in a move profile n would correspond to the beginning of the move In the following move profile AC units seconds VE units RPS see illustration ACI 6 DEO 8 VE5 DA20 DC10 AC2 5 DC VE2 5 GO 20 Units Chapter 6 Programming Commands 10 2 12 5 therefore the Using the DC formula and solving for DC DC Sees 2 must be greater than or equal to a position of 12 5 distance units In addition to verifying the DC trigger position it must also be verified that the DC VE2 5 segment can be completed before the beginning of the move deceleration Suppose the was chosen to be 13 35 a valid trigger posit
154. ng Acceleration Maximum C gt SETUP gt MECH gt AMAX Default 0 002 seconds or 999999 units sec Acceleration Maximum command sets a maximum acceleration and deceleration limit for programmed move profiles in the current acceleration units Programmed accelerations and decelerations for moves will be limited by this parameter analogous to VMAX for velocity 1 Enter the desired Acceleration Maximum 2 Press ENTER 5 21 Chapter 5 Configuring Your System Configuring Your Inputs amp Outputs The function of each input and output in your system is easily configured with I O SETUP menus Once you have defined your I Os it is a good idea to document your configuration O SETUP INPUTS OUTPUTS OPTOS scheme for later reference when developing future motion programs Configuring Your Inputs Configuring Input Definition IDaaaaaaaa SENE gt SETUP gt I O gt INPUTS Default UUUUUUUU IN1 UNASSIGNED UUUUUUUU 1j The function of each input is easily configured using the keypad as described below The function for each input channel is indicated by a letter along the bottom of the display 1 Use lt and keys to select an Input The function of the highlighted input will be displayed on the top line 2 Once your cursor is on the desired input use 1 to select from the following list of dedicated functions for each
155. nge Unit Number is used to set the device address of the control that Send Receive Program uploads and downloads to on a single RS 232C daisy chain Each unit must have its own unique software address The Unit number of each control should be set BEFORE the units are connected in a daisy chain the default address is one Send Program only sends information to the unit selected here new unit number must be set to download to the next unit on the daisy chain See RS 232C Protocol earlier in this chapter for hardware information on daisy chain wiring Setup Comm Port Comm Port is used to select a Comm Port when your PC has multiple serial ports This dialog box also has a comm port test utility to verify proper RS 232C operation IDC Terminal Terminal is a standard terminal emulator used for on line communication with a SmartStep control It is very useful for troubleshooting interactive host control communications Run Program is used to run a specific program from Application Developer Programs can also be initiated via dedicated program select inputs through the keypad or via any terminal using the RN command Run is only accessible from the main menu bar Chapter 8 Programming With Serial Communication This page intentionally left blank 8 18 Chapter 8 Programming With Serial Communication Section 3 RS 232C Protocol IDC s SmartStep series controls use a 3 wire implementation of RS 232C The RX TX and COM
156. nput Value Chapter 8 Programming With Serial Communication Chapter 8 Programming with Serial Communication Overview Any RS 232C terminal PC computer serial RS 232C card or RS 232C equipped PLC can be used to configure program and operate IDC s SmartStep controls IDC provides and strongly recommends using our Windows based Application Developer for configuration and programming If you choose not to use this tool all of the Deal RS 232C programming and setup commands are listed alphabetically later in this chapter Application Developer provides a graphical configuration environment a program development editor and a terminal communication package Application Developer also provides application upload and download utilities and an online software reference help utility This chapter is divided into 4 sections Section 1 covers the installation of Application Developer Section 2 covers Using Application Developer to setup and program SmartStep systems Section 3 covers common RS 232C details including baud rate settings as well as hardware and daisy chaining information Section 4 provides details on all of the RS 232C commands that Application Developer employs This section will be useful to users who are not using Windows or who plan to run the SmartStep in a hosted environment i e the host streams down individual commands for immediate execution or calls previously defined programs The host could be a PC RS 232C
157. ny place that a number can be used a variable can be used 7 2 Chapter 7 Programming Your Application Legal Variable Names The SmartStep allows you to create descriptive variable names as opposed to V1 V2 etc Variables can be up to 14 characters but the first 10 characters must be unique They can contain other printable ASCII characters such as numbers underscores exclamation points even spaces Upper and lower case characters are supported within variable names and these variable names are case sensitive ASCII control characters such as LF and CR are not supported AII variables must be enclosed in parentheses variable name Parentheses are not legal variable characters The standard software allows for up to 100 variables All variables are stored as fixed point numbers variables are global All standard variables are volatile though non volatile variables are available as well Built In Variables The following variable names are pre defined in the control They can be used throughout your programs in expressions to set voltages to test conditions or even to display information to the keypad screen or some other external serial device Variable Name Description Type Al1 thru 16 Analog Input 1 thru 6 Read Only AROWREL Current status of any of the four arrow keys Read Only CPOS1 Commanded position of axis 1 Read Only EPOS1 Encoder positio
158. o ID n MVr n ODaaaaaaaa OE OP Output States on Event Configures output states on an event specified by a OPTO positions 9 16 are only definable if configured as an output using OP command a P Power Up F Fault S Stop Kill i 0 Off 1 On X No Change Example OER0001XX0IXXXXXXXX OPTO Configuration i Input O Output Example OP IIIIOOOO First four configured as inputs last four as outputs lt n gt OPIIll PU Position Maintenance Gain Sets position maintenance correction gain i 1 to 32 767 Power Up Program Example PU105 Runs program number 105 on power up n PGi lt n gt PUi PV Position Maintenance Max Velocity Sets position maintenance maximum correction velocity Units specified by VU command lt n gt PVi 8 29 Chapter 8 Programming With Serial Communication Serial Setup Commands These are the commands that the Application Developer program uses to configure the SmartStep according to the choices made in the SETUP dialog boxes Command Command Description and Application Examples Syntax PW Password Up to 4 characters a z A Z 0 9 Entering a dash will clear the password Skipping a parameter will leave the password unchanged see examples below Examples using PW Example 1 PW4FT Q12h Set the OPRATR password to 4FT and the ADMIN password to Q12h Example 2 PW New Changes ADMIN password
159. o require the next user to enter a password Chapter 6 Programming Commands Chapter 6 Programming Commands This chapter defines in alphabetical order all of IDC s IDeal M commands that can be used in a program Please refer to Chapter 4 Using the Keypad for more information on entering these commands with the keypad Some IDeal M commands are supported only in serial communication mode These commands are listed and defined in Chapter 8 Programming with Serial Communication and they can also be found in the Summary of Commands immediately inside the back cover of this manual The commands in this chapter are defined according to the following example Distance Incremental syntax DI r r v1 00 C d impl ted Units selected from the EDIT SETUP MECH menu Range unit scaling dependent Default If the command has a default it will be listed here n a if there is no default DI specifies a move distance relative to the current position Such moves are called incremental moves as opposed to the absolute zero reference used in DA Incremental moves are typically used in applications where there is no concern for origin such as feed to length applications Incremental moves are also often used inside a loop to shorten a program Incremental and absolute moves may be mixed the control always keeps track of the absolute position Example Move 2 unit
