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Power Mate J for Series 90-30 User`s Manual, GFK-1256

1. 1 16 Table 1 7 Power Mate J Specifications Ss eneg eeii saoe na eens 1 18 Table 2 1 Module Configuration Data 6 nee eens 2 3 Table 2 2 Serial Communications Port Configuration Data ooooocooocooorrorooooccnn ee 2 6 Table 2 3 Axis Configuration Datat tnh iah ta ie nee 2 7 Table 2 4 Program Zero Motion Program Commands 6c ccc ee 2 13 Table 3 1 I Status Bits 1 Axis Ar AEAEE EEREN nen etn et ene tenn ences 3 2 Table 3 2 Vol Status Bits 2 Asds il Sie bbe Pe ee eee eS ee ee eee She Oe eee 3 3 Table 3 3 AI Status Words 1 Axis 00 ee ete etn t ene tenn ene eae 3 5 Table 3 4 AI Status Words 2 AXiS 0 0 ee etn tenn t rererere 3 5 Table 3 5 Q Discrete Commands 1 AXiS 6 eee cnet eee ene eae 3 8 Table 3 6 Q Discrete Commands 2 AXiS 6 ee ence etn net teen ences 3 9 Table 3 7 Immediate Commands Using the 6 Byte Format 0 6 66 3 12 Table 3 8 DST Status Bits viii hs Seed eet ENEE See SE Be eet 3 18 Table A 1 Status Word Error Codes oeh aas ia a ccc ccc cece een t teen ene een e eae A 3 Table A 1 Status Word Error Codes Continued 00 cece o A 4 Table A 1 Status Word Error Codes Continued 0 0 eee teen eens A 5 Table B 1 Power Mate J Interface Module Internal Status Alarms 00 c cece nee B 3 Table B 2 Power Mate J Servo Status Alarms 000 c cece cect ence eens B 4 Table B 3 Status Alarms 0 cee cee ee teeta A
2. Chapter 1 Product Description Power Mate APM to DSI High Speed Serial Communications Table 1 6 High Speed Serial Communications Power Mate APM to DSI JD35 Connector a Ja o RA JR sp Pp a The connector contains three RS 422 signal pairs SDIN SDIN SDOUT SDOUT and SDCLK SDCLK These must be connected as twisted pairs Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 High Speed Serial Cable Diagram The following figure is a High Speed Serial cable diagram for the cable that connects the Power Mate APM module to the DSI a45640 Interface Module Connector ControllerModule Connector B JD35 DSI Power Mate APM 24 Pin i i 20 Pin Male Male connector Fujitsu Honda connector connector connector Figure 1 15 Controller Module to Interface Module Cable Diagram Cable Components m The cable should be made from high speed communications data quality cable consisting of 28 AWG wire x 4 twisted pairs with an overall shield m 20 Pin Female Honda solder connector kit m 24 Pin Female Fujitsu connector kits Note An eight inch pre fabricated High Speed Serial Power Mate J cable is included with the Power Mate J GFK 1256 Chapter 1 Product Description 1 17 Power Mate J System Specifications Table 1 7 Power Mate J Specifications ControllerModule Power Mate APM Power Supply Voltage PowerSupply Current Available 5V Current Module Interf
3. GFK 1256 Chapter 4 Motion Control 4 15 Subroutines The Power Mate J can store up to ten separate programs and forty subroutines Subroutines can be defined as two types single axis and multiaxis Commands within single axis subroutines do not contain an axis number this allows single axis subroutines to be called from any single axis program written for either axis 1 or axis 2 Commands within multiaxis subroutines contain axis numbers just like commands within multiaxis programs multiaxis subroutines can only be called from multiaxis programs or subroutines Single axis subroutines can only be called from single axis programs or subroutines On a two axis Power Mate J a single axis program for axis 1 and a single axis program for axis 2 can call the same single axis subroutine simultaneously The CALL command is used to execute a subroutine with the subroutine number specified as an argument Program execution continues at the start of the subroutine and resumes at the command after the CALL command when the subroutine finishes Subroutines can be called from another subroutine but once a subroutine has been called it must be completed before it can be called again for the same axis Thus recursion is not allowed Block Numbers and Jumps Block numbers are used as reference points within a motion program and to control jump testing A AI data word displays the current block number which can be monitored to ensure correct program execu
4. cece eee eens B 4 Power Mate J InternalAlarms 20 0 cece eee eee eee B 5 Appendix C Data Parameters From the PLC cc cee eee eee cee eee C 1 Appendix D Serial Encoders teve ordre cds tense Keele a ee D 1 Serial Encoder Models 0 00 cece teen eens D 1 Serial Encoder First Time Use or Use After Loss of Encoder Battery Power 666 cece eee eee D 1 Serial Encoder Modes 0c e eee cece teen e een eee eee D 2 Limitations on Total Travel for FOT Mode 0 002 0 eee eee D 2 Incremental Encoder Mode Considerations 0e eee eee D 3 Absolute Encoder Mode Considerations 0 eee eee ee eee D 3 Absolute Encoder Mode Position Initialization D 3 Absolute Encoder Mode Power Mate J Power Up 5 D 4 Absolute Encoder Mode with Rotary Mode 0 0 20005 D 4 GFK 1256 Power Mate J for Series 90 30 User s Manual August 1996 vii Contents Figure 1 1 Power Mate 00 040 la e aa ri 1 1 Figure 1 2 Power Mate J System Block Diagram ooooooooccocccnnnnrrrrrrrro eee eee 1 2 Figure 1 3 Controller Module LEDs and Connectors 0 6 ccc eens 1 3 Figure 1 4 Connecting Power Mate J Modules in a multidrop Configuration 1 5 Figure 1 5 Multidrop Cable for the Power Mate J 066s 1 5 Figure 1 6 I O Cable and Terminal Block 0 666 eee 1 6 Figure 1 7 Enable Relay Output Ci
5. Move At Velocity AQ Immediate Com mand Move at Velocity Command 4 4 Move Commands Programmed 4 10 Move Continuous CMOVE Move Positioning PMOVE 4 10 Move and Move Modes Moves Programmed Moving l Status Bit 3 3 MultiAxisProgramming Multidrop Connection 1 5 Multiple Alarms N Neg EOT Negative Software End of Trav el Negative End Of Travel 2 7 Non Programmed Motion Normal Stop Before JUMP Null 4 6 Power Mate J for Series 90 30 User s Manual August 1996 Null AQ Immediate Command O OK LED Open Loop Mode 2 15 OT Limit SW Other Considerations Other Programmed Motion Consider ations 4 25 Out of Sync Override Feedrate Overtravel Limit Switch p 7 Overview of PM J System 1 2 P Parameters for Programmed Moves distance to move position to move to 4 7 type of acceleration 4 7 type of positioning reference h 7 Parameters in the PM J a 30 Parity Pin Definitions of the Serial COMM Con nector PLC Configuration Complete I Status BtB PLC Control Active I Status Bit 8 4 PM APM 1 18 PM J 1 1 PMOVE 4 10 PMOVE Command Program Zero 2 14 Ports and Connectors 1 15 Pos Positive Software End of Travel 2 8 Pos Err Lim Position Error Limit 2 8 Pos Loop TC Position Loop Time Constant Position Error Limit b 7 Position Feedback Types Position Increment AQ Immediate Com ma
6. Unconditional Jumps do not force the axis to stop before jumping to a new program block For example a CMOVE followed by a JUMP Unconditional to another CMOVE will behave just as if the two CMOVEs occurred without an intervening Unconditional JUMP If Conditional Jump testing is active when the Power Mate J command processor encounters a CALL SUBROUTINE command the axis will stop and terminate jump testing before the CALL is executed If Conditional Jump testing is active when the Power Mate J command processor encounters an END SUBROUTINE command the axis will stop and terminate jump testing before the END SUBROUTINE is executed Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Jump Testing Conditional jumps perform jump testing If the CTL bit is ON the jump is immediately performed If the CTL bit is OFE the Power Mate J watches the CTL bit and keeps track of the JUMP destination This monitoring of the CTL bit is called jump testing If during jump testing the CTL bit turns ON before a BLOCK command another JUMP command or a CALL command is encountered the jump is performed These commands will end jump testing Example 7 Jump Testing Consider the following two program sections In the program on the left the move to position 2000 is completed before jump testing begins The BLOCK command immediately after the JUMP command ends jump testing Thus the duration for which the CTL bit is monitored is ver
7. sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply The following are trademarks of GE Fanuc Automation North America Inc Alarm Master GEnet PowerMotion Series One CIMPLICITY Genius ProLoop Series Six CIMPLICITY PowerTRAC Genius PowerTRAC PROMACRO Series Three CIMPLICITY 90 ADS Helpmate Series Five VuMaster CIMSTAR Logicmaster Series 90 Workmaster Field Control Modelmaster Copyright 1996 GE Fanuc Automation North America Inc All Rights Reserved Preface This manual describes the Power Mate J which is a complete Series 90 30 integrated motion control system The Power Mate J system consists of two Series 90 30 modules a controller module and an interface module which communicate over a high speed serial link The controller provides the position control motion program and interface to the I O The interface module is the interface to the digital servo system providing digital torque and velocity control Content of this Manual Chapter 1 Product Description This chapter provides a description of the controller and interface modules including module features specifications and I O connections Chapter 2 Installation and Configuration This chapter provides information on installing the Power Mate J in a Series 90 30 PLC system and configuring the modules with Logicmaster 90 30 software Chapter 3 Power Mate J to PLC Interface This chapter d
8. 16 bits of I data GFK 1256 Section 1 Power Mate APM Command and Status Data Controller Module l Status Bits PM APM The following I Status Bits are transferred automatically from the controller to the CPU each sweep The actual addresses of the Status Bits depend on the starting address configured for the I references The bit numbers listed in the following table are offsets to this starting address Table 3 1 l Status Bits 1 Axis 00 AxsEnabled ANT 06 PositonSiobe ANT MIN ET Co reserved The bit numbers represent an offset to the starting address for I references 3 2 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 Table 3 2 l Status Bits 2 Axis 00 AxisEnabled Axisl Front Panel Input CTLO1 Status Strobe 1 State Front Panel Input CTLO2 Status Strobe 2 State Front Panel Input CTL03 Status Home Switch 1 Overtravel 2 Home Switch 2 06 PositionStrobe Ast _ 08 Axistnabled Axis 09 Position Valid Axis Position Strobe Axis2 PLC Control Active InErrorLimit Axis The bit numbers represent an offset to the starting address for I references Axis Enabled The Axis Enabled status bit is ON when the controller is ready to receive commands and control a servo An error condition which stops the servo will turn Axis Enabled OFF Position Valid The Position Valid status bit indicates that the value in the AI Actual Position status word has b
9. 16384 and so forth Under this condition the controller will always initialize Actual Position to the correct rotary position after a power cycle 2 If the power of 2 condition for Rotary Count Modulus is not met the rotary motion must be limited to a range of 268 427 264 counts after a Set Position or Find Home position reference operation This restriction can be handled in some systems by periodically performing a Set Position when the axis is stopped and holding a known rotary position Note Performing a Set Position or Find Home cycle in Absolute Encoder mode causes the controller to recalculate the encoder Absolute Feedback Offset An Update Flash Memory command must always be sent to permanently save the new Absolute Feedback Offset The flash memory in the controller has a limited number of update cycles 20 000 100 000 cycles This limitation should be considered if a system design required the Absolute Feedback Offset to be saved more than 10 times per day GFK 1256 Appendix D Serial Encoders D 5 Symbols AI Position Error AI Status Words B 5 Actual Velocity B 7 Commanded Velocity B 7 Actual Position Command Block Number Commanded Position 3 6 Status Code Strobe Position B 6 for the 1 Axis B 5 for the 2 Axis B 5 AQ Immediate Commands Load Parameter Immediate Absolute Feedback Offset Configuration Modes Force D A Output B 13 In Position Zone Jog Acceleration Jog Velocity Move B 1
10. used and this setting is used to configure Velocity Loop Gain Default 0 Note Configuration software prior to Release 7 0 only allows Intgr TC to be 0 or 0 10 000 Configuration software versions 7 0 and later allow a range of 0 10 000 Therefore VLGN values of 1 9 can only be configured with Configuration software versions 7 0 and later Intgr Mode Integrator Mode Operating mode for position error integrator However the position error integrator is not used for DIGITAL mode of operation The Integrator Mode field is used to configure Incremental or Absolute feedback type for the digital serial encoder OFF or IN ZONE means that feedback counts from the serial encoder will be interpreted as INCREMENTAL counts encoder battery alarms are not reported CONTINUOUS means the serial encoder feedback will be considered as ABSOLUTE battery alarms will be reported See Appendix D for more information about using absolute mode encoders Default OFF Selects Incremental Encoder Rev Comp Reversal Compensation User Units A compensation factor which allows the servo to reverse direction and still provide accurate positioning in systems exhibiting backlash Default 0 Chapter 2 Installation and Configuration 2 9 DisDly Servo Drive Disable Delay milliseconds The time delay from zero velocity command to the drive enable output switching off Disable Delay is effective when the Enable Drive Q bit is turned off or certain error condit
11. 01h the Q Enable Drive ON OFF command Enables and Disables servo power to the motor The motor shaft will have no torque when the Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 servo power is Off The MCON relay will remain energized This function is useful when the torque must be removed and reapplied repeatedly from the motor and will help avoid wear on the MCON relay With MCON CTL set to 01h a Q CTL output will control the ON OFF state of the magnetic contactor MCON CTL11 is the Axis 1 MCON control output CTL12 is the Axis 2 MCON control output for the two axis Power Mate J Absolute Feedback Offset This command updates the Absolute Feedback Offset counts used to initialize Actual Position from an AbsoluteDigital Encoder To permanently save the encoder offset entered with this command the Update Flash Memory AQ command must also be used Normally the Absolute Feedback Offset is calculated automatically by the Set Position or Find Home commands Refer to Appendix D Serial Encoders for additional information Set Configuration Complete This command sets the Configuration Complete l bit Once set the Configuration Complete bit is only cleared when the PLC resets or reconfigures the controller module The PLC can monitor the bit to determine if it must resend other AQ commands such as In Position Zone or Jog Acceleration This would only be necessary if the AQ commands were used to override contr
12. 1 Section 2 Configuring the Power Mate J Using Logicmaster 90 30 Controller Configuration Power Mate APM The controller module Power Mate APM is configured using the Logicmaster 90 30 configuration software Configuration is a two part procedure consisting of m Rack Slot Configuration m Module Configuration Rack Slot Configuration Logicmaster 90 30 is used to define the type and location of all modules present in the PLC racks This is done by completing setup screens which represent the modules ina baseplate and saving the information to a configuration file which is then downloaded to the CPU Once a baseplate and slot location is defined for the Power Mate APM you can continue to the second part of the configuration process Module Configuration Module Configuration This section is divided into three parts m Setting the Configuration Parameters m Essential Configuration Parameters Important Configuration Considerations 2 2 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Setting the Configuration Parameters Aswith I O Rack Configuration module configuration is done by completing screens in the Logicmaster 90 30 configuration software The Series 90 30 Hand Held Programmer can only configure the Module and Serial Port Configuration Data Controller module configuration data consists of four types m Module Configuration Data Programmer Port Configuration Data m Axis Configura
13. 1996 GFK 1256 Example 14 S CURVE Jumping to a Higher Velocity While Acceler ating or Jumping to a Lower Velocity While Decelerating In this example a JUMP command is triggered during the initial phase of acceleration before the first dotted line and the velocity at the jump destination is higher than that of the current move The first dotted line indicates the maximum acceleration of the first CMOVE This value is held as the axis continues to accelerate until it s curves back to constant velocity Constant velocity the second dotted line indicates the beginning of the second CMOVE This move continues until it decelerates to zero at the end of the program ACCEL 50000 VELOC 30000 BLOCK 1 JUMP CTLO2 2 CMOVE 150000 INC SCURVE BLOCK 2 VELOC 90000 ACCEL 25000 CMOVE 500000 INC SCURVE V a45267 t Figure 4 15 Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating Other Programmed Motion Considerations GFK 1256 Maximum Acceleration Time The maximum time for a programmed acceleration or deceleration is 64 seconds for the 1 axis Power Mate J and 128 seconds for the 2 axis Power Mate J If the time to accelerate or decelerate is computed to be longer than this time the Power Mate J will compute an acceleration to be used based on 64 or 128 seconds To obtain longer acceleration times multiple CMOVEs with increasing or decreasing velocities must be used Example 15 Maxim
14. 30 User s Manual August 1996 1 0 Connector A GFK 1256 Functional Connection Diagram 2 Axis 1 0 CONNECTOR A VO CONN TERM BLK TERM A8 B7 A7 B6 B12 B11 A12 B10 A11 B9 A10 A9 B8 A5 A6 B5 B4 B12 B3 A4 A1 B2 A3 4 17 3 16 13 18 5 19 6 20 8 21 14 15 13 22 23 10 ENABLE RELAY OUTPUT ENABLE RELAY OUTPUT 5 VDC POWER 0 VOLTS AXIS 1 NEGATIVE OVERTRAVEL LIMIT SWITCH HOME SWITCH or ON a47109 AXIS 1 POSITIVE OVERTRAVEL LIMIT SWITCH OT CTLO6 CTLO3 HOME1 rt OT CTLOS HOME2 a q Ht INCOM1 l SHIELD STROBE 1 CTLO1 aah STROBE 1 CTLO17 I OV STROBE 2 CTLO2 STROBE 2 CTLO2 lt 5V DRIVER GENERAL PURPOSE 5V INPUTS 5V DRIVER Figure 1 13 Connection Diagram for 2 Axis Power Mate J Digital Mode 1 0 Connector A Note If the Axis 1 Overtravel limit Switches are disabled in the Configuration Software then CTLO5 is available for use as the Axis 2 Home Switch Overtravel Limit Switches are not available for Axis 2 when the controller is used with the interface module GFK 1256 Chapter 1 Product Description 1 13 Interface Module DSI The interface module is a standard PowerMotion single slot module The interface mod ule allows the motion controller to interface to
15. BY BLKMV R0201 NO_USE2 NOT USED ZEROED BY BLKMV RO202 CMDTYP COMMAND TYPE E501 FOR APM R0203 BYTECNT BYTE COUNT OF DATA RO204 MEMTYP MEMORY TYPE OF DATA 8 REG R0205 DATAST START OF DATA BLOCK 1 205 R0206 RO206 PAR_NO STARTING PARAM NUMBER R0207 NO_VALS NUMBER OF PARAMETERS TO SEND RO208 RO239 PAR DAT Data for 16 Parameters 32 words GFK 1256 C 1 CREARAAA AA AAA A AAA A AAA AAA AA AAA IAA KAA AA AAA AAA AA AK KK AKIRA KAA AAA A HAHA RE CLEAR THE REGISTER BLOCK THEN LOAD THE COMM_REQ HEADER DATA 5 AAA A A A A A A A O A TS ARA OA OS O ER S SEND STOO1 k 23 gt Hd a Bie tS SS a BLKMV CLR_ INT WORD CMREQST CONST IN1 Q R0195 R0195 IN 00000 LEN 00045 CONST IN2 00004 4 CONST IN3 00000 CONST IN4 00008 CONST IN5 00194 CONST IN6 00000 CONST IN7 00000 RRR RR KARR RR KR KK KR KR KR KAKA RR KR RRR SRK IK KAA AA AR AKIRA KAKA AK AKA RK Y PUT THE COMMAND TYPE E501 IN THE FIRST DATA WORD R202 PUT THE BYTE COUNT OF THE DATA IN THE NEXT WORD R203 PUT THE MEMORY TYPE OF THE DATA 8 REG IN THE NEXT WORD R204 PUT THE z STARTING LOCATION OF THE DATA BLOCK 1 IN THE NEXT WORD R205 PUT THE STARTING PARAMETER NUMBER 1 IN THE LOWER BYTE OF R206 AND THEN THE NUMBER OF PARAMETERS TO BE SENT 16 IN THE LOWER BYTE OF R207 open eRe CoA aOR ON eR en ea en Coe o eM ee
16. Execute Motion Program4 Execute Motion Program5 Execute Motion Program7 Execute Motion Program8 Execute Motion Program9 Execute Motion Program 10 The bit numbers represent an offset to the starting address for Q references Execute Motion Program1 06 ExecuteMotionProgram2 Execute Motion Program3 08 ExecuteMotionProgram4 09 ExecuteMotionProgram5 10 reserved 26 Execute Motion Program6 a 11 Execute Motion Program7 Execute Motion Program8 Execute Motion Program9 Execute Motion Program10 3 8 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 Table 3 6 Q Discrete Commands 2 Axis MN AbortAlIMoves IN IL CTL CUA CTA IR 06 ResetStrobeFlag Ast 05 AbortAIMoves Axis 09 Reedhoid AB Execute Motion Program 10 ResetStrobe Flag Axis2 Execute Motion Program10 The bit numbers represent an offset to the starting address for Q references Abort All Moves This command causes any motion in progress to halt at the current Jog Acceleration rate Any pending programmed or immediate command is canceled and therefore not allowed to become effective The abort condition is in effect as long as this command is on If motion was in progress when the command was received the Moving status bit will remain set and the In Zone status bit will remain cleared until the commanded velocity reaches zero and the In Zone condition is achiev
17. Power Mate J modules can be installed in any I O module slot in the CPU rack in any expansion rack or in any remote rack in the Series 90 30 PLC However for best performance they should be located in a CPU rack orin a local expansion rack Programmer Series 90 30 Hand Held Programmer Logicmaster 90 30 Programming Software Configuration release 6 01 or later The Power Mate J system is not compatible with earlier versions of the Logicmaster software When using the Logicmaster 90 30 configuration software the DSI must be configured as a generic 16 point input module Beginning with Logicmaster 90 30 Programming Software release 7 01 or later the DSI will exist as a configuration selection within the configuration software CIMPLICITY Control 90 30 With CIMPLICITY Control 90 30 version future product the DSI will exist as a configuration selection within the configuration software No further configuration of the DSI itself will be required Any additional configuration requirements will be satisfied through enhancements to the configuration of the controller module Controller Modules The interface module must be used with controller modules release 2 50 or later IC693APU301K or IC693APU302K When a two axis controller module is configured to work with a digital servo on one axis it cannot simultaneously be configured to work with an analog servo on the second axis Caution The controller module must be at least relea
18. Velocity Feed forward is used to produce the ve locity command output to the interface module The Position Loop Time Constant will not be accurate unless the Vel at 10 V value is set correctly Default 1000 Velocity at 10 Volts All controller module and servo functions depend on this value being correct for proper operation The Velocity at 10 v configuration field should be set to a conversion constant value of 139820 multiplied by the decimal value of the User Units to Counts ratio For example with a User Unit value of 1 and a Counts value of 2 the decimal value of the ratio would be 0 5 The conversion constant multiplied by 0 5 yields the value 69910 for the Velocity at 10 v 1 2 139820 69910 If the user sends the Power Mate J a velocity command which exceeds the capability of the servo system the Power Mate J will clamp that command value at the appropriate maximum boundary no error will be reported back to the controller module Default 4000 Vel FF Velocity Feed forward gain percent The percentage of Commanded Velocity that is added to the controller module velocity command output Increasing Velocity Feed forward causes the servo to operate with faster response and reduced position error Optimum feed forward values are 80 90 The Vel at 10 V value must be set correctly for proper operation of Velocity Feed forward Default 0 Intgr TC Integrator Time Constant The position error integrator in digital mode is not
