SmartStack™ Stepper Positioning Module
Contents
1. 36 Resume 4 4 36 Set Current Position 37 Configuration 2 19 Using 19 Deceleration 28 Destination Position 26 Differential 11 Differential 402222 12 Encoder nenn 25 39 cado 39 40 Encoder Tolerance Configuring 41 PAGE 47 SUPO270 02 Motor Stall Detection Configuring 42 Multiplier and Divisor Value Examples 41 Types of 39 Error and Status Input Bit Register 24 External 16 Features iier RR eR e i i ei ei e RR IRR RR 9 VO nn 16 I O Register Assignments 21 Indexed Deceleration 28 Indexed Window Close Position 28 Indexed Window Open Position 28 INdICAtOrS cid 12 Installation 15 Isolated 0000 cnn 11 Motion Profiles 12 Motor Position 252. ee Milliseconds 28 10 2000 4 REGISTERS SUPO0270 02 4 2 8 6 Deceleration Time AQ7 This command word determines the maximum time in mS spent decelerating from the Running Velocity to the Base Velocity at the end of a move If AQ7 is zero deceleration time is the same as the acceleration time set via AQ6 Note that if it is time to start decelerating before acceleration to the Running Velocity is complete the deceleration time is decreased and the velocity profile becomes triangular Also note that the maximum useful value for Deceleration Time AQ7max is dependent on the Base Velocity AQ4 and Running Velocity AQ5 according to the following formula AQT max s Milliseconds 4 2 3 7 Indexed Destination Position AQ8 and AQ9 These two command words AQ8 and AQ9 are treated as a single 32 bit unsigned integer value representing the Indexed Destination Position The Indexed Destination Position contains the number of steps to continue in the current direction after the STP100 detects external activation of the Index Input during a Move Indexed command 011 4 2 38 Indexed Deceleration Time AQ10 This command word determines the time in mS spent decelerating from the Running Velocity to the Base Velocity at the end of a Move Indexed command Q11 after the Indexed Input has been asserted If AQ10 is zero deceleration time is the same as the normal deceleration
3. HILIM can be used to start moves in the Up direction while the Low Limit Input LOLIM can be used to start moves in the Down direction To accomplish this the ladder program needs to be set up the AQ values as for a normal relative or absolute move and the appropriate End Limit Input needs to be activated before Q8 or Q9 is turned ON In this case the actual move does not start until the End Limit input is deactivated 5 COMMANDS 10 2000 35 SUP0270 02 5 3 5 Move Indexed Command Command Bit Q11 Status Bits Required 1 through l8 and 9416 must be OFF Status Bits Affected 11 through l5 and l13 through 96116 Status Words Required None Status Words Affected through AI4 Command Words Required AQ1 through AQ14 This command performs an Indexed Move which is similar to a Relative Move 08 except that the final destination can be modified if the external Index Input becomes active This modified behavior is determined by the user programmed values AQ8 through AQ14 Note that AQ8 through 14 are ignored by all other STP100 commands For details on AQ8 through AQ14 values refer to Table 4 1 and to Section 4 2 3 in Chapter 4 As stated above the Indexed Move is similar to the Relative Move In fact if the Index Input does not become active during an Indexed Move it behaves exactly like a Relative Move The purpose of the Move Indexed command is to provide the ability to s
4. 2000 2 INSTALLATION SUPO0270 02 NOTES 3 CONFIGURATION 10 2000 PAGE 19 SUP0270 02 CHAPTER 3 CONFIGURATION 3 1 General Chapter Three describes the steps necessary to configure the STP100 module and the OCS it is attached to The procedures for using Cscape software are also described 3 2 Configuration Configuration is usually completed after the modules are installed With Cscape however OCS configuration is contained with the source code CSP files The OCS can be configured before the modules are installed or even if the OCS is not available This is a great convenience when programming must start before the hardware has been received 3 2 1 Select the Module to be Configured First invoke Cscape From the Cscape Main Menu select Controller I O Configure Next double click on the empty slot in which the STP100 module will reside or click on the Config button to the right of the slot position Sin Double click here C or click here M p M EY uw uu Figure 3 1 Select the Module Slot This invokes the Add I O Module screen Click on the Other tab Select the OTHER tab Figure 3 2 Select the Other Modules tab 20 10 2000 3 CONFIGURATION SUP0270 02 Then select the STP100 module Select the STP100 module Figure 3 4 STP100 Module is Added The screen returns to the Configure l O dialog box with the