160. oder mode must be configured Ensure that OPEN LOOP is selected if you are not using an encoder and skip to Configuring Your Mechanics Configuring Encoder Mode EMi SETUP ENC MODE ES OPEN pde Default OPEN LOOP This option sets the encoder mode Encoder feedback is strictly optional with the SmartStep Usethe f and ENTER keys to select the encoder mode OPEN LOOP The OPEN LOOP position will be displayed on the keypad OPEN STALL The OPEN LOOP position will be displayed on the keypad and the encoder will be used for stall detection See Following Error CLOSED LOOP The actual encoder position is displayed on the screen All subsequent moves are calculated from this actual position All moves are based on encoder pulses Stall detection is enabled Positioning resolution will equal the resolution of your encoder SERVO CLOSED Displays actual encoder position but moves are based only on LOOP commanded OPEN LOOP position Stalls are detected in this mode CLOSED Functionally identical to CLOSED LOOP with the addition of post LOOP PM move position maintenance of the last commanded position Provides pseudo servoing to stepper systems Use PM GAIN PM VMAX and IN RANGE WINDOW setup parameters to specify position maintenance tuning parameters Application Notes Following error is still active while in CLOSED LOOP PM mode A following error will occur when the number of co
161. on power up on input signal from a PLC or RS 232C host command e Within a program prompt the operator for any program variable the number of parts to run size of parts speed etc e Runa part or program by name e Lock out operators from programming functions For more information on programming your SmartDrive s operator interface see Chapter 6 Programming Commands and Chapter 7 Programming Your Application Keypad Features e Basy to read two line 40 charac ter back lit display e Can be sealed to IP65 NEMA 4 washdown environment e Large scratch proof keys with audible and tactile feedback Connects to SmartDrive and other controls with remote cable e Allows application programs to be copied from one SmartDrive to another or to from a PC 4 1 Chapter 4 Using the Keypad Keypad Hardware Features Setting DIP Switches to Limit Access to Keypad Menus Four DIP switches on the back of the keypad provide a means of preventing access to certain keypad menus If access to a menu is denied pressing that menu key will have no effect For example if 1 is ON and 2 is OFF the operator will be able to stop motion by pressing the ESC escape key but will not be able to access the RUN menus to select another program This is a hardware inhibit and is independent of any firmware or setup parameter in the SmartDrive DIP Switch Settings K d Functi lit eypad Functionali Reserved fo
162. onductive fasteners screws washers etc End View of Wall Mounted Keypad with Cover Removed Mounting Screw mounting surface 77 00 0000000000700 The circuit board may be damaged if any mounting screw is allowed to extend more than 0 20 into the key mounting surface NI Circuit Board Extending the Cable Length to Your Keypad The keypad cable may be extended if necessary but at longer distances your keypad may require a separate regulated 5 VDC 500mA power supply as shown in the illustration below Consult IDC Applications Engineering if you have questions about this procedure GND 5V Regulated Power Supply N C GND RX TX 5V FP220 Keypad Connection SmartStep 9 3 Chapter 9 Hardware Reference FP220 Keypad Mounting Template CAUTION this is scaled down version of the keypad template Use this drawing only for dimensions and locations of mounting holes The actual template is included with your keypad and may also be found on the IDC documentation CD CAUTION Your Keypad will be damaged if mounting screws extend more than 0 2 inches into the keypad E 3 16 CLEARANCEHOLES 4 7 CUT THESE HOLES F
163. osubs from overflowing the stack or returning to the wrong location Example GS Part A GO Run program Part A return and make a 10 unit incremental move Go to syntax GTi or GT name v1 00 Units n a Range 1 1 199 1 400 with 30K memory option name any legal program name Default GT branches to the program number or name specified All subsequent commands in the calling program are ignored Nested loops and subroutines calls are cleared by a GT command Example IF10 GT PART A EB IF input 1 is on and input 2 is off jump to program Part A IF01 GT20 GT30 EBEN IF input 1 is off and input 2 is on run program 20 Program 30 will never run Use the GS command if you want to return to this program and goto program 30 Chapter 6 Programming Commands Df syntax IF See Below v1 00 Units n a Range see below Default n a Syntax s IFi xx checks input range beginning at input IFxx assumes first input is input 1 IF mathematical expression or expressions 2 Range 1 starting input number 1 8 x 0 input high x 1 input low grounded x anything else ignore input changes expression any valid expression defined in math and variables section Allows the conditional execution of a block of commands based on the evaluation of an expression or input state If the expression or input state is TRUE the co
164. ote cable for Keypad Keypad mounting gasket Keypad mounting template CD with Application Developer software and product manual If you ordered a SmartStep only you will receive SmartStep SmartStep23 or SmartStep240 MD will be added if you ordered a minimum depth mounting e g SmartStep MD AC power cord for SmartStep CD with Application Developer software and product manual SmartStep Accessories Currently Available OPTO44 Rack sero z OPTO88 Rack ordered 7 May be ordered with or without 411111111 EK with or without OPTO modules oR RAA oio _ modules installed installed 4 PCS 5004 DHeSBO _ p oe Ne PC Keypad Cable for Screw Terminal Screw Terminal Breakout Board i Breakout Board E Do between Keypad and PC 8540 2ft cable SS RS232 _ SS IO 6 6ft cable SmartStep to PC Cable 2 1 Chapter 3 Chapter 3 Quick Start Quick Start The purpose of the Quick Start is to help an experienced motion control user verify that the SmartStep is operational and ready for configuration and programming The following directions assume the user is familiar with motion controls and their related electrical connections The Keypad FP220 is highly recommended for the easiest possible setup and programming of your application For Quick Start it is assumed that a keypad will be used even though serial communication may be us
165. p an IDC SmartStep with an IDC linear actuator is to configure the distance velocity and acceleration to use meaningful units probably inches or millimeters This is done via the RATIO GR command The RATIO is the number of motor revs per distance unit The Distance Unit used is selected via the SETUP MECH menu from the keypad or Application Developer Example GR5 1 means 5 motors revs per 1 distance unit Several other examples are available in the Configuring Your System chapter of this manual The RATIO is also used to scale the velocity and acceleration numbers when user units sec or units sec have been selected from the velocity or acceleration menus Until now since each actuator has its own revs per inch ratio data from the model number had to be interpreted and then a ratio calculated The following pages reduce that procedure to looking up the inch or mm ratio from a table sorted by actuator model number Instructions are also included to calculate a ratio for other distance units Increased positional accuracy is often achieved when using these values because some ratios aren t exact 3 5 1 is really 50 14 or 3 571428 Shown below are the three different ways to change the RATIO in an SmartStep Please note that some ratios cannot be entered via the keypad or Application Developer The keypad and Application Developer screens only support up to 5 digits in each RATIO number Via RS 232C up to 8 digits can be entered fo
166. pad adjusting display contrast 4 2 COPY menu 4 17 DEL menu DELETE 4 19 EDIT menus 4 9 functions of keys 4 3 HELP menu 4 16 menu structure 4 4 password access 4 2 remote mounting 4 2 RUN menu 4 5 keypad using the IDC Keypad setting DIP switches 4 2 kill motion input 5 24 L legal variable names 7 3 limit error output 5 28 limit switches Index connecting 9 8 types of switches 9 8 limits connections 5 3 line polarity enable 5 41 lock disable keypad 5 23 loop command 6 17 loop until command 6 18 loop while command 6 19 mechanics 5 18 menu operator accessibility 5 42 message to display command 6 22 miscellaneous setup parameters 5 40 motor current 5 0 motor direction 5 14 motor shutdown input 5 25 motor specifications IDC motors 9 17 9 23 motor type 5 9 motor wiring 5 3 motors using non IDC motors 9 24 mounting the SmartStep 9 1 move complete output 5 28 move continuous command0 6 20 multidropping SmartSteps 8 21 N naming a program 4 11 non volatile system variables 7 5 offset potentiometers 5 13 offsets fine tuning 5 13 on command 6 23 operands 7 6 OPTO modules connecting modules 9 11 OPTO racks I O accessories 9 10 types and part numbers 9 14 types of modules 9 13 wiring examples 9 11 9 13 output command 6 24 output characters amplifier fault 5 28 at home 5 28 brake 5 28 direction of motion 5 28 fault 5 28 limit error 5 28 move complete 5 28 programmable 5 29 s