19. Words contains a hexadecimal code which describes the error indicated when the Error status bit is set There are three categories of errors reported by the Status Code m Programming errors which generate a Status Only warning message m Programming errors that halt the servo m Hardware errors encoder out of sync PLC Run switches off loss of programmer comm and others Note The Status LED on the face plate of the module flashes slow four times second for Status Only errors and fast eight times second for errors which cause the servo to stop Error Code Format Error Codes are placed in the Status Code AI word as a hexadecimal value The format for the Status Code word is High Byte Bits 0 7 Error Number 0 FFh Bits 8 11 Axis Number low nibble 0 Axis Independent 1 Axis 1 2 Axis 2 Bits 12 15 Response Method high nibble 0 Status Only 1 Stop Normal 2 Stop Fast Figure A 1 Status Code Organization Response Methods 1 Status Only Errors Set the error flag and status code but do not affect motion 2 Stop Normal Errors Perform an internal abort of any current motion using current Jog acceleration and acceleration mode LINEAR or S CURVE The Drive Enabled and Axis Enabled I bits are turned OFF after the configured Drive Disable Delay 3 Stop Fast Errors Instantly abort all motion by setting the servo velocity command to zero The Drive Enabled and Axis Enabled I bits are turned off after
20. a47102 VOUT 1 ANALOG OUTPUT 125A FUSE ACOM SP e gt ANALOG COMMON Auf gt oV 47 5 s ov Figure 1 8 Analog Output Circuitry GFK 1256 Chapter 1 Product Description 1 7 Strobe Inputs CTL01 CTLO2 m Input Type 5V differential or single ended m Input Impedance 4000 Ohms common mode Input Threshold Single ended 1 5 V nominal 0 4V Differential 0 5 V nominal 0 4V m Input Common Mode Range 15 V m Single Ended Input Voltage 15 V maximum m Minimum 3 microsecond pulse width is required A pulse on the strobe input causes the latest value of Actual Position to be reported in the Strobe Position portion of Al data m Position Capture Delay 0 to 1 millisecond IC693APU301 0 to 2 millisecond IC693APU302 a45272 LINE 2K LINE RCVR 7 SNA 2K ov 0 75V Figure 1 9 Strobe Input Circuitry 5 VDC Power m 5 VDC Power Non isolated current limited 5 V supply is available at the controller module s front panel I O connector A for general use Maximum load must be limited to 500 mA 40 C 104 F 300 mA Q 55 C 131 F a45112 IN OUT 5V POWER 5V tlh REG a ov ov Figure 1 10 5 VDC Power Circuitry 1 8 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 General Purpose 24 VDC Digital Inputs I OConnector A CTLO3 m CTL05 CTL06 Optically Isolated with the following specifications Optically isolated DC source sink bi
21. and directly control a Series or b Series Servo motors and amplifiers Absolute position feedback is supported with the addition of the optional battery pack to the digital servo amplifier unit a45638 Visual Status Display e Seven segment display visually indicates Power Mate J and Servo Status See Appendix B for details DIGITAL SERVO INTERFACE JS1 JS2 FANUCa Series or b Series Digital Servo Amplifier Connectors e Digital control signals to servo system amplifier e Digital serial encoder signals from motor mounted encoder e Standard FANUC type B command cables used High Speed Serial Interface to Power Mate APM Controller Module e Data Rate 1 024MHz e Directly connected to Controller Module Connector B Figure 1 14 Interface Module Visual Status Display and Connectors 1 14 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 Ports and Connectors The DSI has three connectors JS1 JS2 and JD35 All connectors are Honda Tsushin PCR20 Male connectors Premade 2 meter cables 44C742196 004 or connector kits may be ordered with your system The Power Mate APM to DSI cable 44A738935 001 is shipped with your system JS1 Connector to Servo Axis 1 Table 1 4 JS1 Connector to Servo Axis a e a Re a oo ow o ov o o JS2 Connector to Servo Axis 2 Table 1 5 JS2 Connector to Servo Axis e o o os o owa o mo o w a ov sa a o w
22. are five LEDs on the PM APM which provide status indication for the Power Mate J controller module These LEDs are described below STAT Normally ON FLASHES to provide an indication of operational errors Flashes slow four times second for Status Only errors Flashes fast eight times second for errors which cause the servo to stop OK CFG EN1 EN2 The OK LED indicates the current status of the Power Mate APM board ON When the LED is steady ON the Power Mate J is functioning properly Normally this LED should always be ON OFF When the LED is OFE the Power Mate APM is not functioning This is the result of a hardware or software malfunction This LED is ON when a valid module configuration has been received from the PLC Flashes slow four times second during the Motion Program Store function Flashes fast eight times second during the Write User RAM to EEPROM operation When this LED is ON the servo drive for Axis 1 is enabled When this LED is ON the servo drive for Axis 2 is enabled On a 1 axis Power Mate J this LED will not be on ON during normal operation unless a Force D A Analog Output is commanded Section 2 Interface Module Visual Status Display DSI Axis Error Indicator The Power Mate J Digital Servo Interface provides a 7 segment plus decimal point dis play for visually indicating the current alarm status of the module For those alarm types which apply to a particular axis as opposed
23. ee ONO een er eM ee A SEND STOOT ta Fae MOVE_ MOVE Sea MOVE_ WORD INT INT CMDTYP BYTECNT MEMTYP CONST IN Q R0202 CONST IN Q RO0203 CONST IN Q R0204 E501 LEN 00068 LEN 00008 LEN 100001 100001 100001 4 4 4 SEND T0001 MOVE_ 7 7 7 7 7 7 7 7 7 7 7 TMOVE H gt 2 25 7 7 3 MOVE_ INT INT INT DATAST PAR_NO NO_VALS CONST IN Q R0205 CONST IN Q RO0206 CONST IN Q R0207 00205 LEN 00001 LEN 00016 LEN 100001 100001 100001 4 4 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 E KR AR KERR KERR KR ARK RK RAK EKA K KEKE KEKE KES ADD LOGIC HERE TO MOVE THE PROPER CONSTANTS INTO THE REGISTERS R208 R239 SO THEY CAN BE SENT TO THE APM PARAMETERS RRR ERE KK ERK EKER EKER EERE EEE EERE KEKE E REBAR ERE ERE EERE EEK EEE EE EEE GOA pea ere to owe Meee ee a Me Cate SOR E NOW ACTIVATE THE COMM_REQ TO SEND THE PARAMETER DATA TO THE PM APM PR Se EA EA Be Be Bee A A Be Se Be EEE ARA RA SEND T0001 233 COMM_ REQ NOTE SYSID HIGH BYTE COMM_REQ RACK DESTINATION SYSID LOW BYTE COMM_REQ SLOT DESTINATION HDR_WDS RO196 IN FT TASK ALWAYS 0 F
24. for systems with an incremental feedback device that also provides a marker pulse A Home Limit Switch Input from the I O connector roughly indicates the reference position for Home and the next marker encountered indicates the exact position A Chapter 3 Power Mate J to PLC Interface 3 9 3 10 configuration option allows the Home Limit Switch to be ignored The configured Home Offset defines the location of Home Position as the offset distance from the Home Marker Position Valid indication is set at the conclusion of the Home cycle See Appendix D for considerations when using absolute encoder Jog Plus When this command bit is ON the axis moves in the positive direction at the configured Jog Acceleration and Jog Velocity as long as the Jog Plus command is maintained and the configured Positive End Of Travel limit is not encountered Jog Plus may be used to jog off of the Negative End of Travel Limit Switch if the 0 Clear Error bit is also maintained on Jog Minus When this command bit is ON the axis moves in the negative direction at the configured Jog Acceleration and Jog Velocity as long as the Jog Minus command is maintained and the configured Negative End Of Travel limit is not encountered Jog Minus may be used to jog off of the Positive End of Travel Limit Switch if the Q Clear Error bit is also maintained on Reset Strobe Flag The Position Strobe l status bit flag informs the PLC that a Strobe Input has captured an axis positi
25. go to a position less than the Negative EOT then an error will result and the controller module will not allow axis motion Default 8 388 608 If Pos Neg EOT limits are both set to zero the controller module uses 8 388 607 8 388 608 instead Pos Err Lim Position Error Limit User Units The maximum Position Error Com manded Position Actual Position allowed when the controller module is controlling a ser vo Position Error Limit should normally be set to a value 10 to 20 higher than the highest position error encountered under normal servo operation Default 4096 The range formula for Position Error Limitis 256 x user units counts lt Position Error Limit lt 60 000 x user units counts If Velocity Feed forward is not used Position Error Limit can be set to a value approximately 20 higher than the position error required to produce a 4096 rpm command The Position Error User Units required to produce a 4096 rpm command with 0 Velocity Feed forward is Position Error user units Position Loop Time Constant ms x Servo Velocity 10v user units sec 1000 If Velocity Feed forward is used to reduce the following error a smaller error limit value can be used but in general the error limit value should be 10 20 higher than the largest expected following error Note An Out of Sync error will occur and cause a fast stop if the Position Error Limit Value is exceeded by more than 1000 counts The controller
26. module attempts to prevent an Out of Sync error by temporarily halting the internal command generator whenever position error exceeds the Position Error Limit Halting the command generator allows the position feedback to catch up and reduce position error below the error limit value If the feedback does not catch up and the position error continues to grow the Out of Sync condition will occur Possible causes are 1 erroneous feedback wiring 2 feedback device coupling slippage 3 servo drive failure 4 mechanically forcing the motor encoder shaft past the servo torque capability Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 In Pos Zone In Position Zone User Units When the magnitude of servo position error is less than or equal to this value and neither Jog nor Move at Velocity is comman ded the In Zone status bit will be set In Position Zone also determines the position error at which PMOVEs are considered to be complete Default 10 Pos Loop TC Position Loop Time Constant milliseconds The desired servo position loop time constant The lower the value the faster the system response Values which are too low will cause system instability and oscillation For accurate tracking of the commanded velocity profile Pos Loop TC should be 1 4to 1 2 of the MINIMUM system deceleration time Setting Position Loop Time Constant to 0 will place the controller module in open loop mode where only
27. module firmware revision Note All AI data except Actual Velocity is updated within the controller module once every 10 milliseconds Actual Velocity is updated once every second Chapter 3 Power Mate J to PLC Interface 3 5 3 6 Status Code Status Code indicates the current operating status of the module When the Error l flag is set it contains an error code number which describes the condition causing the error For a list of Power Mate J error codes refer to Appendix A Command Block Number Command Block Number indicates the block number of the command that is presently being executed in the active Program or Subroutine It changes at the start of each new block as the program commands are executed and thus identifies the present operating location within the program Block numbers are displayed only if the motion program uses them Additionally the most recently used block number will be displayed until superceded by a new value Commanded Position Commanded Position user units is where the axis is commanded to be at any instant in time The difference between Commanded Position and Actual Position is the Position Error value which produces the Velocity Command to drive the axis The rate at which the Commanded Position is changed determines the velocity of axis motion If Commanded Position moves past either of the count limits it will roll over to the other limit and continue in the direction of the axis motion
28. of Acceleration or Decelera tion Example 14 S Curve Jumping to a High er Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating Example 15 Maximum Acceleration Time 25 Example 16 Feedhold 4 27 Example 17 Feedrate Override Example 18 Multiaxis Programming Example 2 Changing the Acceleration Mode During a Profile Example 3 Not Enough Distance to Reach Programmed Velocity Example 4 Hanging the PM J When the Distance Runs Out Example 5 Dwell 4 15 Example 6 Unconditional Jump Example 7 Jump Testing Example 8 Normal Stop before JUMP PET 19 Example 9 JUMP Without Stopping Execute Motion Program 0 10 Q Dis crete Command 3 10 F Feedback Type Feedback Types Position 4 1 Feedhold Off Transition Q Discrete Command Feedhold On Transition Q Discrete Command Feedhold with the PM J Power Mate J for Series 90 30 User s Manual August 1996 Feedrate Override 4 27 Final Home Velocity Find Home Q Discrete Command 3 9 Find Home Cycle D 3 Find Home Vel Find Home Velocity Find Home Velocity P 7 First Time Use Absolute Encoder Fnl Home Vel Final Home Velocity ForceD A Command 4 4 Force D A Output AOQ Immediate Com mand Functional Connection Diagrams for 1 Axis 1 12 for 2 Axis G General Purpose Input Circuitry H Hi Limit High Count Limit 2 10 Hi LoLimits D 2 High Limit P 7 High Speed
29. offset to the starting address for the AQ references Only 00 or FFh are acceptable xx don t care Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Null This is the default AQ Immediate command Since the AQ words are automatically transferred each PLC sweep the Null command should always be used to avoid inadvertent execution of another Immediate command Rate Override This command immediately changes the feedrate override value frequently referred to as MFO value This new value will become effective immediately when received by the controller module It is stored and will remain effective until overwritten by a different value A rate override has no effect on non programmed motion Feedrate is set to 100 whenever a program is initiated Position Increment Without Position Update user units This command offsets the axis motion from 128 to 127 user units without updating the Actual or Commanded Position The controller module will immediately move the axis by the increment commanded if the servo is enabled Move At Velocity user units sec This command is executed from the PLC to move the axis at a constant velocity The configured Jog Acceleration rate is used for Move at Velocity commands Axis position data will roll over at the configured Hi or Lo Limit when reached during these moves Set Position user units This command changes the axis position register values without moving th
30. sequence of events The DS signal indicates that absolute position data is available If no battery pack is used DS will be reset on each power cycle Absolute Data in One Revolution Incremental Data 2 En Power ON Reference Point Reference Point Encoder Counts prior to AA ye This Point are Lost DS GEK 1256 D 1 Note The a Series digital encoder must be rotated up to one full revolution after the absolute mode battery has been reattached Within one revolution the encoder will reference itself and report a referenced status DS 0 to the controller The encoder will set it s internal counts accumulator to zero at the point where DS switches to a logic zero Counts accumulated prior to the DS transition are lost Serial Encoder Modes The a Series pulse encoders can be operated in either Incremental mode or Absolute mode The Incremental mode is selected by setting the controller module s Logicmaster 90 30 configuration field Intgr Mode Integrator Mode to OFF or to IN ZONE Absolute mode is selected by setting the controller module s Logicmaster 90 30 configuration field Intgr Mode Integrator Mode to CONTINU Additionally proper operation of the Absolute mode requires an external battery pack that must be connected to the appropriate digital servo amplifier connector Refer to the appropriate amplifier manual for selection and installation of the battery pack Note The Position Error I
31. the configured Drive Disable Delay A 2 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 Table A 1 Status Word Error Codes Hexadecimal Po None Nozio Configuration Errors Scaled data too big maximum value in range used Home Position gt Positive EOT Positive EOT used 4 Status Only Home Position lt Negative EOT Negative EOT used Configuration Parameter Errors 12 Position Loop Time Constant computation overflow reduced to non overflow value 1E Immediate command Jog Velocity out of range command ignored 1F Immediate command Jog Acceleration out of range command ignored Program Errors 20 Program Acceleration overrange defaultsto16 7millioncts sec sec 21 Program Accelerationtoosmall defaultedto32cts sec sec 22 Scaled Velocity greater than 1 million cts sec 1 millioncts secis used 23 Program Velocity is zero defaulted to 1 count sec used 24 Program Position too large 25 Unconditional Jump Destination not found 26 Jump Mask error Position Increment Errors Find Home Errors yal Status Only Move at Velocity while Abort All Moves bitis set error Status Only Move at Velocity Data greater than 8 388 607 user units sec Status Only Move at Velocity Data greater than 1 million cts sec error Status erroris reported command is not executed Appendix A Error Word Status Codes A 3 A 4 Table A 1 Status Word Error Codes Continued ErrorNumber Res
32. to the Power Mate J system as a whole the decimal point will distinguish to which axis the error applies When the alarm applies to axis 1 the decimal point will not be displayed if the alarm applies to axis 2 then the decimal point will be displayed Multiple Alarms When more than one error is detected by the Power Mate J prior to the alarm condition being cleared each alarm will be displayed consecutively at an interval of approximately 1 second Power Up Considerations When reset the Power Mate J controller and interface modules will power up indepen dently The interface module will usually be ready to communicate with the controller module before the controller module is ready to communicate with the interface mod ule The interface module will begin to output the communications clock when it com pletes initialization and wait for the controller to establish communication After five seconds of no communications from the controller the interface module will display on its alarm display the error code indicating that no communications is occurring between the controller module and the interface Once communications with the controller is initially established this alarm will automatically be removed from the interface module Clearing Alarms The controller s Q bit Clear Error will function to clear Power Mate J alarms or error status indications Asserting Clear Error will cause the interface module to clear all alarms curre
33. will not be displayed When the alarm applies to axis 2 the decimal point will be displayed 2 Power cycle servo amp 3 Issue Clear Error CommunicationsError Power cycle servo amp Eliminate cause of alarm Power cycle servo amp Issue Clear Error When multiple alarms are detected each alarm will be displayed consecutively every second GFK 1256 Appendix B Visual Status Error Codes B 3 Servo Unit Error Alarm Table B 4 The table below summarizes the Power Mate J servo status alarms Table B 2 Power Mate J Servo Status Alarms Display on 7 Segment LED Alarm Type Inverter Over Current Converter Fan Alarm Inverter Low Voltage for DC Link E a ao Inverter Low Voltage for Y Control Power ConverterExcessive Y Regeneration Converter Over Current or Y L Converter IPM a Converter Overtoad Alarm EE a Converter Low Voltage for DC Link ConverterInsufficient Charge for DC Link Converter Input Power Missing Phase Converter Control Power Supply Low Voltage Converter Over Voltage for Y Y Y DC Link Foralarms which apply to a particular axis a decimal point will distinguish the axis When the alarm applies to axis 1 the decimal point will not be displayed When the alarm applies to axis 2 the decimal point will be displayed AA AN O J A PAT EIN When multiple alarms are detected each alarm will be displayed consecutively every second The same display value is reported for both
34. 4 Move At Velocity Null B 13 Position Increment 3 13 Position Increment With Position Up date Position Loop Time Constant B 15 Rate Override Select Return Data Set Configuration Complete 3 17 Set Position Torque Limit B 16 Update Flash Memory B 17 Velocity Feedforward 8 15 Velocity Loop Gain I Status Bit Axis Enabled B 3 Configuration Complete Drive Enabled Moving 8 3 PLC Control Active Position Strobe 3 4 Position Valid 3 3 Program Active Error B In Error Limit 8 4 In Zone Q Discrete Commands 3 8 Feedhold Off Transition B 9 Jog Minus Index Abort All Moves Clear Error 3 10 Enable Drive Feedhold On Transition B 9 Find Home B 9 Jog Plus Reset Strobe Flag CTLO9 CTL12 Output Controls Execute Motion Program 0 10 3 10 for the 1 Axis 3 8 for the 2 Axis 3 9 Numbers 24 T Digital Inputs General Purpose 1 9 5 VDC Power A A Moves Q Discrete Command 3 9 Absolute Encoder First Time Use D 1 Use After Loss of Encoder Battery Pow Absolute Encoder Mode Hi LoLimits D 2 Limitations on Total a Power Mate J Power Up Restrictions when used with Rotary Mode D 5 with Rotary Mode D 4 al Encoder Mode Considerations D 3 Find Home Cycle Position Initialization D 3 Set Position Command D 4 Absolute Feedback Offset AQ Immedi ate Command 3 17 Absolute Position Offset b 7 Absolu
35. 607 8 388 608 instead Home Positn Home Position User Units The value assigned to Actual Position at the end of a Find Home cycle Default 0 Home Offset Home Position Offset User Units The offset of the servo final stopping point at the completion of a Find Home cycle Home Offset adjusts the final servo stopping point relative to the Encoder marker Default 0 Fni Home Vel Final Home Velocity User Units second The velocity at which the servo seeks the final Home Switch transition and Encoder Marker pulse at the end of a Find Home cycle Final Home Velocity must be slow enough to allow a 10 millisecond filter time delay between the final Home Switch transition and the Encoder Marker pulse Default 500 Find Home Vel Find Home Velocity User Units second The velocity at which the servo seeks the initial Home Switch transitions during the Find Home cycle If desired Find Home Velocity can be set to a high value to allow the servo to quickly locate the Home Switch Default 2000 Home Mode Find Home Mode This method is used to find home during a Find Home cycle HOME SWITCH indicates that a Home Switch is to be monitored to Find Home MOVE and MOVE specify direct positive and negative movement to the next marker at the Final Home Velocity Default HOMESW Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Digital Servo Interface Configuration The interface module can be completely configured by
36. A A A E A B 5 GFK 1256 Power Mate J for Series 90 30 User s Manual August 1996 ix Chapter Product Description 1 The information in this chapter is intended to present a description of the Power Mate J motion control system provide module specifications and indicate system functionality by way of a block diagram Additionally I O connections and diagrams are provided The Power Mate J System The Power Mate J PM J for Series 90 30 is a complete integrated motion control system that supports Standard mode operation Standard mode is the normal controller module mo tion control loop which provides a velocity command proportional to position error with optional Velocity Feed forward The Power Mate J consists of two PowerMotion modules The controller module Power Mate APM and the interface module Digital Servo Inter face The controller provides the position control motion program and interface to the LO The interface module provides the interface to the digital servo system including digital torque and velocity control The two modules communicating together across a high speed serial link form a complete Power Mate J digital motion controller system 245635 EN1 STA Visual indication of axis EN2 OK status information Power Mate CFG APM DIGITAL SERVO INTERFACE Simple Cable Connections e Motion programmer e Standard command cable connectors to amplifiers o e O connections JS2 JS e High Speed
37. Actual Position Actual Position user units is a value maintained by the controller module to represent the physical position of the axis It is set to an initial value by the Set Position Immediate command or to Home Position by the Find Home cycle It is updated by the motion of the feedback device If Actual Position moves past either of the count limits it will roll over to the other limit and continue in the direction of the axis motion Strobe Position Strobe Position user units contains the axis position when a Strobe Input occurs When a Strobe Input occurs the Position Strobe l bit is set to indicate to the PLC that new Strobe data is available in the Strobe Position status word The PLC must set the Reset Strobe Flag Q bit to clear the Position Strobe 1 bit Strobe Position will be maintained and will not be overwritten by additional Strobe Inputs until the Position Strobe l bit has been cleared If the Reset Strobe Flag output is left in the On state thus holding Position Strobe input flag in the cleared state then each Strobe Input that occurs will cause the axis position to be captured in Strobe Position The axis 1 Strobe Position is also placed in data parameter 255 for use within motion programs In a 2 axis Power Mate J the axis 2 Strobe Position is placed in data parameter 254 This feature allows the strobe input to trigger a Conditional JUMP to a program block using the Strobe Position as the destination of a CMOVE