5. AQ5 Running Velocity must be gt AQ4 8191 AQ6 Acceleration Time mS 27 300 20 AQ4 Base Velocity must be AQ5 1 8191 1 1 0 7 Deceleration Time mS 27 300 Indexed Destination Position Lo Word Indexed Destination Position Hi Word je Kanes Indexed Deceleration Time mS 27 300 Indexed Window Open Position Lo Word 16 777 215 Indexed Window Open Position Hi Word Indexed Window Close Position Lo Word Indexed Window Close Position Hi Word 19 771 215 24 10 2000 4 REGISTERS SUPO0270 02 4 2 STP100 Module OCS Register Details This section contains detailed information regarding the STP100 module s use of OCS registers 4 2 1 Error and Status Input Bit Register Details 11 96116 The STP100 uses sixteen 16 Digital Input l registers as Error and Status bits as summarized in Table 4 1 above Table 4 2 shows these bits and the status conditions they represent Table 4 2 Error and Status Input Bit Details Register Description Condition 911 Emergency Stop Error Emergency Stop input activated during move 9612 Low End Limit Error Low Limit input activated during move up High End Limit Error High Limit input activated during move down l4 Illegal Move Error Previous commanded move was not possible 9615 Motor Stalled Error Motor is not moving in response to pulses 96l6 Spare Error future use Not Used 17 Spare Error f
6. see section 3 2 3 Configuring an STP100 for Indexed Moves increases the number of required Command Word Output Registers registers from seven 7 to fourteen 14 NOTE A Move Indexed command has one more difference compared to other move commands In applications where all moves are in the same direction the DIR and DIR outputs can be used as MOVING and MOVING outputs indicating Move in Progress to some external device At the start of a Relative Absolute or Indexed move DIR and DIR are set according to the direction of the move At the end of a Relative and Absolute move the DIR and DIR outputs do not change state However at the end of an Indexed Move DIR and DIR are always taken Low and High respectively Therefore when an Indexed Move starts in the Up direction DIR and DIR start out High and Low respectively and then switch to Low and High respectively when the move completes 36 10 2000 5 COMMANDS SUPO0270 02 5 3 6 Repeat Move Command Command Bit Q12 The Repeat Move command is not really a command at all but can be used to automatically repeat a Relative Move Q8 or an Indexed Move Q11 command When a Relative Move or Indexed Move completes normally the STP100 checks the Q12 bit If the Q12 bit is ON the STP100 automatically repeats the move just completed As long as the Q12 bit stays ON the move is repeated immediately after completion of each move If the Q12 bit
7. 2 1 Select the Module to be 19 3 2 2 Check the Module s I O Register Assignments 0000 21 32 31 Configure the Module i ette deep Ra aa 21 CHAPTER 4 REGISTERS 2 26 62 1 12 92 21 23 Al Generals ne E 23 4 2 STP100 Module OCS Register 24 4 2 1 Error and Status Input Bit Register Details Yol1 116 24 4 2 2 Status Word Input Register Details 5 4 25 4 2 3 Command Word Output Register Details 1 AQ7 or 1 96AQ14 26 4 2 8 Command Bit Output Register Details 01 016 29 CHARTER 5 COMMANDOS 1 1 3 2 22 32 31 5 1 ee 31 5 2 Issuing COMMANGS ed DeL LO Dd Ed 31 5 3 Available Commands OEE 31 5 3 1 Clear Error s Gommland a 31 5 3 2 Find Origin Up and Find Origin Down 32 5 3 3 Up and Jog Down nennen nennen nnns 33 5 3 4 Move Relative and Move Absolute 34 5 3 5 Move Indexed Command ettet redire ci na 35 5 3 6 Repeat Move 36 5 3 7 Resume M
8. accept any other commands until this bit is cleared using the Clear Errors command Therefore the Clear Errors command must be the first command issued after a power ON or reset 32 10 2000 5 COMMANDS SUPO0270 02 5 3 2 Find Origin Up and Find Origin Down Commands Command Bits 04 and Q5 Status Bits Required 1 through l8 and 9116 must be OFF Status Bits Affected 11 through 9615 19 and 96113 through 116 Status Words Required None Status Words Affected through AI4 Command Words Required AQ1 through AQ6 These commands are used to search for the Origin Reference Position as follows Q4 Searches for Origin Position in the Up direction Q5 Searches for Origin Position in the Down direction In the following discussion Origin Source is either the Home Input or the Marker Input depending on how the STP100 module is configured see section 3 2 3 When searching for Origin Position the following search sequence takes place 1 The Current Position Valid status bit 19 is turned OFF position not valid 2 The motor is moved normally starts at Base Velocity and accelerates to Running Velocity in the selected direction up for Q4 or down for Q5 3 When the Origin Source becomes active motion is stopped immediately 4 f the Simple Method radio button was selected during configuration skip to step 8 NOTE The Simple Method variation assumes that the user programmed Running Velocity i
9. equipment such as stepper motor translator drives encoders and switches 7 2 Translator Drives The STP100 does not provide the necessary signals to drive a stepper motor directly A Translator Drive is required The Translator Drive can be in a separate enclosure or it can be contained within the motor housing itself The Translator Drive accepts Step and Direction signals from the STP100 and generates the signals necessary to drive the motor The STP100 is compatible with three common Translator Drive electrical interfaces differential RS 485 5VDC positive going and 5VDC negative going Note that 5VDC signals can be also be referred to as TTL Compatible signals Figures 7 1 7 2 and 7 3 show the proper wiring for the 3 different interface types Note that the Step and Direction signals are not isolated from common ground HES00STP100 Step Pin 17 STEP Step Pin 18 gt STEP Direction Pin 15 DIR Direction Pin 16 n DIR Translator Figure 7 1 Interfacing to a Translator Drive Using Differential Signals 8005 100 GND Pin 8 19 GND Step Pin 17 JM STEP Translator Direction Pin 15 gt DIR Figure 7 2 Interfacing to a Translator Drive Using Positive 5VDC Signals 44 10 2000 7 WIRING SUPO0270 02 8005 100 GND Pin 8 or 19 GND Step Pin 18 Tr