167. plains the functions available when you press any of the non numeric keys Pressing HELP in Menus and Sub Menus HELP explains the selections available from your current menu location Pressing HELP In the Program Edit function HELP Use RUN key to This option is used to select the motor type HELP provides a brief alphabetical list of commands Command syntaxes and details on using commands are available in the Chapter 6 Programming Commands or from HELP in the Application Developer editor Note A program must be selected to view the COMMAND SUMMARY 4 16 Chapter 4 Using the Keypad Using COPY Copying programs from one name or number to another and downloading between key pads or between keypad and PC can save a significant amount of time when programming with a keypad Pressing the COPY key brings up three choices that canbe COPY accessed by pressing the function keys PROG TOPAD FROM PROG PROG allows you to copy any existing program to a new pro 1 SOURCE PROGRAM gram name gt 5 To copy one program to another 1 Press PROG 2 Enter the source program number Or if you wish you can scroll through your list of program names by using the keys 3 Press ENTER Then you are asked to enter the new program Ifthe target program already exists you will have to delete it first see DEL 1 Enter the target program numb
168. process The column of boxes represents the axis to be configured box s color represents its configuration status i e gray indicates a parameter that has not been configured yellow indicates the parameter currently being configured and black indicates the completed configuration of that parameter IDC Project Wizard SmartStep Wizard Navigator 8 5 Chapter 8 Programming With Serial Communication 3 Click on the Next button and the Motor setup window will appear SmartStep Control Units Finish 4 From the pulldown menu select the IDC motor you will be using and the Wizard will calculate the rest Select Other if you are using a non IDC motor 5 Click on the Next button and the Encoder setup window will appear IDC Project Wizard SmartStep Control Finish 6 If you will be connecting an encoder select one of the Encoder Operation Modes Encoder modes are described in Chapter 5 7 Ifyou have made a selection other than Open Loop no encoder you may wish to edit the Encoder Resolution and Following Error parameters at this time 8 6 Chapter 8 Programming With Serial Communication 8 Click Next and you will be in the Mechanics setup window Mechanical System setup is particulary easy if you are using IDC systems Select the IDC Mechanical System and Part you intend to control and the Wizard will calculate the rest Select Other if you are using a system not otherwise specified
169. program names Example RN25 SW Tell Software Version lt n gt SW The control returns its software revision Example 1SW returns V1 40 lt cr gt UA Upload All lt n gt UA Uploads all setup parameters and programs from unit n SmartStep sends an EX to terminate upload UL Upload Program lt n gt ULi Range i 1 199 program up to 400 programs with 30K option Uploads program number 1 to the host SmartStep adds brackets Example 1UL2 Uploads program 2 from unit 1 Response part A AC4 VE30 DI10 5 GO 8 41 Chapter 9 Hardware Reference Chapter 9 Hardware Reference Mounting Your SmartStep The standard mounting bracket on the SmartStep has been integrated with the housing to better facilitate minimum width mounting A minimum depth mounting bracket is available as SmartStep MD These general mounting guidelines should be observed Y The vertical clearance between a SmartStep and other equipment or surfaces of the enclosure including other SmartSteps should be a few inches on top and bottom to allow for power and motor connections Horizontal clearance is not required between SmartSteps but we recommend 0 05 to better facilitate handling of the units Typical Mounting Fasteners Cap Screw Machine Screw 10 8 M4 8 M4 5 1 592 1504 a 2 96 ara 5 1 A e 34 8 7 0 34 8 7
170. put is activated program 98 will run This input is ignored while the keypad is in Edit mode This is a positive edge sensitive input rather than a level sensitive input If multiple inputs are configured as Interrupts only the first edge of the first activated input will be seen If subsequent Interrupt inputs go active while the first Interrupt input is active no additional interrupts will be seen 5 23 Chapter 5 Configuring Your System 5 24 Advanced Interrupt handling can be achieved using the INT98CTRL and ARM INT98 variables The INT98CTRL variable determines whether Interrupts can be disabled or not The ARM INT98 variable allows you to arm and disarm the Interrupt as desired When the SmartStep powers up INT98CTRL is initialized to 0 In this mode every interrupt results in an immediate jump to program 98 even if you just entered program 98 This state is backwards compatible with earlier revision IDC SmartDrives The value of ARM INT98 is ignored When INT98CTRL 1 you can enable and disable Interrupts at will with the ARM INT98 variable Setting INT98CTRL 1 also initializes ARM INT98 to 1 This means the control is watching for interrupts When INT98CTRL is set to 1 an interrupt causes the program to jump to program 98 AND sets ARM INT98 0 disabling any further interrupts until you re enable them by setting ARM INT98 1 This allows you to control when you want to re enable Interrupts in your interrupt ser
171. puts 1 2 and 3 to go active Stop the move Example 2 Demonstrates how to prompt an operator for speed changes on a single axis SmartDrive The move is started after the initial velocity prompt The velocity only changes when the operator enters a new value via the keypad The move can be stopped by entering a velocity of zero or when any of the stop conditions defined above exist One Axis MC MS1 Enter the Velocity IV23 V MC ACI VE V GO GT One Axis MC Prompt the operator Put the operator input in variable V Use operator entered variable V as new speed Change velocity of axis 1 to the new speed Repeat Example 3 Demonstrates the use of WT OT and TD commands in continuous move MC AC3 VE3 GO WT8 1 AC 1 VE10 GO TD5 AC 3 VE 2 GO WT3 1 VE 10 GO OT11 TD10 VEO GO Start first segment Wait for input 8 and change speed Wait for 5 seconds and change speed Wait for input 3 and change speed and direction Turn on outputs 1 and 2 Wait 10 seconds and stop the move 6 21 Chapter 6 Programming Commands 6 22 Message to Display syntax see below v1 00 Units n a Range n 1 40 display position in characters Characters 1 20 on top line 21 40 on the bottom display line Default Syntax MS returns to the default runtime display MSn MSn user text MSn variable MS allows you to put messages on the keypad di
172. r 4 Using the Keypad Functions of the Keypad Keys F Keys F1 F2 F3 Used as Menu selectors Used with numeric keys to select commands in the program editor Programmable as operator menu selections See the FK command for information on using the function keys within a program 0 9 Keys Enters numbers Used with ALPHA to select characters and with F Keys to select commands in the program editor Menu Keys RUN Runs a program jogs an axis or accesses Test Debug functions me For scrolling through menu options setup choices and programs in the editor Moves an axis in JOG mode EDIT Edits Setup param eters and programs lists programs amp resets posi tion counter HELP Provides help on TS pm a e van A COME keys menus and com S 4 Used in multi axis con trols to separate axis command parameters Part of the syntax in message and variable prompt commands COPY Copy programs between keypads between keypad and PC or from program to pro gram within a SmartDrive DEL Deletes characters in the editor or deletes entire programs from memory DECIMAL POINT Used to enter fixed point numbers ENTER Saves parameters that have been typed into a configuration or the pro ALPHA gram editor Enters a space ALPHA plus a numeric key in the program editor sele
173. r copying pro grams between keypad and PC For more information on how to use your SmartStep s inputs and outputs in an application refer to Chapter 6 Programming Commands and Chapter 7 Programming Your Application and Chapter 9 Hardware Reference 5 6 6 AC Power AC power is plugged into the connector on top of the SmartStep SmartStep input voltage must be in the range of 90 120 VAC single phase 50 60Hz 500 VA max 7 9 amp setting SmartStep240 input voltage must be in the range of 190 240 VAC single phase 50 60 Hz 500 VA max 4 0 amp setting SmartStep23 input voltage must be in the range of 90 120 VAC single phase 50 60 Hz 250 VA max 3 0 amp setting Chapter 5 Configuring Your System 120 50 60 Hz OFFSETS 7 CAUTION HIGH VOLTAGE Chapter 5 Configuring Your System Configuring Your System This chapter contains details and directions for customizing the SmartStep to your specific application and mechanical requirements IDC recommends that even experienced users follow this procedure in its entirety Following all the SETUP steps will ensure that important parameters are not overlooked This section is presented from the point of view of the FP220 Keypad user The directions that follow will take you through each of the SETUP menus in the keypad and give you details about each of the choices you will be asked to make Application Developer and serial communicat