38. FANUC GE Fanuc Automation PowerMotion Products Power Mate J for Series 90 30 User s Manual GFK1256 August 1996 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury existin this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness
39. FK 1256 Section 1 Description of the Power Mate This section describes the Power Mate J which consists of a controller module and an interface module Controller Module Power Mate APM The following pages describe the user interfaces of the controller module in Standard control mode when Digital servo command and Digital feedback are selected The release 2 5 IC693APU301K or IC693APU302K or later of the controller module can be configured in DIGITAL mode to operate with the interface module The figure below illustrates module features when used in the DIGITAL configuration a45637 EN1 EN2 Status Indicator LEDs Power Mate e STAT See Appendix B for e OK LED Descriptions e CFG e EN1 e EN2 Serial Communications Port Connector e Program and Subroutine Transfer Status Monitoring for Troubleshooting Connector A e I O Connections Home Strobe Axis Overtravel Connector B e High Speed Serial Communication to DSI module Figure 1 3 Controller Module LEDs and Connectors GFK 1256 Chapter 1 Product Description Serial COMM Connector The controller module s front Panel contains a single 15 pin female D connector for serial communications It is used to connect a computer running the Motion Program mer software to the controller The serial COMM port uses the GE Fanuc SNP protocol and is RS 485 compatible The baud rate is selectable from 300 to 19 200 baud The connection between the programming computer
40. J System Block Numbers and Jumps 4 16 C Cable Controller to Interface Module Call Subroutine Catalog Numbers IC690ACC901 Mini Converter Kit RS 232 to RS 485 422 IC693APU301 1 AxisController 1C693APU302 2 AxisController CFG LED Clear Error Q Discrete Command 8 10 Clearing Alarms CMOVE 4 10 CMOVE Command Program Zero 2 14 COMM_REO COMM_REQ example of Command Block Number AI Status Word Command Name Field Program Zero 2 12 Command Dwell 4 15 Command ForceD A lt 4 GFK 1256 GFK 1256 Command Velocity Command Wait 4 15 Rd nded Position AI Status Word a ele Velocity AI Status Word 7 Commands Position Increment 4 4 Commands Program Zero Motion Pro gram Communications High Speed Serial PM APM to DSI Compatibility Controller Modules Host CPU Programming 1 Servo Units Conditional Jumps Conditions Which Stop a Motion Pro gram Configuration Controller Power Mate APM 2 2 Configuration Considerations Important b i7 Configuration Modes AQ Immediate Command Configuration Parameters Configuration Parameters Essential Configuring the Interface Module 2 11 Configuring the Power Mate J 2 2 Configuring the Rack Slot P 2 Connection Multidrop 1 5 Connector serial COMM 1 4 Connectors and Ports 1 15 Considerations for Power Up Considerations Absolute Encoder Mode Find Home Cycle D 3 Po
41. Limit Switch is OFE Jog and Clear Error may be turned on simultaneously to move away from the open Limit Switch Thus a Jog Plus will not work while the Positive End of Travel Switch is open and Jog Minus will not work while the Negative End of Travel Switch is open Chapter 4 Motion Control 4 3 Move at Velocity Command A Move at Velocity command is generated by placing the value 22h in the first word of AQ data assigned to an axis The second and third words together represent a signed 32 bit velocity Note that the third word is the most significant word of the velocity Once the command is given the AQ data can be cleared by sending a NULL com mand or changed as desired Move at Velocity will not function unless the servo drive is enabled Q Enable Drive and l Drive Enabled are set The listing of AQ immediate commands shows the words in reverse order to make understanding easier For example to command a velocity of 512 user units per second in an Power Mate J configured with AQ data starting at AQ1 the following values should be used 0022h 34 decimal in AQ1 0200h 512 decimal in AQ2 and 0 in AQ3 When the Power Mate J receives these values if Drive Enabled I is ON Abort All Moves Q is OFE and no other motion is commanded it will begin moving the axis at 512 user units per second in the positive direction using the current Jog Acceleration and Acceleration Mode The Drive Enabled I bit must be ON before the Power Ma
42. Mate J The Power Mate J maintains 256 double word parameters 0 through 255 in memory These values can be used as a parameter in ACCEL VELOC DWELL PMOVE and CMOVE motion commands Be aware that range limits still apply and errors may occur if a parameter contains a value out of range The last ten parameters are special purpose parameters The Power Mate J can load data into these parameters which might overwrite user data The following table describes the function of the special purpose parameters Parameter Number Special Purpose Function 246 253 Reserved for future use Stores Axis 2 Strobe Positionvalue user units 2 Axis Power Mate J only Stores Axis 1 Strobe Positionvalue user units Parameters are all reset to zero after a power cycle or after a Power Mate J configuration is stored by the PLC Parameters can be assigned in three ways the motion program command LOAD the immediate command Load Parameter Immediate and the COMM_REO function block in the PLC The COMM_REO function block is described in Appendix B Assigning a value to a parameter overwrites any previous value Parameter values can be changed during program execution but the change must occur before the Power Mate J begins executing the block previous to the block that uses the parameter 4 30 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Appendix Error Word Status Codes GFK 1256 A The Status Code word of the AI Status
43. N a45251 Z SD AJ10 SA 10 RD A o SD B 11 T e 11 RD B K o RD A 12 DAA 12 SD A lo cof RD B 13 gt 13 SD B KG 00 CTS A 6 6 RTS A gt o CTS B 14 1 14 RTS B gt 9 RTS A 15 15 CTS A LG 00 RTS B 8 1 8 CTS B E 99 5 5 11 51 5 B 9 GND 7 11 7 ov Co SHLD 1 w W 1 SHLD LG CONNECTOR 1 _ _ CONNECTOR 2 15 PIN 15 PIN FEMALE MALE NOTES X X 1 Cables can be daisy chained for more CPUs or Power Mate J systems E D O y PIN pa le g E 2 Connector 1 is 15 pin D shell female 10 RD A gt 11 RD B gt 3 Connectors 2 and 3 are 15 pin D shell AS E 8 gt male with right angle hood wires 6 RTS A gt coming out PIN 1 end 14 RTS B 15 cTS Aa 8 CTS B 5 5 gt 7 ov gt 1 SHLD CONNECTOR 3 15 PIN MALE Figure 1 5 Multidrop Cable for the Power Mate J GFK 1256 Chapter 1 Product Description 1 5 1 0 Connectors The controller module s front panel contains two 24 pin male high density connectors Connector A contains connections for I O Connector B contains connections for the high speed serial interface to the Power Mate J Digital Servo Interface Module I O Cable and Terminal Block High density connectors are used on the controller to permit a large number of I O con nections within the physical size limitations of the controller T
44. NDARD STANDARD Ctl Loop STANDARD selects the normal controller module motion control loop The STANDARD loop provides a velocity command proportional to position error with optional Velocity Feed forward CCL1 and CCL2 Custom Control Loops are individually designed for special applications and should not be selected FOLLOWER selects a control loop that allows ratio tracking of a master input with zero following error and is not supported in the Power Mate J Default STANDARD GFK 1256 Chapter 2 Installation and Configuration 2 3 Servo Cmd This parameter defines the type of command output provided to the servo system DIGITAL selects a special digital output for GE Fanuc Digital servo drives Digital servos are only supported in the controller module firmware versions 2 50 or higher Default ANALOG Motor Type Selects the type of GE Fanuc Digital AC servo motor to be used with the Power Mate J The Power Mate J internally stores setup motor parameter tables for each of the servos supported A particular motor for the indicated axis is selected in the Logicmaster 90 30 configuration fields Motor1 Type or Motor2 Type A Motor Type of 0 for a particular axis disables servo control by the interface module for the axis Supported motor types are listed in the tables below Motor Model Motor model information is in the form series peak torque in Newton meters maximum rpm Motor Specification Digital motor specification part numbe
45. OR PM APM COMM_REQ l l CONST SYSID 0007 l l l CONST TASK 00000000 Appendix C Data Parameters From the PLC C 3 Appendix Serial Encoders D Serial Encoder Models There are three pulse encoder models that will function with the Power Mate J 8K 32K or 64K counts per revolution All encoders return position information in the form of a 32 bit value To maintain equal number of counts scaling per motor revolution the 8K encoder position increments its absolute position word data by eight counts whereas the 32K encoder increments its data by two counts and the 64K encoder increments its data by one count However the Power Mate J overrides these additional count inputs thus 8K 32K and 64K encoders are identical for a Power Mate J The Power Mate J will always sense 8192 counts per motor shaft revolution from a serial encoder The one million count 1M encoder is not supported Serial Encoder First Time Use or Use After Loss of Encoder Battery Power The encoder temporarily provides incremental data during the first use or after restoring encoder battery power The incremental data is lost when motor shaft rotation causes the encoder to pass a reference point similar to a marker signal within one revolution of the motor shaft The diagram below describes this situation as well as the state of the DS internal signal The signal DS is not directly available to the user but serves to illus trate the
46. P command Block parameters can be entered in the data field when paired with Block or Jump instructions The data field of a dwell command indicates the number of milliseconds that the program will pause in execution Axis Field This field is only used in the configuration for a two axis controller module module Itis used to set the axis number for commands such as VELOC or PMOVE 2 12 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Table 2 4 Program Zero Motion Program Commands Command Definition Range Default Name NULL DOTES ANNAN ANCANAA CMOVE AL P Continuous move Absolute Linear Use 0 255 1 data in Parameter CMOVE AS Continuous move Absolute S curve 8 388 608 8 388 607 CMOVE AS P Continuous move Absolute S curve Use 0 255 1 data in Parameter CMOVE IL Continuous move Incremental Linear 8 388 608 8 388 607 CMOVE IL P Continuous move Incremental Linear 0 255 1 Use data in Parameter CMOVE IS Continuous move Incremental S curve 8 388 608 8 388 607 CMOVE IS P Continuous move Incremental S curve 0 255 1 Use data in Parameter PMOVE AL Positioning move Absolute Linear 8 388 608 8 388 607 PMOVE AL P Positioning move Absolute Linear Use 0 255 1 data in Parameter PMOVE AS Positioning move Absolute S curve 8 388 608 8 388 607 PMOVE AS P Positioning move Absolute S curve 0 255 1 Use data in Parameter PMOVE IL Positioning move Incremental Line
47. Position as the offset distance from the Home Marker The Enable Drive Q bit and Drive Enabled I bit must be ON during an entire Home Cycle However the Find Home Q bit does not need to be held ON during the cycle it may be turned on momentarily with a one shot Note that turning ON the Find Home bit immediately turns OFF the Position Valid I bit until the end of the Home Cycle The Abort All Moves Q bit halts a Home Cycle but the Position Valid bit does not turn back ON No motion programs can be executed unless the Position Valid bit is ON Home Switch Mode If the Find Home Mode is configured as Home Switch the Home Switch input from the I O connector is used to roughly indicate the reference position for Home The next marker encountered when traveling in the negative direction indicates the exact loca tion An open Home Switch indicates the servo is on the positive side of the Home Switch An OFF to ON transition of the Find Home command yields the following Home Cycle Unless otherwise specified acceleration is at the current Jog Acceleration and con figured Jog Acceleration Mode If initiated from a position on the positive side of the Home Switch the cycle starts with step 1 otherwise the cycle starts with step 3 1 The axis is moved in the negative direction at the configured Find Home Velocity until the Home Switch closes 2 The axis decelerates and is stopped 3 The axis is accelerated in the positive direction and move
48. Serial Cable Diagram 1 17 Home Cycle p a Home Mode Home Mode Find Home Mode P 10 Home Offset Home Position 2 7 Home Positn Home Position Offset 2 10 Home Positn Home Position 2 10 Home Switch Mode Host CPU Compatibility I O Cable and Terminal Block I OCable Connections for 1 Axis for 2 Axis I O Comnectors i d GFK 1256 GFK 1256 I OSpecifications 1 7 Idle Time Immediate Commands Using the 6Byte Format Important Configuration Considerations b 17 In Error Limit I Status Bit In Pos Zone 2 7 In Pos Zone In Position Zone In Position Zone AQ Immediate Com mand In Zone l Status Bit Incremental Encoder Mode Consider ations Incremental Positioning 4 8 Indicators LEDs B 1 Input Circuitry General Purpose 1 9 Installation Interface Module Power Mate J Step by Step Procedure Installing the Power Mate 3 2 1 Integrator Mode Integrator Time Constant Interface Module 1 14 See also Digital Servo Interface Configuration 2 11 Description of Module 1 14 Interface Module Status Bits Internal Alarm table Internal Alarm Type Intgr Mode Integrator Mode Intgr TC Integrator Time Constant 2 9 J Jog ACC Jog Acceleration Rate 2 10 Jog ACC Mod Jog Acceleration Mode Jog Acceleration Jog Acceleration AQ Immediate Com mand Index Jog Acceleration Mode b 7 Jog Minus Q Discrete Command 3 10 Jog Plus Q D
49. Serial communication between modules JD35 O Power Mate J 00000000 o o Figure 1 1 Power Mate J GEK 1256 1 1 System Overview 1 2 The Power Mate J for Series 90 30 allows a Series 90 30 PLC to interface to a Series or b Series Servo Motor Amplifiers and servo motors a Series and b Series digital servo mo tors are connected by a simple cable interface to the motor amplifier and to the Power Mate J The Power Mate J installs easily into the Series 90 30 CPU baseplate or any ex pansion baseplate and will draw all needed power from the PLC backplane power sup ply Power Mate J a45636 SNP High Speed Link Motion Programmer and CPU Programmer Encoder Feedback Encoder Encoder Feedback Encoder ao J Encoder Battery _ I Pack Optional Axis 1 Axis 2 available in 2 axis PM J Figure 1 2 Power Mate J System Block Diagram A Power Mate J system is available as either a one or two axis motion control system as described below Description Power Mate J One Axis Includes Controller Module one axis module Interface Module Eight inch Serial Interface Cable Used to connect controller to interfacemodule Power Mate J Two Axis Includes Controller Module two axis module Interface Module Eight inch Serial Interface Cable Used to connect controller to interfacemodule Power Mate J for Series 90 30 User s Manual August 1996 G
50. Units to 8192 Counts can be configured to allow this With this ratio one user unit would represent 01 millimeters 2540 user units would represent 25 4 millimeters one inch of travel The range for both User Units and Counts is 1 to 65 535 However the ratio of User Units to Counts must be between 8 1 and 1 32 A more detailed example is described below Example A machine has a digital servo motor 8192 counts per revolution that is connected through a 20 1 gear reduction to a 14 336 inch diameter spur gear The programmer wishes to program in 0 01 inch resolution The following is the given data 14 336 inch diameter spur gear 8192 count encoder 20 1 reduction gear 0 01 inch is the desired programming unit First determine the number of Encoder Counts per revolution of the spur gear 8192 20 163 840 Counts per rev The multiply by 20 results from the reduction gear Next determine the number of User Units per revolution using 0 01 inch resolution 14 336 inches z 45 0378 inches per revolution 45 0378 inches per rev 0 01 inches per User Unit 4503 78 User Units per revolution This User Units to Counts ratio would be 4503 163 840 or 0 02748 which is about 1 27 This ratio is less than 1 32 so the resolution is adjusted To assume a new programming unit resolution of 0 001 inch Determine the revised User Units per revolution using 0 001 inch resolution 14 336 inches n 45 0378 inches per revolution 45 0378 inc
51. ace Module DSI Module Type PLC I O Points Used Power Supply requirements 5 VDC 24 VDC Isolated Maximum Numberofmodules system t Model 311 313 321 323 PLCs 5or10 slot CPU baseplates Model 331 340 341 PLC Sand 10 slot CPU baseplates 5 and 10 slot expansion or remote baseplates 5total baseplates per system Model 351 and 352 PLC j 5and 10 slot CPU baseplates 5 and 10 slot expansion or remote baseplates 8 total baseplates per system 5 VDC from PLC backplane 800 mA 1 4 x faceplate connector A 5 VDC current drain 95 mA SNP Mini converter Current if used 500 mA 40 C 104 F derated to 300 mA 55 C 131 F Series 90 30 PLC input module 16 inputs I 450mA 70mA 1 PM JsysteminCPUbaseplate with PWR321 322 3 PM systems in CPU baseplate with PWR330 1 PM JsysteminCPUbaseplate with PWR321 322 3 PM systems in CPU baseplate with PWR330 2 PM J system in expansion remotebaseplatewithPWR321 322 3 PM J system in expansion remote baseplate with PWR330 9total PM J systems per PLCsystem with PWR321 322 15 total PM J systems per PLC system with PWR330 1 PM JsystemsinCPUbaseplate with PWR321 322 3 PM systems in CPU baseplate with PW330 2 PM J system in expansion remotebaseplatewithPWR321 322 3 PM J systems in expansion remote baseplate with PWR330 15 total PM J systems per PLC system with PWR321 322 24 total PM systems per PLCsystem with PWR330 The number of Power Ma
52. and the controller is typically made from the RS 232 port of the computer through an RS 232 to RS 485 RS 422 con verter to the Serial Communications Connector A Mini converter Kit IC690ACC901 which includes a converter and 10 feet 3 meters cable is available for this purpose The port is configured using the Logicmaster Configuration Package or the Series 90 30 PLC Hand Held Programmer The pin definitions for the serial COMM port are listed below Table 1 1 Pin Definitions of the Serial COMM Port Connector RS 232 Converter Power Le RI Ready toSend asa Cleartosend YT 22 1 4 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Multidrop Connection Power Mate J modules can be connected in multidrop fashion A sample configuration is shown in the figure below One cable is necessary for each Power Mate J in the system a45254 Included in Mniconverter Kit IC690ACC901 i Multidrop Multidrop Cable Cable Mini Converter 1 sja RS 232 2 2 3 Logicmaster PLC POWER MATE J POWER MATE J 90 30 PC CPU CONDI IE CONTROLLER MODULE MODULE Figure 1 4 Connecting Power Mate J Modules in a multidrop Configuration The multidrop cable should be made according to the following diagram PIN PI
53. another Thus parameters used in a move must be loaded before the move two blocks previous completes execution When a 2 axis Power Mate J is executing a 2 Axis program the program commands are scanned independently by each axis and only the data designated for that axis is executed Note that some commands do not specify an axis Block Jump Call and End and therefore will apply to both axes A 2 Axis program can contain Sync Block commands to synchronize the two motions at designated points When the first axis reaches the Sync Block it will not execute the next block until the other axis has also reached the Sync Block Refer to Example 18 for an illustration of this type of operation Several aspects of programmed motion are dis cussed below Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Prerequisites for Programmed Motion The following conditions must be satisfied before a motion program can be initiated for a multi axis program the conditions must be met for BOTH axis 1 and axis 2 m The Enable Drive Q bit must be ON m The Drive Enabled I bit must be ON m The Position Valid I bit must be ON m The Moving l bit must be OFF m The Program Active I bit must be OFF m The Abort All Moves Q bit must be OFF m The axis position must be within the configured End of Travel Limits m The Overtravel Limit Switches must be asserted if enabled m AForce D A command must not be active m The progra
54. anual GFK 0664 m a Series Amplifier Manuals SVU GFZ 65192EN 01 m Control Motor Amplifier a Series SVM GFZ 65162E 02 m 4a Series Servo Motor Manuals GFZ 65165E 01 GFZ 65150E 02 GFZ 65142E 02 m b Series Servo Product Specification Guide GFH 001 We Welcome Your Comments and Suggestions At GE Fanuc automation we strive to produce quality technical documentation After you have used this manual please take a few moments to complete and return the Reader s Comment Card located on the next page Henry A Konat Senior Technical Writer iv Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Contents Chapter 1 Product Description sino A ARA 1 1 The Power Mate J System naret a e aana a iaa E EA a eee 1 1 System OVERVIEW 2648 fei lene a A A obs afl bas cists 1 2 Section 1 Description of the Power Mate 1 3 Controller Module Power Mate APM 0 0c eee eee reece 1 3 Serial COMM Connector solaraen a erd o eee eens 1 4 Multidrop Connection 2 6 ene 1 5 T OCOnMeCtOLS sect Sede fetes one A wie sehen landed E cade 1 6 I OCable and Terminal Block o oooooooooooonmoooo o 1 6 T OSpecifications yarara iee ee Pag the adele E AE 1 7 I OCable Connections 1 AXis 6 0 eee eee eee nee 1 10 I OCable Connections 2 Axis 2 6 eee een eens 1 11 Functional Connection Diagrams 000666 c cece eee eee 1 12 Functional Connection Diagram 1 AXxis oooooooooco
55. applies to axis 2 the decimal point will be displayed When multiple alarms are detected each alarm willbe displayed consecutively every second Appendix B Visual Status Error Codes B 5 Appendix Data Parameters From the PLC C This appendix describes an alternate method of loading the controller module s Data Parameter Memory from the PLC using a COMM_REO function block with command code E501h This function block can send up to 16 controller module parameter values at once The total data length of the COMM_REO must be set to 68 bytes 34 words organized as shown below Word Offset Byte Offset an eee ee 1 Starting parameter number 0 255 Number of parameters to load Ist parameter data bytes 2nd parameter data Gbytes 32 33 64 67 16th parameter data 4 bytes Only the number of parameters specified in word offset 1 will be loaded into parameter memory However the 68 byte data block must always be initialized in the PLC If the last parameter to be loaded is greater than 255 the COMM_REO will be rejected A parameter block download is illustrated in the following PLC program segment REFERENCE NICKNAME REFERENCE DESCRIPTION RO195 CMREOST COMM_REQ STATUS WORD Updated by COM_REQ R0196 HDR_WDS COMM_REQ HEADER LENGTH IN WORDS ALWAYS 4 RO197 NO_WAIT NO WAIT ALWAYS 0 R0198 STMEMTP STATUS MEMORY TYPE 8 REG RO199 STLOCM1 STATUS WORD LOCATION MINUS 1 194 R0195 R0200 NO_USE1 NOT USED ZEROED
56. ar 8 388 608 8 388 607 PMOVE IL P Positioning move Incremental Linear Use 0 255 1 data in Parameter PMOVE IS Positioning move Incremental S curve 8 388 608 8 388 607 Use data in Parameter WAIT Wait for CTL XX bit to go high before 1 1 moving LOAD P01 Load controller module Parameter register number LOAD P20 DWELL Wait for specified time in milliseconds DWELL P Wait X milliseconds X is the value in the Parameter JUMP UNCOND Continue program execution at given block JUMP CTLO1 When the given CTL bit goes high during 1 65 535 1 4 the current block execution transfer JUMP CTL12 program execution to the given block GFK 1256 Chapter 2 Installation and Configuration 2 13 Program Zero Motion Command Descriptions 2 14 Each command is briefly described below For a comprehensive explanation of Motion Programming on the controller module refer to GFK 0664 The Series 90 Power Mate APM Programmer s Manual Acceleration ACCEL This modal command is used to specify the axis acceleration and deceleration rate for subsequent moves Once encountered the specified rate will remain in effect until overridden by a later Acceleration command Block BLOCK Block numbers are used to monitor and synchronize program execution terminate jump testing and as jump destinations Block number is an actual command in the Program Zero Editor The default block number is zero The most recently used block numbe
57. at Comma tia GRE OE td da 4 15 SUBLOULMES A O bd a ats 4 16 Block Numbers and Jumps ooooococococcccocorrror eee eee 4 16 Unconditional Jumps 2 6 6 eee eens 4 16 Conditional JUMps eiieeii ee ed hese Ade a ee de hee hoe as 4 17 S CURVE JUMPS jac isn ariba rt tte aa Gabe oats Ween hata eb Gated 4 23 Other Programmed Motion Considerations 0000005 4 25 Feedhold with the Power Mate 0c eee eee e eens 4 26 Feedrate Override 2 0 0 cee eee eee 4 27 Multiaxis Programming 0 eee eee eee 4 29 Parameters in the Power Mate J 00 c cece eee eee eee 4 30 Appendix A Error Word Status Codes ccc cece cece eee eee ee eeees A 1 Error Code Format rere tacts tees e Sec Red hice ae as AN teas A 2 Response Methods r errs herpen paap Gs day eee eee eens A 2 vi Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Contents Appendix B Visual Status Error Codes cece cece eee cence eens B 1 Section 1 Controller Module Status LEDs PM APM B 1 LED Indicators ito ina toe Bde eb trace ne He Bcd ened are Baas B 1 Section 2 Interface Module Visual Status Display DSI B 2 AxisError Indicator vimos a a be B 2 Multiple Alarmas a lab lS Mee a BA MU ot ls B 2 Power Up Considerations ooooooccocccccccccoonnnnr rr B 2 Clearing Alar A A id B 2 DSI Status Information 0 0 cece tee teen ences B 3 Servo Unit Error Alarm Table 0 0
58. ccconnnn 1 12 Functional Connection Diagram 2 AXis oooooooooccccconnon 1 13 Interface Module DSI 0 eee tne teens 1 14 Ports and Connectors 0 6 cece 1 15 JS1 Connector to Servo Axis 1 2 teens 1 15 JS2 Connector to Servo AXiS2 00 cece nent eens 1 15 Power Mate APM to DSI High Speed Serial Communications 1 16 High Speed Serial Cable Diagram 1 0 60 cee eee 1 17 Power Mate J System Specifications 6 666 1 18 Section 2 Compatibility oo oooooomooo 1 19 Chapter 2 Installationand Configuration oo ooooooocmoocmmo cm 2 1 Section 1 Installing the Power Mate J Hardware 2 1 Section 2 Configuring the Power Mate J Using Logicmaster 90 30 2 2 Controller Configuration Power Mate APM 0 000000 2 2 Rack SlotConfiguration 0000 eee ee 2 2 Module Configuration nsi se eena aeia ia PE aaka S ai eens 2 2 Setting the Configuration Parameters oooooooooooooonro momo 2 3 Digital Servo Interface Configuration oooooooororocoroccnnn 2 11 Section 3 Program Zero iris da Peas 2 11 Program Zero Programmer Instruction Format oooooooooooo 2 12 Program Zero Motion Command Descriptions oooooooooooooo 2 14 Essential Configuration Parameters suas ssa 000 ce cece eee 2 15 Important Configuration Considerations 000 c cece eee 2 17 GFK 1256 Power Mate J for Series 90 30 User s Manual A
59. converter errors Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 Power Mate J Internal Alarms The table below summarizes Power Mate J communication status alarms Table B 3 Status Alarms Per Alarm Level Corrective Action Axis Display on 7 Segment LED Description Bad CRC from Controller Fast Servo Stop Handshake Error from Controller Fast Servo Stop Servo Watchdog Time out Fast Servo Stop Fast Servo Stop Clock Error Fast Servo Stop Illegal Parameterfrom Controller Make sure controller to interface module cable connected if not correct and issue Clear Error otherwise Power cycle PLC rack If alarmimmediatelyreoccurs replaceinterfacemodule Make sure controller to interface cable connected if not correct and issue APM Clear Error otherwise Power cycle PLC rack If alarmimmediatelyreoccurs replace DSI module Review controllermodule configuration parameters set with Logicmaster 90 30 and correct Power cycle servo amp Power cycle PLC rack If alarmimmediatelyreoccurs replace interfacemodule Power cycle PLC rack If alarmimmediatelyreoccurs replace interfacemodule Power cycle PLC rack If alarmimmediatelyreoccurs replace interfacemodule Foralarms which apply toa particular axis a decimal point will distinguish the axis When the alarm applies to axis 1 the decimal point will not be displayed When the alarm
60. d at the configured Find Home Velocity until the Home Switch opens The axis decelerates and is stopped 5 The axis is accelerated in the negative direction and moved at the configured Find Home Velocity until the Home Switch closes 6 The Power Mate J continues negative motion at the configured Final Home Velocity until a marker pulse is sensed The marker establishes the Home reference position Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 The axis decelerates and is stopped 8 The axis is moved at the current Jog Velocity the number of user units specified by the Home Offset value from the Home reference position 9 The axis decelerates and is stopped 10 Aninternal Set Position sets the Commanded and Actual Positions to the configured Home Position value Finally the Power Mate J sets the Position Valid l bit to indicate the Home Cycle is complete Move and Move Modes If Find Home Mode is configured as Move or Move the first marker pulse encountered when moving in the appropriate direction positive for Move negative for Move is used to establish the exact location An OFF to ON transition of the Find Home Q bit will perform the following operation 1 The axis is accelerated at the Jog Acceleration rate and moved at the configured Final Home Velocity positive direction for Move negative direction for Move until a marker pulse is sensed This marker pulse establishes the Home
61. d to start A multi axis Motion Program uses both axis 1 and axis 2 so both Program Active bits must be OFF to start a multi axis Motion Program Clear Error When an error condition is reported this command is used to clear the Error status bit and its associated Status Code word Error conditions that are still present such as an End of Travel limit switch error will not be cleared and must be cleared by some other corrective action Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Controller Module AQ Immediate Commands PM APM Each PLC sweep six words of data are automatically transferred from the CPU AQ data to the controller module These six words are used to send Immediate Commands from the PLC to the controller module The first three words offsets 0 through 2 are dedicated to axis 1 of the Power Mate J The second three words offsets 3 through 5 are dedicated to axis 2 of the Power Mate J Thus one command may be sent to each axis of the Power Mate J every sweep The only exception is the Load Parameter Immediate command which is axis independent This command may be sent using either or both sets of three words Thus two Load Parameter Immediate commands can be sent on the same sweep one in the first three AQ words and the other in the second three AQ words Ina 1 axis Power Mate J the only effective commands for the second set of AQ words are Force D A Output Analog Output and Load Parame
62. directional input opto coupler Input ON threshold 18 0 V to 30 0 V Input OFF threshold 0 V to 4 0 V Input resistance 5000 Q 10 Input filtering 5 milliseconds nominal Isolation voltage 1500 V peak transient 5400 OHMS 245110 CTLO3 AN Tus a alt 1K ji Vs Es OPTICAL gt couPLER 5400 OHMS oros gt Tus PTER aie 1K i Vs Re OPTICAL e bd e COUPLER 5400 OHMS oros gt AV E Tus PERO T 1K V gt x 4 OPTICAL INCOM bs coupler NOTE O Connector A is shown ov Figure 1 11 General Purpose Input Circuitry GFK 1256 Chapter 1 Product Description 1 9 I O Cable Connections 1 Axis The following table lists the I O cable connections for connector A on the 1 Axis Power Mate J when the controller is configured for Digital Mode Table 1 2 Cable Connections to Faceplate I O Connector A 1 Axis Power Mate J I O Module Terminal Block Connector A Terminal Number Pin Number A AO CTT Input C C e O e nae Relay O Output Ca s eww O O O A e SOCSC SCSCSC S pani E AAA 3 4 Cable Shield no connection Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 I O Cable Connections 2 Axis GFK 1256 The following table lists the I O cable connections for connector A on the 2 Axis Power Mate J when the controller is configured for Digital Mode Chapter 1 Prod
63. e 4 10 JUMP Without Stopping 6 6 eee eens 4 21 Figure dl Jump Stop sesh Lid Gee ieee ohn wae ie Shed nk lel Weed AAA de 4 22 Figure 4 12 Jump Followed by PMOVE 0 0 iaae EE EEE nents 4 22 Figure 4 13 Jumping After the Midpoint of Acceleration or Deceleration ooooooooooo 4 23 Figure 4 14 Jumping before the Midpoint of Acceleration or Deceleration oooooooooo 4 24 Figure 4 15 Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating umes drasi eee e a a E rr 4 25 Figure 4 16 Maximum Acceleration Time ooooooococoorooooooonnnn rr 4 26 Figure 4 17 Fe dhold reren re a SEA E MSs AAA 4 27 Figure 4 18 Feedrate Override oooooooocooccnnnnnrr rr 4 28 Figure 4 19 Multiaxis Programming 6 66 eens 4 29 Figure A 1 Status Code Organization 6 eens A 2 viii Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Contents Table 1 1 Pin Definitions of the Serial COMM Port Connector 0 cece eee eee eee 1 4 Table 1 2 Cable Connections to Faceplate I O Connector A 1 Axis Power Mate 1 10 Table 1 3 Cable Connections to Faceplate I O Connector A 2 AxisPower Mate 1 11 Table 1 4 JS1 Connector to Servo AXIS 2 0 een etn teen ene eee nee 1 15 Table 1 5 JS2 Connector to Servo Axis 2 0 cent nett e nent eens 1 15 Table 1 6 High Speed Serial Communications Power Mate APM to DSI JD35 Connector
64. e 5000 user units in the positive direction If the initial position was 10000 the axis would move 5000 user units in the negative direction And if the initial position was 5000 no motion would be generated Incremental Positioning In an incremental move the first parameter is interpreted as the distance to move from the position where the move begins The Power Mate J translates incremental move dis tances into absolute move positions so no error accumulates The following is an exam ple of an incremental positioning move PMOVE 5000 INC LINEAR This incremental move will move the axis from its current position to a position 5000 user units greater With an incremental move the first parameter specifies the actual number of user units the axis moves Types of Acceleration Choices for the last parameter which specifies the type of acceleration to use while per forming the move are LINEAR and S CURVE Linear Acceleration A sample profile of a linear move plotting velocity versus time is shown in Figure 4 1 The straight lines on the graph show that a linear move uses constant acceleration The area under the graph is the distance moved ACCEL 1000 VELOC 2000 PMOVE 6000 INC LINEAR v a45256 Figure 4 1 Sample Linear Motion Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 S Curve Acceleration An s curve motion sample again plotting velocity versus time is shown below The curved lines on
65. e axis The Commanded Position and Actual Position values will both be changed so that no motion command will be generated The Actual Position will be set to the value designated and the Commanded Position will be set to the value Position Error Set Position cannot be performed when the I Moving bit or the I Program Active bit is ON The position value must be within the End of Travel Limits and Count Limits or a status error will be reported Position Valid I flag is set after a successful Set Position command See Appendix D for considerations when using absolute mode encoders Note When a servo system is first powered up after removal or replacement of the encoder battery the digital encoder must be rotated past its internal reference point If this is not done the Set Positioncommand will be ignored and Error Code 53h Set Position before encoder passes reference point will be reported Force D A Output This command forces a Velocity Command to the DSI Acceleration control is not used and changes in velocity take effect immediately A D A Output value of 4095 will produce a motor output of 4 095 RPM and 4095 will produce a motor output of 4 095 RPM The DSI may limit actual motor speed to a lower value Care should be taken not to operate a servo motor past it s rated duty cycle The Enable Drive Q bit must be active with no other motion commanded for the Force D A Output command to operate Force D A output is the only continuou
66. ed Feedhold On Transition This command causes any motion in progress to halt at the active acceleration rate Once the motion is stopped the Moving status bit is cleared and the In Zone status bit is set when the In Zone condition is attained Jog commands are allowed when in the Feedhold condition After an ON transition program motion will stop even if the command bit transitions back OFF before motion stops Feedhold Off Transition This command causes any programmed motion interrupted by Feedhold to resume at the programmed acceleration and velocity rate Additional program moves will then be processed and normal program execution will continue If jogging occurred while Feedhold was ON the interrupted Move command will resume from where the axis was left after the Jog The Move finishes at the correct programmed velocity and continues to the original programmed position as if no jog displacement occurred Enable Drive If the Error and Drive Enabled status bits are cleared this command will cause the Drive Enable relay contact to close enabling the drive and the Drive Enabled bit to be set otherwise it has no effect When the Drive Enabled bit is set the path generation and position control functions are enabled and servo motion can be commanded Enable Drive must be maintained ON to allow normal servo motion except when using Jog commands Find Home This command causes the controller module to establish the Home Position
67. eedrate change Note that when a feedrate of 0 is applied no motion will be generated until a new feedrate is commanded Also note the Moving I bit stays ON when the feedrate is 0 Feedrate Override has no effect on non programmed motion such as Jog Find Home or Move at Velocity Chapter 4 Motion Control 4 27 Example 17 Feedrate Override During execution of this program feedrate changes of or 10 are commanded Dotted lines indicate 10 dashed lines indicate 10 ACCEL 1000 VELOC 6000 PMOVE 110000 INC LINEAR v a45270 Figure 4 18 Feedrate Override 4 28 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Multiaxis Programming GFK 1256 Sync Blocks can be used in a multiaxis program to synchronize the axis motion commands at positions where timing is critical Example 18 Multiaxis Programming This example assumes that axis 1 controls vertical motion and axis 2 controls horizontal motion The objective is to move a piece of material from point A to point C as quickly as possible while avoiding the obstacle which prevents moving directly from A to C A simple way would be to move from point A to point B and then from point B to point C This sequence however wastes time A better way would begin the horizontal movement before reaching point B It has been determined that after axis 1 has moved to a position of 30 000 user units axis 2 could then start and still clear the obstacle The pro
68. een initialized by a Set Position command or successful completion of the Find Home cycle Position Valid must be ON in order to execute a motion program If the controller is configured to use an absolute feedback digital encoder Position Valid is automatically set whenever a correct encoder status signal is received See Appendix D for details of operation when absolute mode digital encoders are used Drive Enabled The Drive Enabled status bit indicates the state of the Enable Drive discrete command and the relay contact supplied by the controller module The ON state of the Drive Enabled status bit corresponds to the CLOSED state of the relay contact Drive Enabled is cleared following power up or an error condition which stops the servo Program Active The Program Active status bit for each axis indicates that a Motion Program 0 10 or a AQ Move command 27h is executing on that axis On a two axis Power Mate J executing a multi axis program will set both Program Active bits Moving The Moving status bit is set when commanded velocity is non zero otherwise itis cleared All Positioning Move Continuous Move Jog and Move at Velocity commands will cause the Moving bit to be set The Force D A Output command will not set the Moving bit In Zone The In Zone status bit indicates that the position error is equal to or less than the configured In Position Zone value This condition occurs at the end of each Positioning Move command or an
69. egin reducing the acceleration or deceleration to zero once at zero the Power Mate J will use the jump destination acceleration and velocity and change to the new velocity GFK 1256 Chapter 4 Motion Control 4 23 Example 13 S CURVE Jumping Before the Midpoint of Acceleration or Deceleration In the following example during the acceleration of the first CMOVE a jump takes place at the first dotted line Because the velocity at the jump destination is lower than the velocity of the first CMOVE the Power Mate J slows the acceleration to zero Constant velocity zero acceleration occurs at the second dotted line There the Power Mate J begins decelerating to the new velocity using the acceleration at the jump destination Finally the second CMOVE finishes ACCEL 1000 VELOC 50000 BLOCK 1 JUMP CTLO01 3 CMOVE 50000 INC SCURVE BLOCK 3 VELOC 5000 ACCEL 10000 CMOVE 15000 INC SCURVE v a45266 Figure 4 14 Jumping before the Midpoint of Acceleration or Deceleration The second case involves jumping to a higher velocity while accelerating or a lower velocity while decelerating When this occurs the Power Mate J continues to the first move s acceleration or deceleration This acceleration or deceleration is maintained similar to be a linear acceleration until the axis approaches the new velocity Then the normal s curve is used to reduce acceleration or deceleration to zero Power Mate J for Series 90 30 User s Manual August
70. er Mode Position Initialization When a system is first powered up in Absolute Encoder mode a position offset for the encoder must be established This can be done by using the Find Home cycle or the Set Position command Find Home Cycle Absolute Encoder Mode The Find Home cycle mode can be configured for Move Move or Home Switch operation Refer to Chapter 4 for additional details of Home Cycle operation The Home Offset and Home Position configuration items function the same as in Incremental Encoder mode At the completion of the Home Cycle Actual Position is set to the configured Home Position value The controller internally calculates the encoder Absolute Feedback Offset needed to produce the configured Home Position at the completion of the Home Cycle This Absolute Feedback Offset must be permanently saved in the controller by sending AQ command 4Ah Update Flash Memory after completion of the Home Cycle Once the Absolute Feedback Offset is saved in Flash memory the APM will automatically initialize Actual Position after a power cycle and set the Position Valid l bit GFK 1256 Appendix D Serial Encoders D 3 Set Position Command Absolute Encoder Mode The AO Set Position command functions the same as in Incremental Encoder mode At the completion of the Set Position operation Actual Position is set to the Set Position value The controller internally calculates the encoder Absolute Feedback Offset needed to produce t
71. er a zero velocity is commanded before it turns OFF the Drive Enable output Because turning OFF the Drive Enable Relay stops the controller module from commanding the servo there are times when the relay should stay ON For example if the servo runs into an End of Travel Limit and the Drive Enable Relay was immediately turned OFF because of the error the servo may continue moving until it coasted to a stop Thus to allow the controller module to command and control a fast stop the Drive Disable Delay should be longer than the deceleration time of the servo from maximum speed The disable delay may be used to control when torque is removed from the motor shaft Applications using an electro mechanical brake may need time for the brake to engage prior to releasing servo torque Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Chapter Power Mate J to PLC Interface 3 The Power Mate APM and DSI both transfer command data and status bits to the PLC This chapter describes data used by each module in the Power Mate J Input Status Data Transferred from PM APM to PLC m Status Bits 32 bits of I data m Status Words 15 words of Al data for a 1 axis Power Mate J 28 words of AI data for a 2 axis Power Mate J Output Command Data Transferred from PLC to PM APM m Discrete Commands 32 bits of Q data Immediate Commands 6 words of AQ data Input Status Data Transferred from DSI to PLC Status Bits
72. es of Acceleration Types of Positioning Reference U Jnconditional Jumps pdate Flash Memory AQ Immediate Command a E User Units User Units and Counts 2 16 User Units Counts b 7 V VELOC Command Program Zero Velocity Velocity at 10 V Velocity at 10 Volts Velocity at 10 volts Velocity Command Move at 4 4 Velocity Feedforward AQ Immediate Command Velocity FF p 7 Velocity FF Velocity Feed Forward Gain 2 9 Velocity Loop Gain AQ Immediate Command Visual Status Display DSI Visual Status Error COdes W Wait Wait Command WAIT Command Program Zero 2 14 Wiring Controller to Interface Module Cable GFK 1256
73. escribes the operation of the Power Mate J interface to the Series 90 30 PLC Chapter 4 Motion Control This chapter provides practical information on Power Mate J motion control and includes several examples Appendix A Error Word Status Codes This appendix describes the errors reported by the status code word of the AI Status Words Appendix B Visual Status Error Codes This appendix describes the status indications provided by the LEDs on the Power Mate J controller module and the status information available from the 7 segment display on the Digital Servo Interface module Appendix C Data Parameters From the PLC This appendix describes how to use the COMM_REQ function block to load Data Parameter Memory from the PLC to the Power Mate J Appendix D Serial Encoders This appendix describes information needed to use serial encoders with the Power Mate J GFK 1256 Power Mate J for Series 90 30 User s Manual August 1996 iii Preface Related Publications For more information refer to these publications m Series 90 30 Programmable Controller Installation Manual GFK 0356 m Installation Requirements for Conformance to Standards GFK 1179 Logicmaster 90 Series 90 30 20 Micro Programming Software User s Manual GFK 0466 m Hand Held Programmer for Series 90 30 20 Micro User s Manual GFK 0402 m Power Mate APM for Series 90 30 Standard Mode Users Manual GFK 0840 m Series 90 PLC Power Mate APM PM APM Programmers M
74. fter the CMOVE command Thus it comes to a stop before the DWELL is executed Since jump testing does not be gin until the DWELL is executed testing begins after motion stops Jump testing ends when the following CMOVE begins because of the BLOCK command associated with it The dotted lines in the velocity profile indicate when jump testing is taking place The CTLO3 bit does not turn ON during the program GFK 1256 Chapter 4 Motion Control 4 19 BLOCK 1 ACCEL 5000 VELOC 10000 CMOVE 60000 INC LINEAR BLOCK 2 JUMP CTLO3 4 DWELL 4000 BLOCK 3 ACCEL 10000 VELOC 5000 CMOVE 15000 INC LINEAR BLOCK 4 NULL V a45310 JUMP t TESTING Figure 4 9 Normal Stop Before JUMP Jumping Without Stopping If the Type 3 command following a conditional jump is a CMOVE and the Type 3 command at the destination is a move command with sufficient distance to fully decelerate to zero when completed the jump will be executed without stopping This is the only way to sustain motion when a jump is performed Example 9 JUMP Without Stopping This is a simple example of a conditional jump from one CMOVE to another While jump testing the CTLO3 bit the first CMOVE accelerates to the programmed velocity Before the dotted line the CTLO3 bit is OFE but at the dotted line the CTLO3 bit turns ON Program execution is immediately transferred to block 3 and the CMOVE there begins Because the velocity at the jump destination is different the velocity changes at
75. g the JUMP contains a new Block Number 2 GFK 1256 Chapter 4 Motion Control 4 17 Changing the location of Block Number 2 will cause the CTL bit to be tested throughout the PMOVE following the JUMP Begin Program 1 CMOVE 1 20000 ABS LINEAR 2 JUMP CTLO1 3 PMOVE 1 40000 ABS LINEAR CTLO1 tested throughout PMOVE 3 DWELL 1 100 End Program The Power Mate J can perform a Conditional JUMP from an active CMOVE to a program block containing a CMOVE or PMOVE without stopping For the axis to jump without stopping the distance represented by the CMOVE or PMOVE in the Jump block must be greater than the servo stopping distance The servo stopping distance is computed using the present commanded velocity and the acceleration parameters that would be in effect when the jump block became active The axis will STOP before jumping if a Conditional Jump trigger occurs under any of the following conditions m When a PMOVEis active m When a CMOVE is active and the Jump destination block contains a CMOVE or PMOVE representing motion in the opposite direction m When a CMOVE is active and the Jump destination block contains a CMOVE or PMOVE representing motion in the same direction with insufficient distance for the axis to stop m When a CMOVE is active and the Jump destination block contains a DWELL WAIT or END program command If the axis does STOP before a Conditional Jump the JOG acceleration and acceleration mode will be used