174. r each number The rounding error caused by only being able to enter 5 digits is very minimal for most actuators and stroke lengths and is often much less than the positional uncertainty caused by mechanical backlash and windup Methods For Configuring Ratio There are three methods for entering the ratio information The keypad is the quickest method if your system includes that option 1 SmartStep Keypad EDIT SETUP MECH RATIO Menu 2 Application Developer software Setup Axis Menu 3 Direct RS 232C connection GR Command Using the Keypad to Enter Ratio Information Press Keypad Display um Axis One Ratio EDIT gt SETUP gt MECH gt RATIO sp il gg We Default 1 to 1 These two integer values set the number of motor rev s per distance unit inch mm cm etc Appendix A IDC Actuator Ratios Application Developer Axisi 52 2 Axis 4 Max Velocity revs sec en Gc Note Your entire application setup parameters and pro grams must be downloaded to the SmartStep before the new RATIO scaling will be used You cannot download only a new RATIO from Application Developer RS 232C Terminal Example 1DU2 distance unit inches 1GR10 1 gear ratio 10 1 JIndustrial Devices Corporation Gear Ratio Notes You can change DIST or RATIO at any time Changing them will not change the associated DI or DA values in a program so a
175. r future functions Notes Power must be cycled before DIP switch setting changes take effect Access to the JOG menu can be enabled or disabled from software Using Passwords to Limit Access to Keypad Functions Another method of limiting access to keypad functions 1s to assign passwords when configuring your setup parameters See Configuring Your Miscellaneous Setup Parameters in Chapter 5 for more information on passwords Please note that DIP switch settings have priority over passwords Adjusting Contrast On the back of the keypad there is a plastic potentiometer adjustable with a flathead screwdriver This is used to adjust the contrast on the LCD display If the SmartDrive and keypad were purchased together this adjustment has been made by IDC Some adjustment may still be necessary to accommodate unusual lighting or viewing angles a Keypad Connector Pins _ _ Switches shown in GND RX TX 5VDC OFF position e 5 4 3 2 1 4 Contrast Potentiometer IL Turn clockwise to increase contrast 2 E om E Remote Mounting the Keypad The keypad can easily be mounted and sealed to NEMA 4 specifications by using the included mounting gasket and 6 foot communication cable Refer to page 9 3 Hardware Reference for information on mounting the keypad and extending cable length 4 2 Chapte
176. r over RS 232C Output States lt n gt OS Real time status of discrete and OPTO outputs Current Position lt n gt PA1 Real time position in user units of axis 1 Stop lt n gt S Issues program terminaiton decelerates to a halt Axis Status lt n gt SA1 Returns axis specific status i e limit and home states of axis 1 Drive Status lt n gt SD1 Returns drive specific status i e type of amp fault of axis 1 System Status lt n gt SS Returns general system status and operation 8 34 Chapter 8 Programming With Serial Communication Serial Immediate Status Commands Note but the S and commands require an address Command Command Description and Application Examples Syntax CB Clear Command Buffer Clears the terminal input buffer and buffered command buffer Tell Input States Returns the current state on or off of the 8 inputs The status is returned as a four digit hexadecimal number preceded by an asterisk The least significant digit represents the binary value of inputs 4 1 Example IS returns 00F6 cr with the input conditions shown in this table Inputs m me 7 ere TS T8 TS ETATE foro er or er er or or on on on on t on fon oF o8 d d Your computer program must decode the hexadecimal number to determine the state of each input n CB lt n gt IS Kill Issuing the K command causes the control to abruptly stop commanding further
177. r the fault generated by hitting an End of Limit switch Alternatively an S or K command sent over serial communication will also clear the fault as will pressing the ESC key on the keypad The velocity is determined by the Jog Speed J input and the Jog Low and Jog High setup parameters When the input is OFF the speed is low and vice versa If none of the inputs are configured for Jog Speed the motor will jog at the Jog Low setting S Stop When activated any program execution or functional operation is immediately stopped This includes any motion time delays loops and faults Moves will be decelerated at the stop deceleration rate New programs will not execute until the stop input goes inactive See the SCAN setup parameter for more information on stopping program execution See the ST command in Chapter 3 for more information on stopping moves without halting command execution U Unassigned An Unassigned input functions as a programmable input and can be used in IF and WT statements just like any of the dedicated function inputs Default configuration 5 25 Chapter 5 Configuring Your System V Data Valid When this input is configured it determines if the Binary BCD program select lines are processed or ignored If the input is active program select lines are processed otherwise they are ignored This allows applications to be wired in a pseudo bus architecture fashion with each unit sharing the same program select
178. re three modes of operation Switch Only us will only search for the appropriate edge of a Switch Switch Then Z Channel The control first looks for a home switch aligns to the edge and then slowly moves until an encoder Z pulse is found Z Channel Only The control does not search for a home switch instead it rotates at a slow speed until an encoder Z pulse is found regardless of the home switch state The magnitude of GH velocity parameter is ignored The sign of the velocity parameter determines the low speed direction Requires an encoder Use 1 keys to select the homing method 5 36 Chapter 5 Configuring Your System Configuring Your PROGRAM SETUP Parameters The Program Setup menu allows selection of 1 a program to PROGRAM SETUP be immediately run when the SmartStep is powered up and 2 pwrup SCAN DELAY scanning conditions for the BCD or binary program select inputs Configuring Power Up Program PUi gt SETUP gt PROG gt PWR UP bec UL Uus Range 0 0 400 Default 0 This option selects a power up program The selected program is executed run when your SmartStep is powered up or reset If a value of 0 is entered in this menu or if the specified program does not exist no program is run Use numeric Keys to enter a program number Configuring Scan Conditions SNaaaaaaaa m gt SETUP gt PROG gt SCAN m o M
179. re used as delimiters for commands e Pressing DEL deletes characters e The left and right arrows or scroll through programs one character at a time e The up and down arrows or scroll through programs one line at a time Naming Programs Any or all of the programs stored in the non volatile memory of the SmartDrive can be given descriptive names in addition to the program number that the SmartDrive assigns it Program names must be put inside square brackets program at the start of a program The name can be up to 14 characters but the first 10 must be unique They can like variables be almost any combination of characters Programs or subroutines are often named to help self document a program It is usually easier to remember and understand a name then a number You may call a program or branch to them by name This feature also makes it easier for operators to run programs and easier for the programmer to develop systems requiring operator interfacing with our keypad Suppose your system will run 20 different parts and each part has a different program With a SmartDrive all you have to do is name each of your programs so an operator will easily recognize them When the keypad RUN key is pressed instead of entering a number simply scroll through the list of program names possibly part names using the keys When the desired part is displayed simply press ENTER to run the program for that part C
180. ress f and keys to scroll through the list of available 3 programs until you find the program you want Press ENTER Select JOG To Jog the Motor To jog the motor l 2 3 Press RUN Press JOG F2 Press lt f and keys to jog the motor PROG JOG TEST 1 RUN PROGRAM gt 5 1 RUN PROGRAM 212 GRIND JOG AXIS 1 0 0000 LO HIGH Change between LO and HIGH speeds with the F1 and F2 keys Jog speeds and accelera tions can be changed in the EDIT gt SETUP gt menu To jog an incremental distance 1 2 3 4 5 Press RUN Press JOG F2 Enter the desired distance number 1 0 012 JOG AXIS 1 0 0000 Dist 012 Press and release an arrow key to make the motor move this distance The arrow pressed determines the direction of the move Repeat steps 3 and 4 until desired position is reached Repeatedly pressing the arrow keys will jog the same distance until a new distance is defined This feature is intended for very fine final positioning The incremental jog speed is therefore fixed at a very low speed Note Pressing ESC at any time will terminate the incremental JOG mode 4 5 Chapter 4 Using the Keypad Using TEST For Testing and Debugging 4 6 TEST Sub Menus TRACE The trace feature allows you to debug programs by sequential 5 TRACE PROGRAM ly executing one program command at a time 1