76. gram segment could be programmed as follows BLOCK 10 CMOVE 30000 INC AXIS 1 BLOCK 20 SYNC PMOVE 50000 INC AXIS 1 PMOVE 150000 INC AXIS 2 When this program is executed axis 1 immediately begins its 30 000 unit move Axis 2 would ignore the first command because it applies only to axis 1 and see the Sync Block Axis 2 waits for axis 1 to reach the Sync Block before it continues executing the program When axis 1 reaches the 30 000 unit mark it begins the 50 000 unit PMOVE at the Sync Block without stopping the first move was a CMOVE Now that axis 1 has reached the Sync Block axis 2 begins its 150 000 unit move Looking at the position profile below axis 1 completes its move first and stops at the end of the PMOVE When axis 2 reaches point C it also stops a45271 AXIS 2 lt S 0 150 000 80 000 B C PA AXIS 1 30 000 OBSTACLE Figure 4 19 Multiaxis Programming If this program segment is not at the beginning of a program and for some reason axis 2 has not yet reached Block 20 when axis 1 has moved 30 000 counts an error would occur Axis 1 would continue to 80 000 counts and the Power Mate J would report a Block Sync Error during a CMOVE in the Status Code Chapter 4 Motion Control 4 29 If it is imperative that the axes synchronize at Block 20 then changing Block 10 to a PMOVE would guarantee synchronization but then axis 1 would always stop momentarily at 30 000 counts Parameters in the Power
77. hanged If the position in crement with position update is used AQ command 25h the Actual Position and Com manded Position reported by the Power Mate J will be changed by the increment Position Increment can be used at any time though simultaneous use with the Force D A command is impossible because the Force D A command must continuously appear in the AQ data Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Other Considerations Other considerations when using non programmed motion are as follows m The Abort All Moves bit when ON will prevent any non programmed motion from starting m Turning ON the Abort All Moves bit will immediately stop any current non programmed motion at the current Jog Acceleration m A Set Position command during non programmed motion will cause a status error m Turning OFF the Enable Drive bit while performing a Home Cycle or Move at Velocity will cause a stop error m The Feedhold bit has no effect on non programmed motion m The Rate Override command has no effect on non programmed motion m Changing the Jog Velocity or Jog Acceleration will not affect moves in progress GFK 1256 Chapter 4 Motion Control 4 5 Programmed Motion The Power Mate J executes program motion commands sequentially in a block by block fashion once a program is selected The program commands can be categorized as follows Type 1 Commands m Call Subroutine Jump Type 2 Commands m Bl
78. he commanded Set Position value This Absolute Feedback Offset must be permanently saved in the controller by sending AQ command 4Ah Update Flash Memory after the Set Position command Once the Absolute Feedback Offset is saved in Flash memory the APM will automatically initialize Actual Position after a power cycle and set the Position Valid l bit Absolute Encoder Mode Power Mate J Power Up The battery pack attached to the servo subsystem will maintain power to the encoder counter logic Once the encoder has referenced through first time start up the actual position is automatically maintained by the encoder even if the axis is moved during servo power loss The encoder will monitor the status of the battery pack and report loss of battery power or low battery power to the Power Mate J The Power Mate J will complete a power on diagnostic and when configured for abso lute encoder mode interrogate the referenced status of the serial encoder A valid refer enced status from the encoder will signal the Power Mate J to read the encoder absolute position The controller will report the Actual Position as the sum of the encoder position and the Absolute Feedback Offset established by the initial Find Home cycle or Set Position command Absolute Encoder Mode with Rotary Mode Some restrictions are necessary when Absolute Encoder mode is selected along with Rotary mode Absolute Encoder mode causes the controller to automatically initial
79. he velocity control loop gain for an axis may be set with the Velocity Loop Gain command The VLGN value is used to match the load inertia J1 to the motor inertia Jm VLGN is defined with a value of 16 representing an inertia ratio of 1 to 1 The VLGN value is calculated assuming that the load is rigidly applied to the motor Therefore in actual machine adjustment the set value may significantly differ from the calculated value due to rigidity friction backlash and other factors A PLC reset or power cycle returns this value to the configured data The user must set the velocity loop gain VLGN such that it satisfies the following equation JL VLGN 16 J Where JL Load Inertia JM Motor Inertia VLGN Velocity Control Loop Gain 0 255 For example The rotor inertia Ju of a particular servo is 0 10 Ib in s The load inertial JL in this application is 0 05 Ib in s VLGN 0 05 0 10 16 8 The default Velocity Loop Gain is set using the Integrator Time Constant setting in the Configuration Software Since the Integrator is unused by the controller module in Digital mode the Integrator Time Constant data is used to set the initial Velocity Loop Gain Changing the VLGN value may cause an axis to be unstable and care should be used when making any change to the VLGN value GFK 1256 Chapter 3 Power Mate J to PLC Interface 3 15 Select Return Data This command allows alternate data to be reported in the AI Com
80. hen a jump occurs during an s curve move while changing velocity depends on whether the jump occurs before or after the midpoint the point where the acceleration magnitude is greatest and whether the velocity at the jump destination is higher or lower than the current velocity If the jump occurs after the midpoint of the change in velocity the change will continue normally until constant velocity is reached then the velocity will be changed to the new velocity using the acceleration mode of the move at the jump destination Example 12 S CURVE Jumping After the Midpoint of Acceleration or Deceleration In the following example a jump occurs during the final phase of deceleration at the dotted line The deceleration continues until constant velocity is reached and then the acceleration to the higher velocity begins ACCEL 50000 VELOC 100000 BLOCK 1 JUMP CTLO01 3 CMOVE 500000 ABS SCURVE BLOCK 2 VELOC 60000 CMOVE 500000 INC SCURVE BLOCK 3 VELOC 85000 ACCEL 100000 CMOVE 250000 INC SCURVE v a45265 t Figure 4 13 Jumping After the Midpoint of Acceleration or Deceleration If a jump takes place before the midpoint of acceleration or deceleration the result depends on whether the velocity at the jump destination is higher or lower than the velocity before the jump took place In the first case when accelerating but the new velocity is lower or decelerating and the new velocity is greater the Power Mate J will immediately b
81. hes per rev 0 001 inches per User Unit 45 037 8 User Units per revolution This User Units to Counts ratio would be 45 037 163 840 or 0 27488 which is about 1 3 6 Thus values of 2749 for User Units and 10 000 for Counts could be used to obtain 0 001 inch resolution Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Acceleration Mode The controller module supports two types of acceleration Linear and S Curve Linear motion consists of constant linear acceleration and deceleration to specified velocities A profile of velocity versus time would show straight lines S Curve motion uses a variable acceleration An S Curve acceleration would begin slowly and increase up to the specified acceleration then decrease back to zero when the specified velocity was reached S Curve motions require twice the time and distance to change velocity compared to linearmotions with the same acceleration CMOVE and PMOVE motion commands specify the acceleration mode for all programmed motion except the jump stop condition which is described in Chapter 4 Jog Find Home Abort and Move at Velocity use the configured Jog Acceleration Mode Important Configuration Considerations Software End of Travel Limits positive and negative are used to bound commanded motion The controller module will not execute any programmed motion which takes the Commanded Position to or past an EOT Limit If the Position Valid l bit is ON a Jog will im
82. ime will be treated as a NULL command if the parameter value is 65000 This feature allows a DWELL P command between a CMOVE and another Move to be skipped if the DWELL P value is 65000 The CMOVE continues to the Move following the DWELL without stopping Example 5 Dwell A simple motion profile which moved to a specific point waited and returned to the original point could use the following program and would have the following velocity profile ACCEL 30000 VELOC 15000 PMOVE 120000 ABS LINEAR DWELL 4000 PMOVE 0 ABS LINEAR V a45262 P1 t P2 Figure 4 7 Dwell Wait Command The WAIT command is similar to the DWELL command instead of generating no motion for a specified period of time a WAIT stops program motion and monitors a CTL bit until it is ON Thus motion will stop any time a WAIT is encountered even if the CTL bit is on before the WAIT is reached in the program The trigger to continue the program can be any of the twelve CTL bits If in the previous example WAIT was substituted for DWELL the motion profile would be the same except the second PMOVE would not start until the CTL bit turned ON If the CTL bit was ON when the program reached the WAIT the second PMOVE would begin immediately when the first PMOVE finished Also if WAIT was used instead of DWELL in the previous example CMOVEs and PMOVEs would generate similar velocity profiles The WAIT will stop motion whether the previous move is a CMOVE or PMOVE
83. ions occur Disable Delay should be longer than the deceleration time of the servo from maximum speed Default 100 Jog Vel Jog Velocity User Units second The velocity at which the servo moves during a Jog operation Default 1000 Jog Acc Jog Acceleration Rate User Units second second The acceleration rate used during Jog Find Home Move at Velocity and Abort operations The Jog Acceleration is used when an acceleration has not been programmed Default 10000 Jog Acc Mod Jog Acceleration Mode LINEAR or S CURVE The acceleration mode for Jog Find Home Move at Velocity and Abort operations LINEAR causes commanded velocity to change linearly with time S CURVE causes commanded velocity to change more slowly than the linear mode at the beginning and end of acceleration intervals Default LINEAR Hi Limit High Count Limit User Units When moving the Actual Position will roll over to the low limit when this value is reached The Count Limits are used for rotary applications See Appendix D for considerations when using absolute mode encoder Default 8 388 607 Lo Limit Low Count Limit User Units When moving the Actual Position will rollover to the high limit when this value is reached The Count Limits are used for rotary applications See Appendix D for considerations when using absolute mode encoder Default 8 388 608 If Hi Low Count limits are both set to zero the controller module uses default limits 8 388
84. irection A jump stop will occur if the PMOVE or CMOVE at the jump destination does not represent sufficient distance or represents motion in the opposite direction In an s curve move a jump stop will do one of two things If the jump takes place after the midpoint of the acceleration or deceleration the acceleration or deceleration is completed before the jump stop is initiated If the jump occurs before the midpoint of the acceleration or deceleration the profile will immediately begin leveling off Once acceleration or deceleration is zero the jump stop begins See the s curve jump examples Example 10 Jump Stop The following is an example conditional jump with a jump stop An enhancement on Example 5 DWELL would be to watch an external CTL bit which would indicate a problem with the positive motion If the CTL bit never turns on the profile for the following program will be identical to the profile shown in the DWELL example If the CTL bit turned on during the first PMOVE or the DWELL the reverse movement would immediately commence The following profile would appear if the CTL bit turned on during the first PMOVE at the dotted line and the Jog Acceleration was 75000 Because the first move completed early due to the CTL bit and a faster acceleration Jog Acceleration versus programmed acceleration the second move would not have to move as far to get back to 0 position as it did in the DWELL example Note that because the motion p
85. iscrete Command 3 10 Jog Vel Jog Velocity Jog Velocity Jog Velocity AQ Immediate Command 3 14 Jogging with the PM J 4 3 JS1 Connector to Servo Axis 1 1 15 JS2 Connector to Servo Axis 2 1 15 Jump 4 6 JUMP Command Program Zero P 14 Jump Stop 4 21 Jump Testing Jumping Without Stopping 4 20 Jumps and Block Numbers 4 16 Jumps Conditional 4 17 Jumps S CURVES 4 23 Jumps Unconditional 4 16 L LED Indicators Controller Module LED Indicators on Power Mate APM STAT OK CFG EN1 EN2 Limitations on Total Travel Linear Acceleration Lo Limit Low Count Limit LOAD Command Program Zero Load Parameter Immediate AQ Im mediate Command 3 17 Logicmaster 90 30 Configuration of Controller Module 2 2 of Interface Module Loss of Encoder Battery Power Low Limit 2 7 M Maximum Acceleration Time Mode Home Switch Power Mate J for Series 90 30 User s Manual August 1996 Index 5 Index Index 6 Models of Serial Encoders D 1 Modem Turnaround Time Modes Move and Move Modes Serial Encoders D 2 Module Configuration Controller Power Mate APM Inter face Module Module Configuration Data AI Position Error Control Loop Feedback Type Power Mate J Ref Adr Motion Control Motion Program Commands Program Zero voten Program Conditions Which Stop 4 7 Motion Non Programmed h a Motion Programmed 4 6 Move AQ Immediate Command
86. ize Actual Position from the battery backed absolute encoder after a power cycle Absolute Encoder mode is selected by setting the Intgr Mode to CONTINU in the Configuration software Rotary mode allows the controller to create continuous motion in one direction by the use of multiple CMOVE or PMOVE incremental commands As the axis moves Actual Position will reach a Hi or Low Count Limit then roll over to the other limit The distance between Actual Position rollovers is the Rotary Count Modulus Rotary Mode is selected by configuring the EOT Limit gt Hi Count Limit and EOT Limit lt Low Count Limit The battery backed absolute encoder has a total absolute counting range of 8192 cts rev x 32767 revs 268 427 264 counts This is the maximum number of counts the encoder can move after a position reference operation Find Home or Set Position and still retain absolute position If the encoder rotates more than this number of counts after a position reference operation the absolute position is lost and the encoder starts a new counting cycle Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 o Restrictions when Absolute Encoder Mode is used with Rotary Mode 1 If the Rotary Count Modulus in counts is a power of 2 then no restrictions exist on rotary travel This means the distance defined as Hi Limit Low Limit 1 in counts must be a number which is a power of 2 such as 128 256 512 8192
87. jump occurs during a move the remainder of the move is aborted and the command at the destination location is immediately effective Jump destinations must be limited to the bounds of the program containing the Jump command Load Parameter LOAD This command initializes or changes a controller module data parameter value The new value becomes effective immediately when encountered in the program Program Zero may load parameters 1 to 20 Pmove PMOVE Positioning Move this command is used when it is necessary for the axis to be within the configured In Position Zone before proceeding to the next command If no previous acceleration or velocity has been specified in a motion program the configured Jog Accelerationand or Jog Velocity will be used The axis movement will stop for one or two milliseconds in the In Zone range then the next program command will execute Velocity VELOC This modal command specifies the velocity of axis motion Once encountered this command will remain in effect until overridden by a later Velocity command Wait WAIT This command synchronizes the start of axis motion with an external input or event reported in CTL 1 12 The start of motion is suspended until the bit being monitored is true Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Essential Configuration Parameters GFK 1256 To correctly configure the controller module several configuration parameters must be prope
88. l position The second CMOVE will automatically decelerate to the PMOVE s velocity as it approaches its final position The dotted lines indicate when the second CMOVE begins and ends ACCEL 100 ACCEL 100 VELOC 12000 VELOC 6000 PMOVE 1500000 INC LINEAR CMOVE 180000 INC LINEAR VELOC 12000 CMOVE 1 140000 INC LINEAR VELOC 6000 PMOVE 180000 INC LINEAR a45312 Vv a45314 Ja Figure 4 16 Maximum Acceleration Time t t Feedhold with the Power Mate J Feedhold is used to pause program execution without ending the program often to examine some aspect of a system It causes all axis motion to end at the programmed acceleration When feedhold is ended program execution resumes Interrupted motion will resume at the programmed acceleration and velocity Feedhold is asserted by turning ON the Feedhold Q bit and lasts until the Q bit is turned OFE The Abort All Moves Q bit turning ON or an error which would normally cause a stop error will end feedhold as well as terminate the program During feedhold jogging positive and negative is allowed but no other motion When feedhold is terminated and program execution resumes the Power Mate J remembers and will move to its previous destination Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Example 16 Feedhold The following example illustrates a motion profile when feedhold is applied The linear move accelerates to the programmed velocity at the program
89. m Zero S Curve Acceleration Program Zero Commands S CURVE Jumps Select Return Data AQ Immediate Com mand Serial COMM Connector 1 4 iz ea connector pin definitions 1 4 GFK 1256 Power Mate J for Series 90 30 User s Manual August 1996 Index 7 Index Index 8 Serial Communications Port Configura tion Data Baud Rate 2 6 Data Bits 2 6 Idle Time 2 6 Modem Turnaround Time p d Parity 2 6 SNP ID 2 6 Stop Bits Serial Communications High Speed PM APM to DSI Serial Encoder Modes Serial Encoders Models of Servo Motors Digital b 4 Servo Unit Error Alarm table B 4 Servo Units Compatibility Set Configuration Complete AQ Im mediate Command 3 1 Set Position AQ Immediate Command 3 13 Set Position Command Setting the Configuration Parameters SNP ID 2 6 Specifications Power Mate J Status Bits Interface Module 3 18 Status Code AI Status Word 3 6 Status Display Visual on DSI Status LED B 1 Stop Before JUMP Normal Stop Bits p d Strobe Input Circuitry Strobe Position AI Status Word B 6 Subroutines la 16 Sync Out of 2 8 System Overview of PM J T Table Visual Displa Internal Alarm Internal Alarm Type Servo Unit Error Alarm B 4 Terminal Block and I O Cable Power Mate J for Series 90 30 User s Manual August 1996 Testing Jump 4 19 Torque Limit AQ Immediate Command Bid Turnaround Time Typ
90. m to be executed must be a valid program stored in the Power Mate J Conditions Which Stop a Motion Program A motion program will immediately cease when one of the following conditions occurs m The Abort All Moves Q bit turns ON m The Enable Drive Q bit turns OFF m An OvertravelLimitSwitch turns OFF when OT Limits are configured to be enabled m The next programmed move either PMOVE or CMOVE will pass a Software End of Travel Limit m A Stop Error occurs See Appendix A Error Codes Parameters for Programmed Moves Programmed moves have three parameters 1 The distance to move or position to move to 2 The type of positioning reference to use for the move and 3 The type of acceleration to use while performing the move Types of Positioning Reference The choices for the type of reference to use for the move are ABSOLUTE and INCRE MENTAL This reference determines how the first parameter the distance to move or position to move to is interpreted GFK 1256 Chapter 4 Motion Control 4 7 4 8 Absolute Positioning In an absolute positioning move the first parameter is the position to move to The fol lowing is an example of an absolute positioning move PMOVE 5000 ABS LINEAR This move will move the axis from its current position whatever it may be to the posi tion 5000 Thus the actual distance moved depends upon where the axis is when the move is encountered If the initial position was 0 the axis would mov
91. manded Position location for each axis The alternate data includes information such as Parameter Register contents controller module s Firmware Revision and interface module s Firmware Revision The Select Return Data command uses a mode selection and an offset selection The mode selection byte offset 1 of the six byte command determines the Return Data type The offset selection byte offsets 2 3 of six byte command selects an individual data item for some modes Setting the mode to 00h causes the default Commanded Position to be reported The following Return Data selections are allowed Selected Return Data Data Mode Data Offset Commanded Position 00h not used Absolute Feedback Offset cts 07h not used Parameter Register 08h Parameter Number 0 255 APM Firmware Revision 10h not used DSI Firmware Revision 11h not used Absolute Feedback Offset is the position offset that is used to initialize Actual Position when Absolute Encoder is used Actual Position Absolute Encoder Data Absolute Feedback Offset Controller and interface module Firmware Revisions should be interpreted as two separate words for major minor revision codes At least three PLC sweeps or 20 milliseconds whichever represents more time must elapse before the new Selected Return Data is available in the PLC Torque Limit TRLMT The Torque Limit Command provides a method of limiting the torque produced by a digital servo motor on each axis The con
92. med rate Feedhold is applied at the dotted line so velocity decreases at the programmed acceleration to zero Then a Jog is performed using the Jog Minus Q bit This is evident because the Jog Velocity is negative Note the acceleration used during the Jog is the current Jog Acceleration which is different than the programmed acceleration Note also the feedhold must be applied during the entire duration of the Jog After the jog motion has ceased the feedhold is ended and the program continues to completion ACCEL 1000 VELOC 2000 PMOVE 12000 INC LINEAR V a45269 Ni0s 4 t Figure 4 17 Feedhold Feedrate Override GFK 1256 Some applications require small modifications to a programmed velocity to handle outside changes A Feedrate Override immediate command allows changes to a programmed velocity during program execution Whenever a program begins the override rate is initially set to 100 Thus changes to feedrate before the execute program bit is turned ON will be ignored but a feedrate commanded on the same sweep as an execute program bit will be effective A percentage can be assigned to the feedrate from 0 to 120 When a Feedrate Override is commanded the Power Mate J internally multiplies the feedrate percentage by programmed velocity to obtain a new velocity If the axis is moving the current move s Jog Acceleration Mode is used to change velocity to the new velocity All future move velocities will be affected by the f
93. mediately be stopped at the EOT Limit Jogs with Position Valid OFF and Move at Velocity immediate commands ignore the EOT Limits This enables movement outside the EOTs while setting up a system High and Low Count Limits can be used for rotary type motion in which a servo can move forever in either direction When a Count Limit is reached the reported position wraps around to the opposite limit where it can continue changing Thus if the Count Limits are set equal to or within the End of Travel Limits the End of Travel Limits will never be reached See Appendix D for consideration in using absolute encoder mode In Rotary mode Jogs or Incremental Moves can be used to cause continuous motion in either direction and the EOT limits will never be exceeded In EOT Mode Non Rotary Mode Jogs and Programmed Motions beyond either EOT limit are not allowed Rotary Mode selection is based on the relative values of Hi Lo Count Limits and the Pos Neg EOT limits The controller module will be in Rotary Mode if the Hi Count Limit is lt the Pos EOT limit AND the Lo Count limit is gt the Neg EOT limit The controller module will be in EOT Mode Non Rotary Mode if the Hi Count Limit is gt the Pos EOT limit OR if the Lo Count limit is lt the Neg EOT limit Rotary Mode is the DEFAULT operating mode for the Standard Control Loop because the default Count limits and EOT limits are 8 388 607 8 388 608 GFK 1256 Chapter 2 Installation and C