181. rni syntax FKi i i v1 00 Units n a Range i 1 28 Default n a Note 24 the ESC key cannot be assigned since it stops a program The FK command allows you to redefine a keypad key function within your program The FK command pauses processing until the buttons you have armed are pressed The number of the armed button is assigned to the sy stem variable FKEY You can then manipulate or directly use this variable to branch to other routines or make other decisions FK allows the programmer to redefine the keypad function keys as operator menu selection buttons You can even write your program with menus that look and feel like IDC s setup menus Example FK1 2 3 4 GS FKEY Pauses command execution until F1 F2 F3 or RUN is pressed on the keypad FKEY is assigned a value of 1 4 Subroutine 1 4 is called with the GS gosub command See the illustration below for the value of FKEY returned for each key HELP CcoPY DEL JS J Se lt 12 13 I n 17 218 P 22 23 ALPHA ENTER 27 28 The following example shows how to use the keypad function keys as an operator interface 1 Write a menu message MS on the keypad display above the corresponding function keys 2 Use the FK command to pause command processing until the operator selects a valid function key Only keys explicitly defined in 3
182. rom the OPTO module representing the analog signal These input values are updated every 16 milliseconds If your program needs to display this value in units such as VOLTS you will need to scale the value to VOLTS in your program The scaling factor depends upon the type of OPTO module used For example a J thermocouple uses a different factor than a K thermocouple Due to slight variances in the output frequency from module to module it is recommended that the be calibrated by querying the corresponding AIx value with no input signal connected to the OPTO This value should be used as the zero input reference frequency Example Using a 0 10 VDC analog input 0 14 400 10V 72 000 or 5 760 Hz volt VOLT AI2 Read the value of analog input 2 into variable volts VOLT VOLT 14400 Remove frequency offset VOLT VOLT 1 736 Scaling factor multiplied by 10 000 VOLT VOLT 0001 Scaling back to volts The variable VOLT is now in units of volts If you are waiting for a condition to occur or doing a comparison see below there is no need to go through the conversion process TEMP AI5 Read in temperature from analog input WT AI3 lt 45000 GO Wait for analog input 3 lt 45000 lt 5 3 VDC using the previous example before moving IF AI2 lt 45000 GO EB Go if analog input 2 lt 45000 72 80 p lt 70 Output 60 Freq 50 KHz 40 2 30 14 4 20 10 Min Input Signal Max Input Value I
183. rrection steps exceeds the following error value This allows the unit to signal a fault when the displacement cannot be corrected i e an obstruction CLOSED LOOP PM will not attempt to correct position while navigating menus with the keypad 5 15 Chapter 5 Configuring Your System 5 16 Configuring Encoder Resolution ERi Axis One Encoder Res EDIT gt SETUP gt ENC gt E RES lt 2000 Default 2 000 pulses per rev This option is used to set the encoder resolution The resolution is specified in encoder pulses per revolution of the motor post quadrature To prevent end of move dither with a SmartStep we recommend an encoder resolution of 8000 pulses per revolution or less 1 Use the numeric keys to enter the encoder resolution Configuring Following Error Limit FEi Axis One Fol Error 1 750 steps pec EDIT gt SETUP gt ENC gt FOL ERR Default 750 motor steps Range 0 999 999 motor step counts 0 OFF Units motor steps This option defines the maximum position Following Error allowed during motion A fault occurs when the error between the commanded and feedback signal exceeds the Following Error value 1 Use the numeric keys to enter the Following Error limit If a Following Error occurs the control will enter a fault state where e Any motion or program being executed is immediately terminated e The LCD Display will ind
184. s or to scroll through the list until the desired character is displayed When you find the desired character press ALPHA or ENTER to insert the character The character will be displayed and the cursor will move one space to the right Scroll through the list to select your next character or press ESC to leave the editor Chapter 4 Using the Keypad Example of Naming a Program Add the name MINE to the program created earlier AC 3 VE2 DI1 GO To insert MINE 1 Press 2 Press 0 zero key 3 Press ALPHA 4 Press 5 key 5 Press ALPHA 6 Press 3 key three times 7 Press ALPHA 8 9 Press 5 key two times MINE AC 3 VE2 GO Press ALPHA 10 Press 2 key two times 11 Press the key to move cursor to the right of the bracket gaye Program 12 Press ESC You will be prompted as shown YES NO 4 13 Chapter 4 Using the Keypad Using the SETUP Sub Menus for Configuring Your System The following table shows the structure within the EDIT gt SETUP sub menu For com plete descriptions of each system parameter in the SETUP sub menus see Configuring Your System Setup Parameter Description of Setup Parameter TYPE Motor parameters D RES E RES Drive resolution Direction of travel Select open closed loop mode Encoder resolution FOL ERR IN RANGE Following error Position maintenance window PMGAIN RATIO
185. s in the positive direction Move 1 more unit in the direction Move 4 units in the negative direction Program AC 1 VE60 DD GO DII GO DI 4 GO Note Additional programming examples are found in the next chapter Summary of IDeal Commands Command Description Command Description Acceleration Go Immediate On Command Break Go Start a Move Output Distance Absolute Gosub Message to Serial Port Distance to a Change Go To Registration Move Deceleration If Then Set Position Distance Incremental Input Variable Square Root Enable Amplifier Loop Stop on Input End of Block Loop Until Time Delay End of Routine Loop While Velocity Function Key Move Continuous Wait Go Home Message to Display 6 1 Chapter 6 Programming Commands IDeal Commands 6 2 AC Acceleration einn nen nnn aai syntax ACr v1 00 Units sec rps or unit s selected from the EDIT SETUP MECH menu Range unit scaling dependent Default n a AC sets the acceleration and deceleration ramp on all velocity changes The deceleration value DE will be the same as the acceleration value unless it is specifically set after the AC command The value of DE must be reset every time AC is changed Use only AC if you want a symmetrical move profile Use DE if you want a different deceleration rate Subsequent moves will use the last DE or AC value specified Examples AC2 VE12
186. s the square root of 27 96 and stores the value in the user defined variable SQRESULT Program SQRESULT 0 SQ27 SQRESULT The returned value in SQRESULT would be 5 28 ST TD Chapter 6 Programming Commands Stop On Input s syntax STn or ST n v1 00 Units n a Range 0 8 Inputs 1 Axes Default n a Syntaxes ST stops move execution upon activating the input specified by n STO disables turns off the STn command ST 1 stops move execution on axis 1 ST n functions identically to the STn command without the use of an input allowing program command conditional motion termination After the ST command is executed the specified input is monitored during every move profile If the input is activated the current move in progress is terminated stopping all motion until the input is deactivated or a STO is processed the drive will process and calculate commands but it will wait at the next GO command until the ST input changes The motor is stopped at the deceleration rate specified in the Stop Decel Rate setup parameter Once issued Stop on Input remains active until it is turned off by the STO command a reset is issued or power is cycled Example Move to absolute position of 6 distance units If A gt 10 motion is stopped AC 1 VE25 25 DA6 6 GI Move to 6 absolute distance units and Go Immediate IF A gt 10 Check value of A assume A was previously
187. s to help you select the proper system install it correctly and get it up and operating to your satisfaction The toll free number is 800 227 1066 Outside of the United States call 603 893 0588 Email should be directed to sales 9 idcmotion com Actuator motor and gear motor CAD drawings in dxf format are available to save you valuable design time and prevent transcription errors Low volume requests are complimentary Check the web site for CAD drawings that may be downloaded Check us out at www idcmotion com for information on our products and support Hn Welcome to Danaher Precision Systems ea en Forward Stop Refresh Home 7 AutoFill Print Mail We can help take your ideas from initial concept to proven reality Welcome to Danaher Precision Systems your partner in precision positioning DPS provides positioning solutions in several markets Life Science Semiconductor Photonics Digital Imaging Factory Automation and Disk Drive Please click on the brand of positioning products which best fit your needs N 5 1 1 panas Visit our divisional web sites Danaher Danaher Danaber ont 7 Precision Precision CT Precision Systems Systems Systems rA 2 S e e 2002 Danaher Precision Systems sales neat com 603 893 0588 Disclaimer Disclosures Regarding Forward looking Statements
188. splay Messages are typically used to prompt for operator input display function key prompts or as a diagnostic tool MSn clears the display from the n character MSn user text prints user text beginning at the character MSn variable writes the value of the variable on the display beginning at the character The above variations to MS will disable the default position and I O display until program execution stops MS can be used to restore the default axis position and I O display during program execution Examples MS1 Clears the Display MS3 Part Count Writes string beginning at character 3 top line MS27 COUNT Displays the value of the variable COUNT beginning at position number 27 7th character 2nd line Below is an example of one segment of the Keypad Programming Template which can be found immediately inside the back cover of this manual The template is provided to allow you to write MS programs by hand exactly as they will appear on the 40 character keypad display Please feel free to make copies of the template for writing your programs Chapter 6 Programming Commands ON Command On Event syntax ONn GTx ONn GSx ONn 0 v1 8 Units n a Range n a Default n a The ON command allows the user to define conditional program execution based on the occurrence of a certain event When the programmable ev
189. ss Note See AA Command in Programming with RS 232C for Auto Addressing 5 39 Chapter 5 Configuring Your System Configuring Your Miscellaneous Setup Parameters 5 40 The miscellaneous setup MISC SETUP parameters include MISC SETUP auto formatting of the keypad display and setting the DISP STOP RATE TEST deceleration rate used with a stop input or with the ESC key while an axis is moving Configuring Display Format DF MISC SETUP er d d Dor STOP RATE TET Default Quad 1 POSI Quad 2 BLANK on SmartStep lt QUAD 1 gt QUAD 2 Quad 3 INPUTS QUAD 1 QUAD 2 Quad 4 OUTPUTS Range n a Display format allows the user to customize the data displayed on the keypad run time screen The run time screen has been divided into 4 10 character configurable quadrants The DISP menu displays labels for the 4 quadrants with carets gt denoting the selected quadrant Use f and keys to move quadrant selection delimiters gt 2 Press ENTER to edit quadrant Once a quadrant is selected there are 9 possible data types that can be displayed in that quadrant Data Type Quadrant Display BLANK No display POS1 Axis position POS1 UNIT Axis position with axis units VEL1 Axis commanded velocity INPUTS Discreet input status 0 off 1 on OUTPUTS Discreet output status 0 off 1 on SA STATUS1 Displays SA serial command response for axis SS STATU
190. ssages to the right will appear sequentially on the keypad display ere UOT When the messages disappear the download is complete Waiting For Processing Saving To Memory To copy programs from the keypad to a PC 1 Connect keypad to Computer using RS232 cable IDC P N PCS 5004 2 In Application Developer Communications menu click on Retrieve All and choose From Keypad The keypad will display the message Sending to PC and a few more messages will quickly appear then disappear from the screen When the keypad display goes blank the keypad to PC upload is complete 4 18 Chapter 4 Using the Keypad Using DELETE DEL The DEL key allows you to delete any motion program currently in your SmartDrive To delete a program 1 Press DEL 2 Enterthe number ofthe program to delete Or if you wish you can scroll through a list of existing program names by using the 4 keys 3 Press ENTER DELETE PROGRAM gt To Delete a single entry letter or number 1 Move the cursor over the entry you wish to delete move with 2 Press DEL 4 19 Chapter 5 Configuring Your System Chapter 5 Configuring Your System This chapter provides procedures for configuring your SmartStep to your specific equipment and application requirements SmartStep configuration is divided into two categories First is Connecting Your Hardware which is preceded by IDC s recommended wiring practices
191. ssuming the presence of an operational home switch the control will ultimately seek a home position according to the home setup parameters you specified edge level final approach direction and offset Closed loop systems will normally home with more accuracy than open loop systems because encoders come with a Z marker pulse 1 8000 of a revolution on our B Series In atypical Go Home routine the control will first sense the edge of the switch defined in the Go Home SETUP menu It will then decelerate the motor to a stop at the last defined deceleration rate The final homing motion will now be determined by the Go Home options selected in the SETUP menu The final homing direction dictates the direction from which the final approach to the switch is made The edge selected will determine which side of the home switch this final approach will be based from In a closed loop mode Go Home routine the control will additionally slow to a creep speed and stop when it sees the encoder s Z Marker Pulse after seeing the reference edge of the switch If a marker pulse is not seen within one motor revolution after the reference edge of the switch is seen the final homing routine will be aborted Note Homing Mode directly affects or reconfigures the function of the GH command see Configuring Your Home Parameters in Chapter 5 Examples AC 5 DE 5 GH 20 Go Home in the negative direction at a speed of 20 AC 5 DE 5 GH20 Axis one Go Home in
192. tall 5 29 Index output power available specs 9 5 output states of fault 5 30 output states on power up 5 30 output states on stop kill 5 31 P passwords 5 42 pause continue 5 25 position maintenance gain 5 17 position maintenance in range deadband 5 17 position maintenance max velocity 5 17 power connection AC 5 7 product support 11 11 PROG sub menus 4 5 program creating a new program on the keypad 4 9 editing an existing program 4 11 naming a program 4 11 program setup parameters 5 37 power up program 5 37 scan conditions 5 37 scan delay 5 38 programmable output 5 29 programming 7 1 Boolean operators 7 7 built in variables 7 3 conditional expressions 7 7 examples create a message and input a variable 7 8 create an operator menu 7 8 fast in slow feed move 7 8 7 9 input a 4 digit BCD number reading 2 digits at a time 7 9 turning on an output on the fly 7 9 FLASH variables 7 5 incrementing and decrementing variables 7 7 legal variable names 7 3 logical operations on expressions 7 7 non volatile variables 7 5 operands and equations 7 6 reading an analog input 7 10 variables 7 2 programming commands IDeal Commands 6 2 Q quick starting the SmartStep 3 1 quote command 6 24 R regional offices 11 11 registration command 6 25 registration input 5 23 resolution 5 14 rest mode 5 13 retract jog 5 25 returning the SmartDrive for repair 11 12 RS 232C communication connecting to SmartStep 8 19 RS 232C
193. tem Motor Reference 1 IDE CORRENU Inductance Unloaded De CURRENT Inductance VANS MOTOR MOTOR Anti Res SERIES T 9120 240 Setting Anti Res PARALLEL V 120 240 Setting 12 1 0 1 0 LOW 29 12 2 0 LOW 29 21 1 2 1 2 HIGH 30 21 2 3 LOW 27 22 1 5 1 5 HIGH 28 22 3 0 LOW 24 23 1 7 1 7 HIGH 25 23 3 4 LOW 22 32 2 8 2 8 HIGH 22 32 5 6 LOW 18 33 3 5 3 5 HIGH 21 S33 7 0 LOW 17 42 6 0 4 0 LOW 16 42 7 9 LOW 12 P21 0 7 HIGH 30 P21 1 3 LOW 27 P22 1 0 HIGH 28 P22 2 0 LOW 24 P31 1 5 HIGH 27 P31 2 9 HIGH 23 P32 1 6 HIGH 24 P32 3 3 HIGH 20 P33 2 0 HIGH 22 P33 4 0 HIGH 18 P41 2 8 HIGH 21 P41 5 7 HIGH 17 P42 3 3 HIGH 18 P42 6 6 LOW 17 P43 3 3 HIGH 15 P43 6 6 HIGH 14 K31 1 5 HIGH 24 K31 2 9 HIGH 20 K32 17 HIGH 22 K32 3 4 HIGH 18 K33 1 7 HIGH 20 K33 3 8 HIGH 16 K41 2 8 HIGH 18 K41 5 7 HIGH 14 K42 3 2 HIGH 17 K42 6 4 HIGH 13 K43 3 3 HIGH 15 K43 6 6 HIGH 11 Motor Reference 2 MOTOR 521 S22 S23 S32 533 S42 P21 P22 P31 P32 P33 P41 P42 K42 K43 OFFSET 4 46 3 91 3 57 2 98 276 2 11 378 406 3 54 3 49 3 36 2 85 2 75 3 14 3 75 TEST SPEED RPS WAVEFORM 1 12 98 89 74 69 0 53 0 95 1 01 88 87 84 71 69 78 94 TEST SPEED RPS Jr 1 17E 5 2 34E 5 3 51E 5 1 21E 4 1 88E 4 8 0E 4 2 48E 5 4 31E 5 1 40E 4 2
194. tem 7 1 Chapter 7 Programming Your Application Command Summary The chart below lists all the Deal commands that can be stored and executed as a part of a program In Chapter 5 Programming with Serial Communication there is more information on serial commands such as Setup Immediate Status and Supervisory Commands Also included in Chapter 5 is a list of Commands Not Available in Hosted Command Description Command Description AC Acceleration IV Input Variable BR Break LP Loop DA Distance Absolute LU Loop Until DC Distance to a Change LW Loop While DE Deceleration MC Move Continuous DI Distance Incremental MS Message to Display EA Enable Amplifier ON On Command EB End of Block OT Output EN End of Routine RG Registration Move FK Function Key SP Set Position GH Go Home SQ Square Root GI Go Immediate ST Stop on Input GO Go Start a Move TD Time Delay GP Go Point VE Velocity GS Gosub WT Wait GT Go to oen Message to Serial Port IF If Then Variables and Arithmetic Variables The SmartStep will accept a variables in a commands instead of a constant Examples include e Arithmetic e Conditional Expressions e Loop Counts e Distance and velocity commands Set values e Set command values or parameters e Set analog signals e Read analog or temperature input e Display information such as position or velocity e A