94. n the Series 90 30 PLC system 3 Align the controller module Power Mate APM with the desired slot in the baseplate and backplane connector Tilt the module upward so that the top rear hook of the module engages the slot on the baseplate Detailed module installation information can be found in the Series 90 30 Programmable Controller Installation Manual GFK 0356 4 Swing the module down until the connectors mate and the lock lever on the bottom of the module snaps into place engaging the baseplate notch Repeat steps 2 and 3 for the interface module Digital Servo Interface The DSI should be installed adjacent and to the left of the controller module 5 Connect the included cable from controller module connector B to interface connector JD 35 Complete cable connections to I O and digital servo systems as indicated in Chapter 1 Product Description 6 Repeat this procedure for each Power Mate J 7 Power up the PLC rack The Status LED of the Power Mate APM will turn ON when the module has passed its power up diagnostics 8 When you have completed the hardware installation configure the controller module s as explained in the next section For instructions about installation of the Power Mate J when IEC and other standards must be observed see Installation Requirements for Conformance to Standards GFK 1179 Please pay particular attention to the installation specifics of the controller module and the interface module GFK 1256 2
95. nd GFK 1256 Index Position Increment Command U 4 Position Initialization D 3 Hopibon EoD tune Constant Program Zero Motion Program Com Position Loop Time Constant AQ Im mands medial Command Pals Program Zero Programmer Instruction Position Strobe I Status Bit B 4 Format 2 12 Axis Field 2 12 Position Valid I Status Bit Comand on ART Positioning Move Data Field Positioning Move PMOVE Programmed Motion 4 6 Positioning Reference Types of h 7 Programmed Motion Considerations Other Programmed Move Commands Programmed Moves 4 11 Programmed Moves Parameters h 7 Positioning Absolute 4 8 Positioning Incremental 4 8 Positive End Of Travel P 7 te AP DSI JD ta Misc AEM toa Jag Connector Programmer Compatibility Programming multiaxis Power Mate J Description of Installing Hardware 2 1 R Power Up D 4 Specifications Rack SlotConfiguration 2 2 Power Up Considerations Rate ae i T Immediate Com Prerequisites for Programmed Motion 4 7 mand Program Active l Status Bit 3 3 Recircs 2 7 Program Motion Commands Ref Adr Type 1 Reset Strobe Flag Q Discrete Command Call Subroutine 4 6 Jump Response Methods A 2 Type 2 o kd E o o Mode with Null 4 Rev Comp Reversal Compensation ao 1 6 Reversal Compensation 2 7 Continuous Move p d Rotary voded Dwell 4 6 Restrictions D 5 End of program Positioning Move 4 6 S Wait l4 6 Progra
96. nes the positive axis direction as clockwise CW shaft rotation In practice the motor direction configuration allows the user to reverse the motion caused by all commands Chapter 2 Installation and Configuration 2 5 2 6 Serial Communications Port Configuration Data The Power Mate J can be programmed using the Motion Programmer software The computer running the Motion Programmer software connects to the Serial Communications Port which supports the SNP protocol on the face plate of the controller module The Serial Communications Port must be configured properly to communicate with the Motion Programmer Make sure the configuration parameters for the Motion Programmer and the Serial Communications Port match The configuration parameters for the Serial Communications Port Configuration Data are described in Table 3 2 Table 2 2 Serial Communications Port Configuration Data Configuration Description Values Defaults Units Parameter Baud rate of SNP Port 300 600 1200 2400 4800 9600 19200 19200 ODD EVEN NONE opp nA NETA 102 CA ZN Data DataBits Number of data bits 7or Zos A CA EA EXC TI Modem turnaround 0 2550 in multiples of 10 time milliseconds Idle Time Maximumlinkidle 1 60 time SNP ID SNP ID 6 characters consisting of A Fand A00001 N A 0 9 First character must be A F Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Axis Configuration Data The controller module Axi
97. ntegrator is not used when the controller module is used to control digital servos Therefore the Intgr Mode Integrator Mode configuration is used for the alternate purpose of selecting Incremental or Absolute operating mode of the a Series pulse encoders Limitations on Total Travel for EOT Mode D 2 The maximum value that can be used for the EOT is 8 388 607 user units User units are configured as a ratio to the encoder count value and are bound to the range of 8 1 to 1 32 Additionally the feedback from a digital servo is fixed at 8192 counts per revolution Using a simple formula will determine the maximum number of motor shaft revolutions possible for axis travel when EOT non rotary mode is used Counts Maximum Revolutions 1024 Tame User Units Using the above calculation the maximum possible move is realized with the User Unit to Count ratio at the maximum 1 32 resulting in a maximum travel of 32 768 motor shaft revolutions The maximum travel originates at the Actual Position zero and can move the number of maximum travel revolutions plus or minus of the zero position There is no restriction on maximum travel for Rotary mode refer to Important Configuration Considerations in Chapter 2 for additional information on EOT Mode and Rotary Mode Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Lo Incremental Encoder Mode Considerations The digital serial encoder can be used as an incremen
98. ntly identified The interface module will reset the visual display and will begin to display any error caused by conditions that remain present Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 DSI Status Information The table below summarizes the status information displayed on the 7 segment display on the Power Mate J Interface Module Table B 1 Power Mate J Interface Module Internal Status Alarms Ready No Information Nonerequired No alarm Servo ON NotReady No Information Nonerequired No alarm Servo OFF Not Ready Waiting gt 5 No Warning 1 CorrectCommunications seconds for communica problem typicallycable tions 2 Checkcontrollermodule configuration Battery Low Yes Warning 2 Install a new battery 2 Issue Clear Error Battery Failed Zero Yes Normal Servo Stop 1 Install a new battery Motor Over Temperature Yes Normal Servo Stop 1 Eliminatecauseofalarm 2 Issue Clear Error Over Current Yes Fast Servo Stop 1 Eliminate cause of alarm 2 Issue Clear Error Pulse Coder Yes Fast Servo Stop 1 Eliminate cause of alarm 2 3 Issue Clear Error Pulse Coder Error Yes Fast Servo Stop 1 Eliminatecauseof alarm 2 Power cycle servo amp 3 Issue Clear Error 7 Servo Unit Error Yes Fast Servo Stop 1 Detailsin following 2 table 3 Foralarms which apply to a particular axis a decimal point will distinguish the axis When the alarm applies to axis 1 the decimal point
99. o facilitate wiring to the drive and machine the high density I O connector is typically connected by a short cable to a terminal block A three meter I O cable IC693CBL311 is available with the Power Mate J system a45113 ZA Connector B not used B Digital Mode A S 1A gajoa AAAA A S Aa nn N M INT CONTROLER MODULE CABLE S TERMINAL BLOCK S Figure 1 6 I O Cable and Terminal Block 1 6 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 I O Specifications The specifications and circuitry for the controller s I O connections are provided below Enable Relay Output Normally open DC solid state relay contact Contacts rated at 30 volts DC 100 mA Re sistive load only The off state leakage current is 10 LA maximum a45106 ENABLE a A RF A ai nod w A Saui Figure 1 7 Enable Relay Output Circuitry Analog Output Output of D A converter with the following characteristics 1 axis Power Mate J only m Resolution 13 bits including sign m Linearity 02 of full scale output m Offset Voltage 500 uV maximum Maximum Output 10 0 V 0 3 V Minimum Load Resistance 2000 Q m Maximum allowable Voltage Between Analog Common and Ground 1 0 V 100 uH
100. ock m Null m Acceleration m Velocity Type 3 Commands m Positioning Move m Continuous Move Dwell m Wait m End of Program Type 1 commands can redirect the program path execution but do not directly affect positioning Call Subroutine executes a subroutine before returning execution to the next command Jump either continues execution at another location or it tests CTL bits and based on the bit condition may or may not alter the program path Type 2 commands also do not affect position The Block command provides an identification or label for the following Type 3 command If no Block is found in the current program block the previous Block is used The Velocity and Acceleration commands specify velocity and acceleration rates for motion of the following Type 3 command Type 3 commands start or stop motion and thus affect positioning control Positioning and Continuous moves command motion Dwell Wait and End of Program stop motion A program block consists of one and only one Type 3 command with any number and combination of preceding Type 1 and 2 commands Type 2 commands are optional a program block could contain a single Type 3 command Type 2 commands and Conditional Jumps do not take effect until the following Type 3 command is executed While the Power Mate J is executing one program block the following program block is processed into a buffer command area to minimize the transition time from one block to
101. of the second CMOVE ACCEL 2000 VELOC 8000 CMOVE 7000 INC LINEAR ACCEL 10000 VELOC 2000 CMOVE 4400 INC LINEAR a45260 t Figure 4 5 Not Enough Distance to Reach Programmed Velocity GFK 1256 Chapter 4 Motion Control 4 13 Example 4 Hanging the Power Mate J When the Distance Runs Out A serious programming error involves hanging the Power Mate J at a high velocity when the distance runs out In the following example the first CMOVE accelerates to a high velocity The second CMOVE has an identical velocity However the distance specified for the second CMOVE is very short Thus the axis is running at a very high velocity and must stop in a short distance If the programmed acceleration is not large enough the following profile could occur In order to not pass the final position the Power Mate J instantly commands a zero velocity This rapid velocity change is undesirable and could cause damage to the controlled machine ACCEL 500 VELOC 3000 CMOVE 9000 ABS LINEAR ACCEL 600 CMOVE 4800 INC LINEAR v a45260 t Figure 4 6 Hanging the Power Mate J When the Distance Runs Out Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Dwell Command A DWELL command is used to generate no motion for a specified number of milliseconds A DWELL after a CMOVE will make the CMOVE perform similar to a PMOVE even if the specified dwell duration is zero A DWELL command using a parameter to set the dwell t
102. oftware will be reinstated Move Command This command will produce a single move to the commanded position each time it is sent The current Jog acceleration and velocity which can also be changed by AQ commands will be used for the move The data field for this command may contain the move position or distance in bytes 2 5 with the command type in hexadecimal format as defined below Move Type byte 1 00h Abs Pmove Linear 01h Abs Cmove Linear 10h Abs Pmove S 11h Abs Cmove S 40h Inc Pmove Linear 41h Inc Cmove Linear 50h Inc Pmove S 51h Inc Cmove S The data field for this command may contain a parameter number in byte 2 bytes 3 5 unused with the command type as defined below Move Type byte 1 80h Abs Pmove Linear 81h Abs Cmove Linear 90h Abs Pmove S 91h Abs Cmove S COh Inc Pmove Linear C1h Inc Cmove Linear DOh Inc Pmove S D1h Inc Cmove S The Move Command is executed as a single move motion program therefore all the restrictions that apply to motion program execution will also apply to it For example if a program is already active for axis 1 then an attempt to send this command for axis 1 will result in an error condition reported Jog Velocity user units sec This command sets the velocity used when a Jog Q bit is used to jog in the positive or negative direction A PLC reset or power cycle returns this value to the configured data J
103. og Acceleration user units sec sec This command sets the acceleration value used by Jog Move at Velocity a Home Cycle and Abort All Moves A PLC reset or power cycle returns this value to the configured data Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Position Loop Time Constant milliseconds This command allows the servo position loop time constant to be changed from the configured value The lower the value the faster the system response Values which are too low will cause system instability and oscillation For accurate tracking of the commanded velocity profile the Position Loop Time Constant should be 1 4 to 1 2 of the MINIMUM system deceleration time The Vel at 10 V configuration value must be set correctly for proper operation of the Position Loop Time Constant gain factor A PLC reset or power cycle returns this value to the configured data Velocity Feedforward This command sets the Velocity Feedforward gain percent It is the percentage of Commanded Velocity that is added to the controller module velocity command output Increasing Velocity Feedforward causes the servo to operate with faster response and reduced position error Optimum Velocity Feedforward values are 80 90 The Vel at 10 V configuration value must be set correctly for proper operation of the Velocity Feedforward gain factor A PLC reset or power cycle returns this value to the configured data Velocity Loop Gain VLGN T
104. oller module configuration data programmed with the PLC configuration software Update Flash Memory This command copies important RAM data including Motion Programs and the latest Absolute Feedback Offset into Flash memory Normally the Update Flash Memory command is sent after a Set Position or Find Home operation when an Absolute Digital Encoder is used Updating the Flash memory permanently saves the Absolute Feedback Offset so that Actual Position can be restored correctly after a system loss of power Refer to Appendix D Serial Encoders for additional information Load Parameter Immediate This command is executed from the PLC to immediately change a controller module data parameter value Data parameters are only used by motion programs A command for each parameter change is required GFK 1256 Chapter 3 Power Mate J to PLC Interface 3 17 Section 2 Interface Module I Status Bits DSI 3 18 The DSI will return 16 bits of status information to configured PLC I references via the normal input scan of the Series 90 30 CPU The meaning of these status bits is shown in the table below Table 3 8 DSI Status Bits PLC Status Bits I Bit Number Bit Number Reserved Reserved Axis1 Servo Enabled Axis 2 Servo Enabled Axis 1 MCON Enabled Axis 2 MCON Enabled Reserved Reserved Axis 1 Error Axis 2 Error Reserved Reserved Reserved Reserved Controller Comm OK DSI Board OK or Interface Module OK Servo Enabled This bit is
105. on that is now stored in the Strobe Position status word When the PLC acknowledges this data it may use the Reset Strobe Flag Q command bit to clear the Position Strobe I status bit flag Once the Position Strobe I bit is set additional Strobe Inputs will not cause new data to be captured The flag must be cleared before another Strobe Position will be captured As long as the Reset Strobe Flag Q command bit is set the Position Strobe bit flag will be held in the cleared state In this condition the latest Strobe Input position is reflected in the Strobe Position status word although the flag cannot be used by the PLC to indicate when new data is present CTLO9 CTL12 Output Controls These command bits may be tested by the controller module during execution of Wait or Conditional Jump commands Execute Motion Program 0 10 These commands are used to select stored programs for immediate execution Each command uses a one shot action thus a command bit must transition from OFF to ON each time a program is to be executed Programs may be temporarily interrupted by a Feedhold command When a program begins execution Rate Override is always set to 100 A Rate Override AQ immediate command can be sent on the same sweep as the Execute Program Q bit and will be effective as the program starts Only one Motion Program can be executed at a time per axis the Program Active Yl status bit must be OFF or Motion Program execution will not be allowe
106. onfiguration 2 17 2 18 The Over travel Limit Switches are external hardware switches The switch status is returned in the CTL bits CTLO5 CTL06 The controller module can be configured to use these CTL bits as Over travel Limit Switches If the switches are enabled whenever the drive is enabled and an Over travel bit is OFF the controller module commands all motion on that axis to immediately cease If this happens the Jog and Clear Error Q bits can be turned on simultaneously to move the servo away from the Over travel switch A Reversal Compensation feature on the controller module allows accurate positioning on systems with backlash Backlash is exhibited by a servo that must move a small amount before the system begins moving when it switches directions For example consider a dead bolt door lock Imagine the servo controls the key in the lock and the feedback reports movement of the bolt When the servo turns the key counterclockwise the bolt moves left However as the servo turns the key clockwise the bolt does not move until the key turns to a certain point The Reversal Compensation feature adds in the necessary motion to move the servo to where motion will begin on the feedback device The controller module removes the compensation when a move in the negative direction is commanded and adds the compensation before a move in the positive direction The Servo Drive Disable Delay specifies how long the controller module will wait aft
107. or PMOVE command Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Commanded Velocity Commanded Velocity user units sec is a value generated by the controller module that indicates the instantaneous velocity command that is producing axis motion At the beginning of a move it will increase at the acceleration rate and once the programmed velocity has been reached it will stabilize at the programmed velocity value Actual Velocity Actual Velocity user units sec is a value maintained by the controller module that is derived from the feedback device Therefore it represents the velocity of the axis movement Position Error Position Error user units is the difference between Commanded Position and Actual Position at any instant in time GFK 1256 Chapter 3 Power Mate J to PLC Interface 3 7 Controller Module Q Discrete Commands PM APM The following Q Outputs representing Discrete Commands are sent automatically to the controller module from the CPU each PLC sweep A command is executed simply by turning on the Output Bit of the desired command The actual addresses of the Discrete Command bits depend on the starting address configured for the Q references See Table 3 1 Module Configuration Data The bit numbers listed in the following table are offsets to this starting address Table 3 5 Q Discrete Commands 1 Axis MOM acute Motion Program Execute Motion Program 2 Execute Motion Program3
108. ponse Description Hexadecimal Jog Errors on JogwhileFind Home ear OSC 2 43 Jog while Program Selected and not Feedholding error x 50 i 51 52 Status Only Set Position while not In Zone error 53 Status Only Attempt to initialize position before digital encoder passes reference point 4 Status Only Digital encoder position invalid must use Find Home or Set Position End of Travel and Count Limit Errors 56 Status Only Commanded Position gt Positive End of Travel or High Count Limit 57 Status Only Commanded Position lt Negative End of Travel or Low Count Limit 58 Te Te 9 T A 5 Status Only AbsolutePosition Position offset gt Positive End of Travel or High Count Limit Status Only AbsolutePosition Position offset lt Negative End of travel or Low Count Limit Drive Disable Errors 5B Stop Normal Drive Disabled while Moving 5C Stop Normal Drive Disabled while Program Active Software Errors 5F Status Only Software Error Call G E Fanuc Field Service al 02 E sates Only Y Request Program Owih other programsat ts Only Too many programs requested insamePECsweep i ER i E 5 H Status Only Request Program 1 10 with multi axis program active Status Only Request two programs on same sweep with program active 4 Status Only Request two programs for same axis lower number program executed 75 StatusOnly Empty or Invalid Program requested Status erroris reported command is not e
109. r Error is the only command that will clear the Error status bit and the associated Status Code word If the condition causing the error is still present the Error status bit will not be cleared Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Controller Module Al Status Words PM APM GFK 1256 The following AI Status Words are transferred automatically from the controller module to the CPU each sweep The actual addresses of the Status Words depend on the starting address configured for the AI references See Table 3 1 Module Configuration Data The word numbers listed in the following table are offsets to this starting address AR ARE Table 3 3 Al Status Words 1 Axis F000 ESTE Commanded Position Axis1 Position Error Axis1 The word numbers represent an offset to the starting address for AI references The AQ Immediate Command Select Return Data 40h can be used to select Command Position or other data such as module firmwarerevision If Module configuration parameter AI Pos Erris DISABLED the value zero will be reported instead of Position Error in AI words 12 13 Table 3 4 Al Status Words 2 Axis P00 enso OOOO Commanded Position Axis1 Commanded Position Axis2 The word numbers represent an offset to the starting address for AI references The AQ Immediate Command Select Return Data 40h can be used to select Commanded Position or other data such as
110. r entering either a signed double integer or the number of a controller module parameter as appropriate for the configured command GFK 1256 Chapter 2 Installation and Configuration 2 11 Program Zero Programmer Instruction Format A Program Zero instruction consists of a command and associated data describing the command The command and data are entered into areas on the program editor screen called fields These fields are described below Command Name Field The English language designation for the command To enter a command position the cursor on a command name field then press the desired function key F1 F9 Most of the commands fall into groups such as CMOVE PMOVE VELOC ACCEL and so forth The variations of these commands can be displayed using the Tab key after pressing the function key for the particular group For example to program a CMOVE IS P Continuous Move incremental s curve using a parameter first select a command field then press the CMOVE function key This causes CMOVE AL to be displayed in the command name field of the screen The variations of the command are cycled through by pressing the Tab key To program a JUMP command press F10 MORE and then press F1 JUMP Data Field Paired with each command is a data field In the data field enter either a signed double integer or the number of a parameter 0 255 as appropriate for the configured command Parameters 1 20 can be loaded with data using the LOAD
111. r will be reported to the PLC until a subsequent block instruction is processed or the controller is reset or power cycled Cmove CMOVE Continuous Move this command is used when it is not necessary for the axis to be within the configured In Position Zone before proceeding to the next command If no previous acceleration or velocity has been specified in a motion program the configured Jog Accelerationand or Jog Velocity will be used Dwell DWELL This command causes motion to cease for a specified time period in milliseconds before proceeding to the next command Jump JUMP This command is used to Branch program execution to another location in the program under certain specified states of the Faceplate control inputs CTL 1 8 and Q control outputs CTL 9 12 The jump will occur when the condition tests true logic 1 An unconditional Jump can also be selected The jump may be forward or backward in the program The jump condition will be tested as soon as the move prior to the Jump command has completed A maximum of 220 jumps can exist for all programs and subroutines Y Once the condition testing is allowed to start the test will occur once each millisecond every two milliseconds for two axis controller module until a Block Number or another Jump command is encountered This will allow continued testing while a move or series of moves takes place if the Jump command is located ahead of the moves in the block If a
112. ratio of 1000 8192 sets 1 user unit 0 001 inch Default is 1 1 OT Limit Sw Selects whether the controller module will monitor axis 1 hardware overtravel input limit switches If axis 1 OT Limit Switches are disabled then Axis 2 Home Switch may be used two axis controller only The one axis controller module can use the hardware Over travel Limit Switch inputs If Limit Switches are DISABLED the Limit Switch inputs can be used as general purpose GFK 1256 Chapter 2 Installation and Configuration 2 7 2 8 inputs If ENABLED then 24 VDC must be applied to both of the inputs in order for the controller module to operate If not then whenever the drive is enabled a Limit Switch Input Error will occur The Jog and Clear Error Q bits can be used simultaneously to back away from the Limit Switch The OT Limit Switch setting for the two axis controller module may be set to ENABLED for axis one only The OT Limit Switch setting for axis 2 should always be DISABLED When axis one overtravel switches are enabled the Home Switch input for axis two Home 2 is unavailable Axis 1 Default ENABLED Pos EOT Positive Software End of Travel limit User Units If the controller module is programmed to go to a position greater than the Positive EOT then an error will result and the controller module will not allow axis motion Default 8 388 607 Neg EOT Negative Software End of Travel limit User Units If the controller module is programmed to
113. rcuitry 0 0066 ees 1 7 Figure 1 8 Analog Output Circuitry 2000 eens 1 7 Figure 1 9 Strobe Input Circuitry 0 eens 1 8 Figure 1 10 5 VDC Power Circuitry 0 eens 1 8 Figure 1 11 General Purpose Input Circuitry 0 0 0 6 eee eens 1 9 Figure 1 12 Connection Diagram for 1 Axis Power Mate J Digital Mode T OCORNECtO A ate ates Poel sigh aed cents EEA eta ibd A ds 1 12 Figure 1 13 Connection Diagram for 2 Axis Power Mate J Digital Mode T OC OnnectOnmAe ch bsss6 fees A eal a Bale sa db aislada 1 13 Figure 1 14 Interface Module Visual Status Display and Connectors 000 c cece e eee 1 14 Figure 1 15 Controller Module to Interface Module Cable Diagram 0000 e ee eee 1 17 Figure 2 1 Example of a Program Zero Editor One Axis 6c cece eee ee 2 11 Figure 4 1 Sample Linear Motion 6c eens 4 8 Figure 4 2 Sample S Curve Motion sesers aeres ty teipe ene eens 4 9 Figure 4 3 Combining PMOVEs and CMOVES 2 6 rr 4 11 Figure 4 4 Changing the Acceleration Mode During a Profile ooooooooooccccnnno 4 12 Figure 4 5 Not Enough Distance to Reach Programmed Velocity 66 66 c cece eee eee 4 13 Figure 4 6 Hanging the Power Mate J When the Distance Runs Out 0 00 eee eee 4 14 Fig re Aa7 WEI ca eS doi d Vie a 4 15 Figure 4 8 Unconditional Jump 2 0 eens 4 16 Figure 4 9 Normal Stop Before JUMP 6 teen eens 4 20 Figur
114. reference position 2 The axis is stopped at the configured Jog Acceleration rate and with the configured Jog Acceleration Mode 3 The axis is moved at the configured Jog Velocity and with the configured Jog Acceleration rate and Jog Acceleration Mode the number of user units specified by the Home Offset value from the Home reference position 4 The axis is stopped at the configured Jog Acceleration rate and with the configured Jog Acceleration Mode 5 Aninternal Set Position sets the Commanded and Actual Positions to the configured Home Position value the Power Mate J sets the Position Valid I bit to indicate the Home Cycle is complete Jogging with the Power Mate J GFK 1256 The Jog Velocity Jog Acceleration and Jog Acceleration Mode are configurable in the Power Mate J These values are used whenever a Jog Plus or Jog Minus Q bit is turned ON Note that both bits ON generates no motion The Jog Acceleration and Jog Acceleration Mode are also used during a Find Home Cycle and when a Move at Velocity immediate command is performed Programmed motions use the Jog Velocity and Jog Acceleration as defaults A Jog can be performed when no other motion is commanded or while programmed mo tion is temporarily halted due to a Feedhold command The Enable Drive Q bit does not need to be ON to Jog but it can be ON Turning on a Jog Q bit will automatically close the Enable Relay and turn on the Drive Enabled YI bit When an Overtravel
115. rly set This section explains how these parameters affect controller module operation and how the parameters relate to each other While all parameters are important some parameters are absolutely essential to correct operation Velocity at 10 volts All controller module and servo functions depend on this value being correct for proper operation The Velocity at 10 V configuration field should be set to a conversion constant value of 139820 multiplied by the decimal value of the User Units to Counts ratio For example with a User Unit value of 1 and a Counts value of 2 the decimal value of the ratio would be 0 5 The conversion constant multiplied by 0 5 yields the value 69910 for the Velocity at 10 v 1 2 139820 69910 If the user sends the Power Mate J a velocity command which exceeds the capability of the servo system the Power Mate J will clamp that command value at the appropriate maximum boundary no error will be reported back to the controller module Position Loop Time Constant The lower the Position Loop Time Constant the faster the axis will respond However if the Time Constant is too low the system may become unstable or even oscillate When decelerating especially at high speeds the controller module could command a servo to stop at a certain point faster than the servo could respond This would result in overshoot For accurate tracking of the commanded velocity profile Pos Loop TCshould be1 4to1 2 of the MINIMUM
116. rogrammed at the jump destination is in the opposite direction as the initial motion the profile would be identical if the moves were CMOVEs instead of PMOVEs GFK 1256 Chapter 4 Motion Control 4 21 ACCEL 30000 VELOC 15000 BLOCK 1 JUMP CTLO9 2 PMOVE 120000 ABS LINEAR DWELL 4000 BLOCK 2 PMOVE 0 ABS LINEAR V a45268 Figure 4 11 Jump Stop Example 11 Jump Followed by PMOVE In this JUMP example the command after the JUMP is a PMOVE in the same direction The velocity profile below shows the acceleration and movement for the first CMOVE and the deceleration to the PMOVE s velocity The CTLO1 bit OFF when the PMOVE begins turns ON at the dotted line Motion stops after a PMOVE even if a conditional jump goes to another block Thus the CTLO1 bit triggers a deceleration to zero before the final CMOVE begins BLOCK 1 ACCEL 2000 VELOC 8000 CMOVE 76000 INC LINEAR BLOCK 2 ACCEL 1000 VELOC 4000 JUMP CTL01 3 PMOVE 50000 INC LINEAR BLOCK 3 ACCEL 6000 VELOC 6000 CMOVE 36000 INC LINEAR V a45311 Figure 4 12 Jump Followed by PMOVE 4 22 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 S CURVE Jumps Jumps during linear motion and jumps during s curve motion at constant velocities immediately begin accelerating or decelerating to a new velocity Jumps during an s curve acceleration or deceleration however require different rules in order to maintain an s curve profile What happens w
117. rs are in the form AD6B xxxx yyyy where xxxx represents the motor type field For example When reading a Motor Specification number from a motor label of A06B 0032 B078 the significant digits 0032 indicate the motor model of b 2000 the Series table references the Motor Type Code 36 needed for the configuration field a Series Servo Motor Motor Type Code Motor Model Motor Specification a0 5 3000 a1 3000 a2 2000 a2 3000 a3 3000 a6 2000 a6 3000 a12 2000 a12 3000 a22 1500 a22 2000 a22 3000 a30 1200 a 30 2000 a30 3000 a40 2000 a40 FAN Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 a L Series Servo Motor Motor Type Code Motor Model Motor Specification aL3 3000 aL6 3000 aL9 3000 aL25 3000 aL50 2000 ac3 2000 aC6 2000 aC12 2000 aC22 1500 a HV Series Servo Motor Motor A Code Motor Model _ Model Motor Motor Specification a a12HV 3000 3000 a22HV 3000 a30HV 3000 a M Series Servo Motor Motor AS Code Motor Model Model Motor Motor Specification aM3 3000 3000 aM6 3000 aM9 3000 b Series Servo Motor Motor Type Code Motor Model Motor Specification b 1 3000 b2 3000 b3 3000 b6 2000 Motor Dir A configured motor direction of POS Positive defines the positive axis direction as counter clockwise CCW motor shaft rotation when viewed looking into the motor A configured motor direction of NEG Negative defi
118. s AQ immediate command It must remain continuously in the AQ data for proper operation Thus any other AQ immediate command will remove the Force D A command For the single axis Power Mate J only a Force D A Output immediate command and a D A Output value in the AQ Words 3 5 will operate the analog output on I O connector A A D A Output value of 32000 will produce 10 00 Vdc and a D A Output value of 32000 will produce 10 00 Vdc Position Increment With Position Update user units This command is similar to the Position Increment without position update command 21h except that Actual and Commanded Position returned in AI data are both updated by the increment value If the servo is enabled the controller module will immediately move the axis by the increment value GFK 1256 Chapter 3 Power Mate J to PLC Interface 3 13 3 14 In Position Zone This command can be used to set the active In Position Zone to a value different than the configured value The In Position Zone is used by the controller module to determine when a PMOVE is complete and also when the axis motion feedback position is close enough to the commanded position to allow position critical operations such as Set Position to take place The In Zone l bit is set to indicate this If the controller module is power cycled or the PLC CPU is reset for any reason the value set by this command will be lost and the In Position zone value set by configuration s
119. s 1 Home Switch Input CTLO5 Axis 1 Overtravel Switch Input or Axis 2 Home Switch Input CTL06 Axis 1 Overtravel Switch Input The configuration software selects whether the Axis 1 Overtravel Switches are enabled or disabled If they are disabled on a Two Axis Power Mate J CTLO5 can be used as the Axis Two Home Switch Input Configuration Complete The Configuration Complete status bit is set by AQ Immediate command 49h This status bit is cleared whenever the PLC sends a reset command or new configuration to the controller module Configuration Complete can be set by a PLC program after other AQ Immediate commands such as In Position Zone or Position Loop Time Constant have been sent to the controller module The status bit can then be monitored by the PLC If the bit is cleared then the controller module has been reset or reconfigured and the PLC should re send all necessary AQ configuration commands before setting the bit again PLC Control Active Normally the PLC Control Active status bit is set indicating that the Q discrete commands or AQ immediate commands from the PLC can control the controller module PLC Control Active is cleared only when the Status screen in the Motion Programmer is used instead of the PLC to control the controller module a capability not yet implemented Error This status bit is set when the controller module detects any error When set the AI Status Code word identifies the error condition Clea
120. s Configuration Data consists of base values for configuration parameters used by one or more motion programs The values of these configuration parameters do not usually change therefore they are not included in the motion program The configuration parameters are defined and briefly described here Table 2 3 Axis Configuration Data Configuration Description Values Defaults Units Parameter Positive End oF Travel Negative End of Travel vare velocity Feed Forward 0100 O ooo nigr TC _ IntegratorTimeConstant 0 1000 fo fw Rey Comp _ ReversalCompensation 0 25 fo users High CountLimit Home Position 538880818388607 0 userni HomeOiiset Home Offset value 32768 232767 __ userunits Find Home Mode HOMESW MO E HOMESW MOVE Scaling dependent configuration parameter value range depends upon user scaling 2 Intgr TC is not used This location is used to configure Velocity Loop gain with a range of 0 255 3 Intgr Mode is not used CONT selects Absolute Encoder OFF or IN ZONE selects Incremental Encoder User Units Counts The ratio of User Units to Counts sets the number of programming units for each feedback count This allows the user to program the controller module in units appropriate for the application The RANGE for user units and counts is 1 to 65 535 The RATIO of user units to counts must be in the range 8 1 to 1 32 For example if there is 1 000 inch of travel for 8192 feedback counts a user units counts
121. s it is followed by a DWELL or a WAIT the next programmed velocity is zero or it is the last program command It does not wait for the position to be IN ZONE before going to the next move A CMOVE reaches its programmed position at the same time it reaches the velocity of the following Move command A special form of the CMOVE command can be used to force the Power Mate J to reach the programmed CMOVE position before starting the velocity change associated with the next move command that is execute the entire CMOVE command at a constant velocity Programming an incremental CMOVE command with an operand of 0 CMOVE INC 0 will force a delay in the servo velocity change for the next move command in sequence The following sequence of commands illustrates this effect Command Data Comments VELOC 10000 Set velocity of first move 10000 CMOVE 15000 ABS LINEAR Reach velocity of second move at position 15000 VELOC 20000 Set velocity of second move 20000 CMOVE 0 INC LINEAR Force next velocity change to wait for next move command CMOVE 30000 ABS LINEAR Stay at velocity 20000 until position 30000 then change to velocity 5000 VELOC 5000 Set velocity of third move 5000 PMOVE 45000 ABS LINEAR Final stop position 45000 4 10 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 Programmed Moves By combining CMOVEs and PMOVES absolute and incremental moves and linear and s curve motion virt
122. se R09 Label on circuit board Firmware upgrades of earlier hardware release versions will not function with the interface module Servo Units a Series Servo Amplifier Units SVU or SVM b Series Servo Amplifiers a Series and b Series Servo Motors Chapter 1 Product Description 1 19 Chapter Installation and Configuration 2 This chapter contains information about installing the Power Mate J in the Series 90 30 PLC and configuring the modules with Logicmaster software The Power Mate J can operate in any Series 90 30 CPU or expansion baseplate Series 90 30 release 3 52 or later required For limitations on the maximum number of Power Mate J systems you can install per baseplate and system refer to Module Specifications in Chapter 1 The modules are connected by an eight inch high speed serial interface cable included with Power Mate J and are installed adjacent to each other with the interface module to the left of the controller module The configuration files created by Logicmaster 90 30 configuration software must match the physical configuration of the modules Section 1 Installing the Power Mate J Hardware To install the Power Mate J modules on the baseplate follow these steps 1 Use the Logicmaster 90 30 software or the Series 90 30 Hand Held Programmer to stop the PLC This will prevent the local application program if any from initiating any command that may affect the operation of the module 2 Power dow
123. set whenever the servo amplifier power inverter is on The motor shaft will be uncontrolled and may freely rotate whenever this bit is off Consult appropriate amplifier manual for further details MCON Enabled This bit is set whenever the magnetic contactor MCON is commanded on When this bit is off hysteresis braking is applied to the motor Consult the appropriate amplifier manual for further details Axis Error This bit is set whenever an amplifier or serial encoder problem is detected The specific error will be displayed on the DSI visual indicator and will also be reported to the PLC in the controller module AI Status Word Controller Comm OK Bit 7 Controller Comm OK is always set to a 1 except when a communications failure within the controller module has been detected During the power up sequence while the DSI is waiting for the controller module to communicate for the first time this bit will be initialized to a 1 until the power up wait time has been exhausted This will avoid false reporting of a communications error while the DSI waits on its initial communication from the controller module DSI Board OK or Interface Module OK Bit 15 DSI Board OK or Interface Module OK will always be set to a 1 except when a fatal system alarm has been detected Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Chapter Motion Control 4 This chapter provides practical information on Power Mate J Motion Control
124. sition Initialization D 3 Set Position Command D 4 Considerations Incremental Encoder Mode Continuous Move p d Continuous Move CMOVE Control Loop 2 3 Index Controller Module Configuration 2 2 description of Module Compatibility serial COMM connector Count CTLO9 CTL12 Output Controls Q Dis crete Command 3 10 D D ACommand Force al Data Bits 2 6 Data Field Program Zero 12 Description Controller Module Interface Module Power Mate fa Digital Servo Interface 1 14 Digital Servo Motors list of P 4 Disable Delay DisDly Servo Drive Disable Delay 2 10 Display Visual Status DSI Drive Enabled lI Status Bit 3 3 Dwell Dwell Command DWELL Command Program Zero 2 14 E EN1 LED EN2 LED Enable Drive Q Discrete Command 3 9 Enable Relay Output Circuitry End of Program 4 6 Error I Status Bit 3 4 Error Code Format A 2 Error Word Status Codes A 1 Essential Configuration Parameters Acceleration Mode Open Loop Mode Position Loop Time Constant 2 15 User Units and Counts Velocity at 10 Volts Power Mate J for Series 90 30 User s Manual August 1996 Index 3 Index Index 4 Example 1 Combining PMOVEs and CMOVEs Example 10 Jump Stop 4 21 Example 11 Jump Followed by PMOVE ren 22 Example 12 S Curve Jumping After the Midpoint of Acceleration or Decelera tion 4 23 Example 13 S Curve Jumping Before the Midpoint
125. system deceleration time For users familiar with servo bandwidth expressed in rad sec Bandwidth rad sec 1000 Position Loop Time Constant ms For users familiar with servo gain expressed in ipm mil Gain ipm mil 60 Position Loop Time Constant ms Gain Bandwidth Position Loop Time ipm mil rad sec Constant ms ae 85 va Pee E oo f e o o Open Loop Mode For applications which do not require feedback control or employ very crude positioning systems an Open Loop Mode exists Setting a zero Position Loop Time Constant which indicates that the positioning loop is disabled selects this mode Note that in Open Loop Mode the only way to generate motion is to program a non zero Velocity Feed forward The Position Error is no longer used to generate motion because Position Error is based on feedback and Open Loop Mode ignores all feedback Chapter 2 Installation and Configuration 2 15 User Units and Counts The controller module has a very powerful scaling feature A User Units to Counts ratio can be configured to allow programming in other than default counts In a simplified example all digital encoders used with the Power Mate J produces 8 192 counts per revolution and is geared to a machine which produces one inch per revolution The default units would be one thousandth of an inch 1000 8192 However you may want to write programs and use the controller module with metric units A ratio of 2540 User
126. tal encoder returning 8192 counts per shaft revolution with no revolution counts retained through a power cycle The equivalent of a marker pulse will occur once each motor shaft revolution All Home modes Home Switch Move Move and Set Position reference the axis and set the Position Valid bit upon successful completion High count limits and Low Count limits are valid and the Actual Position as reported by the controller module will wrap from high to low count or from low to high count values This is an excellent mode for rotary applications that will always operate via incremental moves in the same direction Home Offset and Home Position configuration items allow simple referencing to the desired location Incremental mode is selected by setting the controller module s Logicmaster 90 30 configuration field Intgr Mode Integrator Mode to OFF or to IN ZONE Absolute Encoder Mode Considerations The a Series serial pulse encoder can be used as an absolute type encoder by adding a battery pack to retain servo position while system power is off A Find Home cycle or Set position must be performed initially or whenever encoder battery power is lost with the servo amplifier also in a powered down state Absolute Encoder mode must be configured in the controller module to function properly Absolute mode is selected by setting the controller module s Logicmaster 90 30 configuration field Intgr Mode Integrator Mode to CONTINU Absolute Encod
127. te J receives the immediate command or an error will occur Also if a Move at Velocity command is already in the AQ data the velocity value must change while the Drive Enabled bit is ON for the Pow er Mate J to accept it The Power Mate J detects a Move at Velocity command when the AQ values change When the Power Mate J is performing a Move at Velocity it ignores the Software End of Travel Limits Hardware Overtravel Limits must be ON if they are enabled A Move at Velocity can be stopped without causing an error in two ways a Move at Velocity command with a velocity of zero or turning the Abort All Moves Q bit ON for at least one PLC sweep Force D A Command The Force D A command is the only command that must be maintained in the AQ data for proper operation If any other immediate command is sent to the Power Mate J the Force D A operation will end A one shot Force D A command will operate only during the sweep in which it appears Refer to Chapter 2 for details on use of this command Position Increment Commands To generate small corrections between the axis position and the Power Mate J tracking the Position Increment commands can be used to offset Actual Position by a specific number of user units If the Drive Enabled I bit ON the axis will immediately move the increment amount If the position increment without position update is used AQ command 21h the Actual Position reported by the Power Mate J will remain unc
128. te J systems in a PLC depends on the available power from the installed power supply The total power consumption of all modules in a baseplate must be calculated so that the total load capacity of the supply is not exceeded Refer to Chapter 3 of GFK 0356 for detailed information on load requirements for Series 90 30 modules The available power supplies are IC693PWR321 Standard AC DCPower Supply allows 15 watts for 5 VDC IC693PWR322 24 48VDC Power Supply allows 15 watts for 5 VDC IC693PWR330 High Capacity AC DCPower Supply allows 30 watts for 5 VDC The CPU 352 will be available 4th Quarter 1996 NOTE Refer to GFK 0867B GE FanucProduct Agency Approvals Standards General Specifications or later version for product standards and general specifications Note Installation instructions in this manual are provided for installations that do not require special procedures for noisy or hazardous environments For installations that must conform to more stringent requirements such as CE Mark see GFK 1179 Installation Requirements for Conformance to Standards 1 18 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Section 2 Compatibility GFK 1256 The Power Mate J is compatible with the following devices Host CPU Series 90 30 PLC s models 311 313 321 323 331 340 341 351 and 352 release 3 52 or later The
129. te Positioning ACCEL Command Program Zero 2 14 Acceleration Linear 4 8 Mode 2 17 S Curve 4 9 Time Maximum Types of Power Mate J for Series 90 30 User s Manual August 1996 Index 1 Index Index 2 Actual Position AI Status Word Actual Velocity AI Status Word Alarms Clearing B 2 Alarms Multiple B 2 Analog Output Circuitry Appendix A Error Word Status Codes Appendix B Visual Status Error Codes Appendix C Data Parameters From the PLC Appendix D Serial Encoders D 1 Axis Configuration Data Absolute Position Offset 2 7 Counts Disable Delay DisDly Final Home Velocity 2 7 Find Home Vel Find Home Velocity 2 7 Fnl Home Vel Gradient 2 7 High Limit 2 7 Home Mode Intgr Mode Intgr TC Jog Acc Mod 2 10 Jog Acceleration Jog Acceleration Mode Neg EOT Negative End Of Travel 2 7 OT Limit SW Overtravel Limit Switch P 7 Pos EOT 2 8 Pos Err Lim Pos Loop TC 2 9 Position Error Limit b 7 Position Loop Time Constant p 7 Power Mate J for Series 90 30 User s Manual August 1996 Positive End Of Travel 2 7 Recircs Rev Comp Reversal o le b 7 User Units User Units Counts Velocity at 10 V Velocity at 10 Volts 2 9 Velocity FF 2 7 2 9 Axis Enabled I Status Bit 3 3 Axis Error Indicator AxisField Program Zero B Baud Rate Block BLOCK Command Program Zero P 14 Block Diagram of PM