195. ter to allow more control of your system and greater capacity for applications The Setup Wizard remains available at any time by clicking on the Wizard button The Axis Setup I O Setup and Misc toolbar buttons provide access to the setup parameters that will be explained throughout the remainder of this chapter Setup Tool Bar Buttons To access the setup windows and menus simply click on the desired toolbar buttons as shown here m i wise Y o Y Sew Chapter 8 Programming With Serial Communication Axis Setup Axis Setup Click on the Axis Setup button The first menu to appear will be the Motor menu as shown below Note please refer to Chapter 5 for detailed descriptions of setup parameters IA Axis Setup Axis 1 Axis 1 is automatically selected SmartStep is a single axis drive Configure each parameter as it applies to your application Motor Encoder Mechanics Jog Limits Motor Menu shown above Settings for Drive Type Resolution Stop Decel Rate and motor Directions are selected in the Motor menu Motor Type automatically defaults to Stepper no options 8 9 Chapter 8 Programming With Serial Communication Encoder Menu If you are not using an encoder only the Encoder Mode must be configured Ensure that OPEN LOOP is selected if you are not using an encoder and skip to the Mechanics menu 4 Axis Setup SmartStep Mechanics Menu The Mechanics menu allows you to
196. tests are performed by toggling the F1 F2 and F3 buttons Disabl Enable F1 allows you to disable the amplifier and manually turn the motor shaft As you turn the shaft you should see position changes on the first line of the display i e plus positions in one direction and minus positions the other direction OneRMov F2 allows you to command the motor to turn one full revolution in either direction Selecting OneRMov gives you two choices EXTEND moves the shaft in one direction and RETRACT moves it back FindZ F2 commands the motor to rotate until it finds the Z pulse position This allows you to accurately center the position of the Home switch Enc One 0 0000 Disabl OneRMov FindZ ENC AXIS 1 0 0000 EXTEND RETRACTS Find Z Marker Chapter 4 Using the Keypad Using the EDIT Menus Pressing the EDIT key reveals three sub menus called PROG ____ JEDMI BETUR and PUR PROG SETUP POS Pressing the 1 or key reveals three more EDIT sub menus VEDIT eos called LIST and TUNING LIST TUNING Access the PROG SETUP POS LIST and TUNING menus by pressing the appropriate function key Descriptions of these sub menus follow Using the PROG Sub menu to Create and Edit Motion Control Programs This menu allows you to edit an existing program or enter a new program from the keypad Use the numeric keys to enter a program number to start a new motion program or
197. the Stop Decel Rate USING THE GI COMMAND EXAMPLES The following examples are provided to help further explain the use of the command A If a GI move is in progress and an additional move is commanded on the same axis the additional move will not begin until the GI move has completed For example VEI DA100 GI OT1 1 DAO GI IF1 1 MS1 All moves done TD5 EB In this program one may expect to see the message All moves done immediately after the DA100 move begins In reality the program will wait at the DAO GI until the DA100 move has completed before continuing More simply stated a move cannot be commanded to begin on an axis that is already moving Chapter 6 Programming Commands B Since allows program execution to continue there can be programming issues when using GI For example in the following program fragment Axisl Outputl Axisl Outputl V LP VE2 DI10 GI OTI TD1 EB The programabove will functies shown hee 1 second 1 second NOT as shown here X V After the first pass through the Loop command LP will wait at the GI command since subsequent GI moves must wait for the present move to finish Chapter 6 Programming Commands Go Start a MOVE syntax GO or GOi v1 00 Units n a Range i 1 16 Default n a GO executes a move profile defined by some combination of AC VE DE DI
198. the positive direction at a speed of 20 Chapter 6 Programming Commands Go Immediate syntax GI or Gli v1 00 Units n a Range n a Default n a The GI command begins a defined move profile in the same manner as the GO command Unlike the GO command where program execution waits until all defined moves have terminated GI allows program execution to continue once the move has begun This allows for other program defined processes to take place while an axis is moving such as independent multi axis moves OT commands and conditional IF blocks One axis is not required to wait for another axis to finish a move before beginning its own move Following is an example of a program using the GI command VEI DI20 GI MS1 Axis 1 is moving TD2 In this example once the DI20 move begins program execution immediately displays the Axis 1 is moving message for 2 seconds Once the TD2 command has executed the program will terminate however axis 1 will continue to move until the DI20 distance is reached A Stop Kill or press of the ESC key will halt a GI based move either inside or outside program execution The GI command can cause program execution and moves to be asynchronous In order to re synchronize the end of a GI move with program execution use the Wait WT command and its new syntax i e WT 1 will wait for only axis 1 If a program error occurs during a GI move the move will stop at
199. tion of time distance or input states e Change speed based on analog inputs or variables e Have an operator update the speed of an axis through the keypad e Servo to an analog input e Make a one or two axis joystick using analog inputs e Start a continuous move on one axis and make distance based moves on another If a motor is making a move when it comes to the end of a program the motor will continue moving even after the program ends This allows you to e Put different MC moves in different programs and select different speeds by running different programs e Change speeds based on Binary or BCD program select lines Chapter 6 Programming Commands e Call MC moves as subroutines e Run from hosted RS 232C mode where the computer commands speed changes e Run another program from the keypad that does not violate MC syntax So you could run another program from the keypad to change speeds move the other axis manipulate I O interface with an operator or calculate arithmetic Example 1 Basic Move Continuous syntax Demonstrates how to change speed and stop MC moves based on time delays and input conditions 1 50 GO TD2 VE25 GO WTI11 VEO GO Enable Move Continuous on axis 1 Set the acceleration rate Set top speed to 50 Start the Move Continuous move command processing will continue when axis reaches constant velocity Delay for 2 seconds at speed Decel to 25 Wait for in
200. tions Command Command Description and Application Examples Syntax AC Acceleration ACr Example AC10 DA Distance Absolute DAr Example DA15 DC Distance to a Change DC r Example DC20 DE Deceleration DE r Example DE 2 DI Distance Incremental DI r Example DI 3 42 EA Enable Axis EAi 1 0 disable drive i 1 enable drive i 2 standby Example EAO disables axis GH Go Home Example GH10 GI Go Immediate Gl Gli GO Begin Move GO GOi MC Move Continuous MC OT Set Outputs OTi iii Example OT5 101 turns on outputs 5 and 7 turns off output 6 CTiii n Send String Over Serial Port user text Example GO End of Move sends End of Move out serial port after move RG Registration RGr Example RG3 5 SP Set Position SPr Example SP15 0 set axis position to 15 0 sQ Square Root SQr var Example SQ16 x ST Stop on Input STi Example ST4 DI50 GO motor will decelerate to a stop or remain stopped if input 4 is activated STO disables the input TD Time Delay TDr Example OT1 1 TD 12 OT1 0 Turn Output 1 on for 120 msec VE Velocity VEr Example VE50 sets speed for the next move to 50 in units set by the VU command 8 31 Chapter 8 Programming With Serial Communication Serial Programming Commands The commands in this category may be sent to the SmartStep s buffer and executed on a first in first out FIFO basis This execution does
201. to STEPPER SETUP i OFF i Chapter 5 Configuring Your System 5 14 Configuring Idle Mode ILi SETUP MOTOR TYPE STEPER REST Default OFF When Idle is enabled the motor current is reduced to 7546 of the programmed value if no motion occurs for 10ms Full programmed current is restored on the first pulse of the next move ty Axis One Idle Mode 2 Use arrows 1 to select ON or OFF 1 OFF i Configuring Drive Resolution MR10 SETUP MOTOR D RES ee ine Default 36000 steps rev fixed 1 The Drive Resolution is fixed at 36 000 as shown in the display example above Configuring Motor Direction MDi gt SETUP gt MOTOR gt DIR oe poate pe Default POSITIVE This option provides a convenient way to change which direction the motor moves when you program a positive distance command When POSITIVE is selected as the motor direction the EOT limit switch should be wired so that moves in the plus direction as shown on the keypad display or via the PA command will activate the switch When NEGATIVE is selected the EOT limit switch should be wired so that moves in the negative direction as shown on the keypad display or via the PA command will activate the switch 1 Usethe 1 and ENTER keys to select a direction Chapter 5 Configuring Your System Configuring Your Encoder If you are not using an encoder only the enc