130. ter Immediate Even though the commands are sent each sweep the controller module will act ona command ONLY if it changed since the last sweep When any of the 6 byte data changes the controller module will accept the data as a new command and respond accordingly The 6 byte format for the Immediate Commands is defined in Table 2 7 The actual addresses of the Immediate Command Words depend on the starting address configured for the AQ references The word numbers listed in the following table are offsets to this starting address The word offsets are shown in reverse order and in hexadecimal to simplify the data entry The following example sends the Set Position command to axis 1 The first word word 0 contains the actual command number For the Set Position command the command number is 0023h The second and third words contain the data for the Set Position command which is a position The second word word 1 is the least significant word of the position and the third word word 2 is the most significant word To set a position of 3 400 250 first convert the value to hexadecimal 3 400 250 decimal equals 0033E23A hexadecimal For this value 0033 is the most significant word and E23A is the least significant word The data to be sent to the controller module would be Word 2 Word 1 Word 0 Command 0033 E23A 0023 Set Position 3 400 250 Setting up word 0 as a hexadecimal word and words 1 and 2 as a double integer in the PLC will simplif
131. the Logicmaster 90 30 configuration software release 6 01 or later It will be necessary to configure the interface module slot as a generic 16 point input module The interface module should be installed in an empty slot to the left of the controller module Section 3 Program Zero Program Zero is a short default motion program 20 commands maximum which is defined in the Logicmaster 90 30 configuration software and downloaded to the Power Mate J whenever the controller module is initialized by the PLC Program Zero is programmed by entering motion commands in an English language format similar to that of the Motion Programmer software In a 2 axis module the controller module determines whether Program Zero is an axis 1 axis 2 or multiaxis program according to which axis or axes are used in the program For example if all Program Zero commands contain Axis number 1 Program Zero will be classified as a Single Axis program for Axis 1 Therefore Program Zero will be allowed to execute concurrently with another Single Axis Program for Axis 2 A multiaxis program 0 requires that both axes in a two axis module be home referenced prior to execution PROGRAM 0 PAGE 1 Data 0000000800 0000004000 0000010000 0000007500 0000000000 0000000000 0000000000 Figure 2 1 Example of a Program Zero Editor One Axis The Program Zero commands are entered using the Function keys F1 F9 Paired with each command is a data field fo
132. the acceleration programmed of the jump destination block Finally as the second CMOVE completes velocity is reduced to zero and the program ends BLOCK 1 ACCEL 2000 VELOC 10000 JUMP CTLO3 3 CMOVE 120000 INC LINEAR BLOCK 3 ACCEL 20000 VELOC 5000 CMOVE 15000 INC LINEAR Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 V a45264 Figure 4 10 JUMP Without Stopping Jump Stop Ajump stop is a stop that is caused by a jump When a jump stop occurs the Jog Acceleration and Jog Acceleration Mode are used instead of any programmed acceleration Note that s curve motion will achieve constant velocity before using the Jog Acceleration and beginning to decelerate See the s curve jump examples for more details The Jog Acceleration is used because a jump stop may indicate something is wrong The current Jog Acceleration which can be changed with an immediate command provides more versatility than the programmed acceleration There are two ways of generating a jump stop each described below A conditional JUMP triggered during a PMOVE will always generate a jump stop Because a PMOVE always stops before continuing to a subsequent motion a jump stop always occurs when a jump takes place during a PMOVE When a conditional jump trigger occurs during a CMOVE however a jump stop will not occur if the motion programmed at the jump destination is a PMOVE or CMOVE representing sufficient distance in the same d
133. the graph indicate that the acceleration was not constant When the move begins the acceleration starts slowly and builds until it reaches the programmed acceleration This should be the midpoint of the acceleration Then the acceleration begins decreasing until it is zero at which time the programmed velocity has been reached An s curve move requires twice the time and distance to accelerate and decelerate that a linear move needs if the acceleration is the same The area under the velocity vs time graph is also the distance moved ACCEL 2000 VELOC 2000 PMOVE 8000 INC SCURVE V a45257 t Figure 4 2 Sample S Curve Motion GFK 1256 Chapter 4 Motion Control 4 9 Types of Programmed Move Commands Positioning Move PMOVE A PMOVE uses the most recently programmed velocity and acceleration If a VELOC command has not been encountered in the motion program the Jog Velocity is used as a default If an ACCEL command has not been encountered in the motion program the Jog Accelerationis used as a default A PMOVE will always stop when it is completed to allow the IN ZONE I bit to turn ON Continuous Move CMOVE A CMOVE uses the most recently programmed velocity and acceleration If a VELOC command has not been encountered in the motion program the Jog Velocity is used as a default If an ACCEL command has not been encountered in the motion program the Jog Accelerationis used as a default A CMOVE does not stop when completed unles
134. tion it accelerates to be at the velocity of the fifth move when it completes The graph shows the acceleration of the fourth move is s curve Chapter 4 Motion Control 4 11 Finally the fifth move begins and moves at its programmed velocity for a time until it decelerates to zero Any subsequent moves after the fifth would begin at zero velocity because the fifth move is a PMOVE Example 2 Changing the Acceleration Mode During a Profile The following example shows how a different acceleration and an even acceleration mode can be used during a profile using CMOVEs The first CMOVE accelerates linear ly to the programmed velocity Because the second CMOVE s velocity is identical to the first the first CMOVE finishes its move without changing velocity The acceleration of the second move is s curve as it decelerates to zero velocity ACCEL 2000 VELOC 6000 CMOVE 13000 ABS LINEAR ACCEL 4000 CMOVE 15000 INC SCURVE v a45259 t Figure 4 4 Changing the Acceleration Mode During a Profile Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Example 3 Not Enough Distance to Reach Programmed Velocity CMOVES and PMOVES can be programmed that do not have enough distance to reach the programmed velocity The following graph shows a CMOVE which could not reach the programmed velocity The Power Mate J accelerates to the point where it must start decelerating to reach the programmed position of C1 at the velocity
135. tion Data m Program Zero Module Configuration Data During each CPU sweep certain data is automatically transferred both ways between the controller module and the CPU CPU Interface data references the starting locations for the automatic transfers The configuration parameters in Module Configuration Data are described in Table 3 1 Table 2 1 Module Configuration Data Configuration Description Values Defaults Units Parameter i Ref Adr Start address for I ref type CPU Dependent 100001 or next higher reference 32 bits Ref Adr Start address for Q ref type CPU Dependent Q00001 or next higher reference N A 32 bits Ref Adr Start address for Al ref type CPU Dependent A100001 or next higher refer N A 15 words for 1 axis 28 words ence for 2 axis Ref Adr Start address for AQ ref type CPU Dependent AQO00001 or next higher refer 6 words ence AI Pos Err On Single Axis Power Mate Js DISABLED DISABLED this parameter adds ENABLED Position Error to AI Data Fdback Type Feedback Type DIGITAL ENCODER Servo Interface Type DIGITAL ANALOG Motor Type GE Fanuc Motor Type 0 127 0 no motor Motor2 Type Motorl Dir Motor direction for POS POS Motor2 Dir positive velocity command NEG Fdback Type DIGITAL selects GE Fanuc Digital AC servo encoder input mode If DIGITAL is selected the SERVO CMD configuration parameter must also be set to DIGITAL Default ENCODER Ctl Loop Control Loop Type STA
136. tion or to determine when events should occur A block number can also be the destination of a JUMP command Unconditional Jumps Jumps are divided into unconditional and conditional An unconditional jump command simply tells the Power Mate J to continue program execution at the destination block number An example of an unconditional jump follows Example 6 Unconditional Jump The program executes a PMOVE dwells for 2 seconds and then unconditionally jumps back to the beginning of the program at block 1 Thus the PMOVE will be repeated until an End of Travel Limit or Overtravel Limit Switch is reached ACCEL 10000 VELOC 30000 BLOCK 1 PMOVE 200000 INC LINEAR DWELL 2000 JUMP UNCOND 1 V a45263 Figure 4 8 Unconditional Jump Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 Conditional Jumps A conditional jump is a JUMP command with a CTL bit specified in the command Conditional jumps are Type 1 commands in that they affect program path execution but they are also similar to Type 2 commands because they do not take effect until a Type 3 command following the JUMP command is executed When a conditional JUMP command is executed the Power Mate J examines the specified CTL bit If the bit is ON program execution jumps to the destination BLOCK if the bit is OF the program continues executing the command after the JUMP Note that the Type 3 command after the conditional jump and at the jump destination
137. troller module will set the torque limit TRLMT at the default 100 whenever a power cycle or reset occurs The PLC application logic must set any other value for desired TRLMT The valid range for TRLMT is 1 to 100 in units of 1 TRLMT can be changed during axis motion Refer to the appropriate servo motor manual for the actual motor torque curve to determine the actual value of torque output at a given velocity Configuration Modes This configuration command permits various configuration changes to the controller module by modifying the byte in the command string associated with the desired feature The values established by the Configuration Mode command are not saved through a power cycle or reset and must be re established on system startup Use of the Set Configuration Complete command is recommended with appropriate application logic to enable the PLC verification of desired modes MCON CTRL has the following possible values m MCON CTRL 00h Digital Servo Magnetic Contactor MCON NOT controlled by CTL Output Default m MCON CTRL 01h Digital Servo Magnetic Contactor MCON is controlled by CTL Output With the default mode of operation the Q Enable Drive command On will energize the digital servo power relay MCON and enable servo power to the amplifier The Enable Drive Q Off will cause the MCON and digital servo power to be removed after the configured Servo Drive Disable Delay DisDly With MCON CTRL byte 4 set to
138. ually any motion profile can be generated The following examples show some simple motion profiles as well as some cases of incorrect motion programming Example 1 Combining PMOVEs and CMOVEs This example shows how simple PMOVEs and CMOVEs combine to form motion profiles ACCEL 1000 VELOC 2000 PMOVE 5000 ABS LINEAR VELOC 1200 PMOVE 10000 ABS SCURVE ACCEL 1500 VELOC 2800 CMOVE 6000 INC LINEAR VELOC 1200 CMOVE 23000 ABS SCURVE ACCEL 1000 VELOC 2800 PMOVE 5000 INC LINEAR 245258 V DAA Figure 4 3 Combining PMOVEs and CMOVEs The move types are indicated under the corresponding move for example P L indicates linear PMOVE The first PMOVE accelerates to programmed velocity moves for a distance and decelerates to a stop This is because motion stops after all PMOVEs When the first move stops it is at the programmed distance The second move is an s curve PMOVE It like the first accelerates to the programmed velocity moves for a time and decelerates to zero velocity because it is a PMOVE The next move is a linear CMOVE It accelerates to programmed velocity moves for a time and then decelerates to a lower velocity using linear acceleration When a CMOVE ends it will be at the programmed position of the move just completed and at the velocity of the next move Thus when the fourth move begins it is already at its programmed velocity The fourth move is a CMOVE so as it approaches its final posi
139. uct Description Table 1 3 Cable Connections to Faceplate I O Connector A 2 Axis Power Mate J I O Module Terminal Block Connector A Terminal Number Description Pin Number Ea O a IEEE ES Pa Cid E TI aa Strobe 1 CTLOI Input Overtravel 1 direction CTL06 Input eed TT asd EA Pe E ani EI Po moconnection ___________ 1 11 Functional Connection Diagrams The Figures below illustrate how the 1 and 2 Axis Power Mate J I O is connected to a drive and a machine in a typical application Shielded cable should be used as indicated Functional Connection Diagram 1 Axis 1 0 CONNECTOR A a47108 VO TERM BLK CONN TERM A8 4 QO ANALOG OUTPUT B7 17 L4 ANALOG OUTPUT COMMON A7 3 e ENABLE RELAY OUTPUT B6 16 __ ENABLE RELAY OUTPUT B12 13 SHIELD B11 18 A12 5 B10 19 A11 6 B9 20 A10 A9 8 5 VDC POWER B8 21 0 VOLTS NEGATIVE POSITIVE OVERTRAVEL OVERTRAVEL LIMIT SWITCH HOME SWITCH y Er SWITCH gt l l l A5 2 OT CTL06 re i Homer crios Y Ht 4 B5 14 OT CTLO5 B4 15 INCOM1 24VDC B12 13 SHIELD B3 22 STROBE CTL01 ime 5V A4 9 STROBE CTLO1 x DRIVER AL 12 Ov GENERAL PURPOSE 5V INPUTS CTLO2 B2 23 N A3 10 CTL02 DRIVER J Figure 1 12 Connection Diagram for 1 Axis Power Mate J Digital Mode 1 12 Power Mate J for Series 90
140. ugust 1996 v Contents Chapter 3 Power Mate J to PLC Interface oo oooocoooccmoocmmom 2 o 3 1 Section 1 Power Mate APM Command and Status Data 3 2 Controller Module I Status Bits PM APM ooococcccccccccccco 3 2 Controller Module AI Status Words PM APM 0 ooocccccccoccccocco 3 5 Controller Module Q Discrete Commands PM APM 3 8 Controller Module AQ Immediate Commands PM APM 3 11 Section 2 Interface Module I Status Bits DSI 3 18 Chapter 4 Motion Control tins to ia A a wea ee ees 4 1 Position Feedback Types ooooooococccconncnccrrrrran eens 4 1 Non Programmed Motion oooooococcocnnnnncrrrrrrr eee eee 4 2 Power Mate J Home Cycle 0 cece nee eens 4 2 Jogging with the Power Mate J 6 cece cece eee 4 3 Move at Velocity Command 0 66 cece eee eee 4 4 ForceD ACommand 0 0 0 ccc cee ee eee een eens 4 4 Position Increment Commands 000 c eee eee eee 4 4 Other Considerations 0 00 4 5 Programmed Motion desak neiaa E rr 4 6 Prerequisites for Programmed Motion 000 c cece 4 7 Conditions Which Stop a Motion Program 6 cece eee eee 4 7 Parameters for Programmed Moves 0oooocoococcooococcnn 4 7 Types of Programmed Move Commands 0 000 e seen eee 4 10 Programmed Moves iiini gurena Eee EA T E E E E E 4 11 Dwell Command See ee a a a r a A aaa a a eee ee 4 15 Ma
141. um Acceleration Time The following 1 axis program shows a problem with a very long acceleration time and a solution In the first program and profile 120 seconds two minutes is required to reach the programmed acceleration Since this is greater than 64 seconds the Power Mate J calculates that an acceleration of 188 would allow a velocity of 12000 to be reached in 64 seconds The left hand velocity profile below shows the slightly higher 188 acceleration used Also shown is a dotted line indicating the programmed acceleration to constant velocity Chapter 4 Motion Control 4 25 One solution for obtaining a low acceleration for a long period of time breaks the move up into separate moves with individual acceleration times less than 64 seconds This method requires some calculation Each acceleration and deceleration must be broken into moves with acceleration times less than 64 seconds Thus to allow an acceleration of 100 during acceleration and deceleration three moves will be required The second program and profile those on the right show how the first program can be broken into three parts The distance at the midpoint of each acceleration when velocity is 6000 is calculated to be 180 000 one fourth the distance required to accelerate to 12000 An initial CMOVE uses this distance The next CMOVE will then accelerate to its velocity at the same acceleration rate The final PMOVE is the midpoint distance 180 000 user units from the fina
142. will affect jump behavior Conditional JUMP commands should not be used with multiaxis programs containing sync blocks unless the Jump is triggered while both axes are testing the same JUMP command Conditional Jump testing starts when the next PMOVE CMOVE DWELL WAIT or END Program command following a Conditional JUMP becomes active When Conditional Jump testing is active the designated CTL bit is tested once every millisecond for the 1 axis Power Mate J and once every 2 milliseconds for the 2 axis Power Mate J Conditional Jump testing ends when the designated CTL bit turns ON Jump Trigger occurs or when a new Block Number becomes active If more than one Conditional JUMP is programmed without an intervening PMOVE CMOVE DWELL WAIT or END Program command only the last Conditional JUMP will be recognized Motion Program Example Begin Program 1 JUMP CTLO1 2 This JUMP command will be ignored JUMP CTLO2 3 This JUMP command will be recognized CMOVE 1 40000 INC LINEAR 2 CMOVE 1 20000 INC LINEAR 3 PMOVE 1 100000 ABS LINEAR 4 DWELL 1 100 End Program When a new Block Number becomes active AFTER a Conditional JUMP command Jump testing occurs one more time Motion Program Example Begin Program 1 CMOVE 1 20000 ABS LINEAR JUMP CTLO01 3 2 PMOVE 1 40000 ABS LINEAR CTLO1 tested only once 3 DWELL 1 100 End Program In the example above The CTLO1 bit will only be tested once because the PMOVE fol lowin
143. with a number of examples The main topics discussed are m Position Feedback Types Non Programmed Motion Programmed Motion Position Feedback Types The initial release of the Power Mate J supports only digital serial encoders used with the a Series or b Series digital servo Encoder resolution is fixed at 8192 encoder counts per motor shaft revolution Incremental or Absolute battery backed encoders may be con figured Refer to Appendix D for additional information about absolute encoder usage GFK 1256 4 1 Non Programmed Motion The Power Mate J can generate motion in an axis in one of five ways without the use of any motion programs m Find Home and Jog use the Q bits to command motion Move at Velocity Force D A Output and Position Increment use AQ immediate commands During Jog Find Home Move at Velocity and Force D A Output any other commanded mo tion programmed or non programmed will generate an error The only exception is Position Increment which can be commanded any time See the description of Position Increment motion for more details Non programmed motions Abort Jog Move at Velocity use the JOG acceleration and ac celeration mode FEEDHOLD uses the programmed acceleration and acceleration mode Power Mate J Home Cycle 4 2 A Home Cycle establishes the Home Position for systems with a serial pulse encoder used in incremental mode The configured Home Offset defines the location of Home
144. xecuted 70 71 72 73 74 75 Power Mate J for Series 90 30 User s Manual August 1996 GFK 1256 GFK 1256 Table A 1 Status Word Error Codes Continued ErrorNumber Response Description Hexadecimal Program Execution Conditions Errors so Status Only Execute Program while Home Cycle active Execute Program while Jog Execute Program while Move at Velocity Execute ProgramwhileD A Forced ss Status Only Execute Program while Program Selected 57 xc Hardware Errors BA CRC error Communication to DSI Communicationsalarm from DSI Stop Fast Servo not ready when MCON command is on may be caused by E STOP input to amplifier Servo Motor Over Current Serial Encoder Communications Alarm Serial Encoder Alarm Servo Unit Alarm Status Only Firmware HardwareAxisNumberMismatch 1 axisfirmware in 2 axis module or 2 axis firmware in 1 axis module Status error is reported command is not executed AO Al A8 A9 B C C Cc C C C Cc C B B B B B E E 1 2 3 5 8 F 0 1 2 3 4 5 6 7 0 1 F E Appendix A Error Word Status Codes A 5 Appendix B Visual Status Error Codes This appendix describes the visual error codes provided by the Power Mate J These visual displays consist of LEDs on the controller module and by the 7 segment plus decimal dis play on the interface module Section 1 Controller Module Status LEDs PM APM LED Indicators GFK 1256 There
145. y immediate command entry GFK 1256 Chapter 3 Power Mate J to PLC Interface 3 11 3 12 The following table applies to both the 1 Axis and the 2 Axis Power Mate J Table 3 7 Immediate Commands Using the 6 Byte Format 5 4 7 1 EM 0 Immediate Command Definition oo a Override RO 0 120 a Incr Position Increment Without PositionUpdate Incr 128 127 User Units Velocity 22h Move At Velocity Vel 8 388 608 8 388 607 User Units sec Position 23h Set Position Pos 8 388 608 8 388 607 User Units xx xx D AOutput 24h Force D A Output 4 095 4 095 RPM Digital D A Output 32 000 32 000 Analog xx Xx E Incr 25h PositionIncrementWith PositionUpdate Incr 128 127 User Units In Position Zone In PositionZone Range 0 2000 Daa O O Data Move Move Type 27h 27h MoveCommand Velocity Jog Velocity Vel 1 8 388 607 User Units sec Acceleration Jog Acceleration Acc 1 8 388 607 User Units sec sec Time Constant 2Ah Position Loop TimeConstant Time Constant 0 5 10000 xx xx xx VFF 2Bh Velocity Feedforward OOO EES pee EE E E A ae VLGN 0 255 Limit Range 1 100 lee ee eee CTRL Pa Pe x o 49m seconfigurationcompee e o aar fupaaterashmemoy O Parameter Data Par h 50h Load Parametedmmediate Par 0 255 Parameter Data Range depends on parameter usage The word numbers represent an
146. y short In the program on the right however the JUMP command is encountered before the move command This starts jump testing before motion begins and jump testing continues as long as the move lasts If the CTL bit turns ON while the move is being performed the jump will be performed After the move completes the BLOCK command ends jump testing and program execution continues normally Jump testing would continue during subsequent moves encountered before the BLOCK command ACCEL 5000 ACCEL 5000 VELOC 1000 VELOC 1000 BLOCK 1 BLOCK 1 CMOVE 2000 ABS LINEAR JUMP CTLO1 3 JUMP CTLO01 3 CMOVE 2000 ABS LINEAR BLOCK 2 BLOCK 2 Normal Stop Before JUMP A conditional jump command is similar to Type 2 commands in that jump testing does not start until the Type 3 command immediately after the JUMP is executed If this Type 3 command would normally stop motion then motion will stop before jump testing begins Type 3 commands that will stop motion are DWELL WAIT End of Program and moves in the opposite direction Thus even though the CTL bit may be ON before the block with the conditional JUMP and Type 3 command is executed axis motion will stop before program execution contin ues at the jump destination This stopping is NOT a Jump Stop which is described in Example 10 Example 8 Normal Stop Before JUMP The following example contains a jump followed by a DWELL command The Power Mate J because it processes ahead knows it must stop a
147. y time the axis commands are halted and the actual position has caught up to the commanded position e g for Dwell Feedhold or Feedrate 0 Chapter 3 Power Mate J to PLC Interface 3 3 3 4 Position Strobe The Position Strobe status bit indicates that the Strobe Input at the I O connector has captured an axis position that is currently indicated by the Strobe Position AI status word The data will remain in the Strobe Position status word until the Position Strobe bit is cleared by the Reset Strobe Flag Q bit Once the Position Strobe bit is cleared new data may be captured by another Strobe Input Position data will be captured within 1 millisecond from a Strobe Input 2 milliseconds for two axis Power Mate J In Error Limit The In Error Limit status bit is set when the absolute value of the position error exceeds the configured Position Error Limit value When the In Error Limit status bit is set commanded velocity and commanded position are frozen to allow the axis to catch up to the commanded position Faceplate Input l Status Bits These inputs indicate the state of the external input devices connected to the controller module s face plate terminals CTLO1 03 and CTLO05 06 These inputs as well as CTLO9 CTL12 from the PLC Q table may be tested by the controller module during the execution of Wait and Conditional Jump commands CTLO1 Axis 1 Strobe Input CTLO2 Axis 2 Strobe Input Two Axis Power Mate J Only CTLO3 Axi

Power Mate J for Series 90-30 User`s Manual, GFK-1256

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