202. ts 1 8 22 23 Common 24 25 OPTO 44 88 Chapter 5 Configuring Your System 5 Configuring Your Inputs amp Outputs I O Your SmartStep has eight optically isolated inputs and eight discrete optically isolated outputs which may be configured to specific machine control functions see page 5 22 for details Unlike other IDC SmartDrives the SmartStep does not have I O positions However the SmartStep does have provisions for convenient connections and conditioning of machine I O A variety of SmartStep I O accessories shown below are available to suit your application requirements SmartStep I O Accessories Accessory P N Description OPTO44 OPTO Rack that accepts up to 8 optional conditioning modules See Opto Module in table in Chapter 9 Hardware Reference for list of modules available from IDC OPTO88 OPTO Rack that accepts up to 16 optional conditioning modules See Opto Module table in Chapter 9 Hardware Reference for list of modules available from IDC DB25BO Screw Terminal Breakout Board See connection information in Chapter 9 SS PNP BO Screw Terminal Breakout Board to Convert to Sourcing Outputs See connection information in Chapter 9 SS IO SS IO 6 I O cables that connect SmartStep to other devices or a PLC SS I O is 2 ft 58 0 6 is 6 ft Cable for connecting SmartStep to PC 9 pin Comm Port PCS 4991 PCS 5004 PC Keypad Cable fo
203. ts velocity to value in variable Displays current position of axis 2 on keypad screen Sends the current position of axis 1 out the RS 232 port of the Smart Drive Reads in temperature from an analog input Stores the value of Pieces in the FLASH variable F1 Using the Built In Variable AROWREL AROWREL is a built in Boolean read only variable which determines the status of any of the 4 arrow keys When used in conjunction with FKEY the user can detect whether or not an arrow key is being held down AROWREL will return one of the following values AROWREL 0 One of the arrow keys is being held down AROWREL 1 The arrow key has been released AROWREL will return key status for the 4 arrow keys only If any other key is pressed AROWREL will return zero regardless if the key is held down or not The following is an example jog application using AROWREL and FKEY MAIN Program 1 FK12 13 Wait for a Left or Right arrow key GT FKEY Jump to arrow key program 12 or 13 LEFTARROW Program 12 MC Enable MC mode AC 1 Start MC move VEI Move in positive direction GO LP IF AROWREL 1 Check status of arrow key VEO Stop MC move on key release GO GTI Return to main program EB EB End loop block RIGHTARROW Program 13 MC Enable MC mode AC 1 Start MC move VE 1 Move in negative direction GO Chapter 7 Programming Your Application LP IF AROWREL 1 Check status of arrow key V
204. use the and keys to scroll through the list of existing programs To Create a New Program 1 2 Press PROG and you will see a display with a gt Press EDIT EDIT PROGRAM blinking cursor as shown to the right Enter an identifying number that will be used later to call up the program The number you enter may be from 1 199 1 400 with 30k memory option but do not use a number that is already being used for another program If the SmartDrive contains several programs scroll the list to determine a number that has not been used Note You may assign a name rather than a number to your program if you wish See Naming Your Programs later in this chapter Press ENTER You will see a completely blank display screen with only a blinking cursor in the upper left corner The SmartDrive is now ready to accept a program Once inside the program editor you will enter commands by pressing a function key and then a numeric key Examples of creating saving naming and editing programs follow 4 9 Chapter 4 Using the Keypad Entering Commands with the Number Keys The programming commands on the number keys have been color coded to match the color coded function keys F1 F2 F3 For example the yellow function key F2 will be used to enter all yellow colored commands on the number keys e g AC command on the number 2 key To enter a command 1 Press the function key that matches th
205. utput Output on power up fault Scan de The configuration setup file is viewed by clicking on the View Configuration button Chapter 8 Programming With Serial Communication Sample configuration file continued Open loop r resolution owing error Range Range Time Method mum vel el limit hunt feed forward gain feed forward gain gain f Clamp current units Anti Res inductance current rm O disabled 1 1 O disabled 1 1 Programs End download O1LEX 8 25 Chapter 8 Programming With Serial Communication Command Syntax 8 26 All Deal commands use two letter UPPER CASE ASCII characters Command delimiters can be a carriage return cr or space sp character The commands that follow define IDC s command syntax A brief command description is given here but the full command definition is found in Chapter 5 This listing is intended only to help programmers with command syntax Deal programming commands are defined in Chapter 6 The table below describes the abbreviations and format used in our command syntax definitions Letter or Description Symbol n Unit address number is optional with RS 232C and the command is sent to all units if no address is specified All Status commands require an address Example n AUi RS 485 users must address all commands Field separator a Alphab
206. utputs ON OFF 6 24 Enable Amplifier 6 6 If Conditional 6 15 Quote 6 24 End Block 6 7 Input Variable 6 16 Registration 6 25 End Routine 6 7 Loop 6 17 Set Position 6 26 Serial Setup Commands Acceleration Max 8 27 Fault Line Polarity 8 28 Jog Enable 8 28 Rel Configuration 8 29 Acceleration Units 8 27 Units Ratio 8 28 Jog High Velocity 8 29 ited Pos Maint Gain 8 29 Anti Resonance 8 27 Home Edge 8 28 Jog Low Velocity 8 29 Maul Power Up Program 8 29 Display Format 8 27 Home Final Direction 18 28 Motor Dir Reference 8 29 Pos Maint Max Vel 8 29 Distance Unit Label 8 27 Homing Mode 8 28 Motor Inductance 8 29 Password 8 30 Scan Delay 8 27 Home Offset 8 28 Motor Current 8 29 Miis Rest 8 30 Enable Line Polarity 8 27 Home Switch 8 28 Motor Resolution 8 29 Scan Conditions 8 30 Encoder Mode 8 27 Input Definition 8 28 Motor Type 8 29 Stop Decel Rate 8 30 Encoder Resolution 8 28 Idle 8 28 Maximum Velocity 8 29 Unit Number 8 30 E O T Switch Polarity 8 28 Pos Maint Deadband 8 28 Output Definition 8 29 Velocity Units 8 30 Following Error Limit 8 28 Jog Acceleration 8 28 3 Output State on Event 8 29 7 Waveform 8 30 Serial Immediate Status Commands W Clear Buffer 8 35 Number Reset System 8 36 Tell Drive Status E 0 Tell Output States 8 35 ES Tell System Status K M Tell Absolute Position 8 35 IS Tell Axis Status 8 37 Serial Supervisory Commands
207. vice routine program 98 To summarize when INT98CTRL 1 If ARM INT98 0 Interrupts are ignored This allows for input debouncing and controlling the ability of program 98 to interrupt itself If ARM INT98 1 The system is awaiting the first INT98 input assert edge Once the interrupt is seen the control will go to program 98 and ARM INT98 is internally set to 0 on the first edge if the previous ARM INT98 value was 1 Interrupt processing will be suspended until ARM INT98 is reset to 1 Subsequent interrupts are ignored until ARM INT98 is reset to 1 INT9SCTRL ARM INT98 are reset to default values on power up Note There is a space in ARM INT98 When activated any executing program or functional operation is terminated and program I98 interrupt program is immediately executed If a move is executing when the interrupt is activated the move is terminated decelerated at a rate determined by the Stop Deceleration rate setup parameter The unit will go into Run mode once program I98 is completed J Jog Speed J specifies axis 1 This input works along with the Extend Jog and Retract Jog When a jog input is activated the control checks the state of this input to determine the jog speed If the input is OFF the system will jog at the Jog Low speed If the input is ON it will jog at the Jog High speed If the input is not configured the jog inputs will induce motion at the low speed K Kill Motion Causes th
208. ysical work area is restricted Incremental DI and absolute moves may be mixed the control always keeps track of the absolute position Examples AC2 DE 5 VEI2 DA3 GO Moves to absolute position 3 units DA3 GO DA3GO Moves once to absolute position 3 units 6 3 Chapter 6 Programming Commands 6 4 DC Distance to Change cina nada asian ibd aa ni nain syntax DC r v1 00 Units selected from the EDIT SETUP MECH menu Range unit scaling dependent Default n a DC is used to define complex multiple velocity move profiles or to change an output at a specific point during the move It defines the distance at which a change will occur the fly while the motor is still moving At the specified distance you can change the velocity or change the state of one or more outputs The DC command must follow the DA or DI commands which specify the total move distance The DC distance is interpreted as an absolute position when used with DA and an incremental position when used with DI When used with DI the value of DC must be specified as a positive number When multiple DC s are specified within an incremental move DJ the incremental distance specified by the DC command is taken from the last DC command not from the beginning of the move See the incremental move examples below for more clarification The standard software supports a maximum of 20 DC commands within a move profile Application Note The DC comma

User`s Manual - Motor Systems, Inc.

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