10. is active An STP100 configured for an Up Down Encoder is especially useful for unidirectional motion control in which some mechanical event provides the feedback such as a proximity detector monitoring gear teeth 6 3 Configuring the Encoder After configuring Encoder Type as either Quadrature or Up Down appropriate values should be entered for Encoder Multiplier Encoder Divisor and Encoder Tolerance In addition the Enable Stall Detection box can be checked if desired 6 3 1 Configuring Step Pulse to Encoder Feedback Ratio Before encoder feedback can be used for Motor Position validation or Motor Stall detection the STP100 must know the ratio of motor step pulses to encoder feedback pulses This is accomplished by setting the Encoder Multiplier and the Encoder Divisor to values which are appropriate for the user supplied hardware Step Resolution specified in micro steps per revolution indicates the number of step pulses which must be sent by the STP100 to move the stepper motor one revolution This value is determined by the connected translator drive and is switch or jumper selectable on some drives Encoder Resolution specified in lines per revolution indicates the number of feedback pulses the encoder sends to the STP100 during one revolution of motion This value is determined by the encoder itself For a given Step Resolution and Encoder Resolution the following formula can be used to determine the proper settings fo
11. time set via 7 4 2 3 9 Indexed Window Open Position AQ11 and AQ12 These two command words AQ11 and AQ12 are treated as a single 32 bit unsigned integer value representing the Window Open Position during a Move Indexed command 96Q1 1 The Indexed Window Open Position contains the number of steps past the beginning of an Indexed Move when the Index Input Window is opened While the Index Input Window is open the STP100 module monitors the external Index Input While the Index Input Window is closed the STP100 module ignores the external Index Input 4 2 3 10 Indexed Window Close Position AQ13 and AQ14 These two command words AQ13 and AQ14 are treated as a single 32 bit unsigned integer value representing the Window Close Position during a Move Indexed command 96Q1 1 The Indexed Window Close Position contains the number of steps past the beginning of an Indexed Movewhen the Index Input Window is closed While the Index Input Window is open the STP100 module monitors the external Index Input While the Index Input Window is closed the STP100 module ignores the external Index Input 4 REGISTERS 10 2000 29 SUPO0270 02 4 24 Command Bit Output Register Details Q1 Q16 The STP100 uses sixteen 16 Digital Output Q registers which are used as Commands These registers are summarized in Table 4 1 above Most commands are positive OFF to ON edge sensitive This means that the STP100
12. to 255 Encoder Feedback is used to validate current position As such the STP100 continuously compares the Encoder Position value AI3 and AI4 to the Motor Position value Al1 and AI2 If the difference exceeds the configured Encoder Tolerance value a position validation error has been detected and the STP100 turns the Current Position Valid Status bit 19 OFF An invalid position during a move does not automatically stop the move It is up to the ladder program to monitor the Current Position Valid bit and then to issue the Immediate Stop command if desired In an ideal motion control loop Encoder Position and Motor Position always match exactly However when Encoder Position and Motor Position become skewed it means that one or more of the following errors has occurred 1 A change in motor direction produced a backlash caused by the mechanical linkage between the motor and the encoder 2 resolution error has occurred because the encoder is less precise than the motor micro stepping rate In other words Step Resolution is greater then Encoder Resolution This is quite common for Step Resolutions greater than 2000 steps per revolution For most motors Step Resolutions greater than 2000 do not afford better positioning accuracy but merely offer smoother operation In these cases it does not make sense to spend the extra money for an extremely fine pitched encoder 3 The Step Resolution exceeds the motor s ability to accu
13. 0 Circuitry inside the dotted line is physically located inside the SmartStack module Home Low Limit High Limit and Index can accept either mechanical switch closures or NPN type proximity switches Normally Open N O switch Isolated Ground Figure 7 6 Isolated Input Schematic Home Low Limit High Limit and Index are active low signals A Normally Open N O switch is required to switch these lines to ground when the switch is activated Emergency Stop is an active high signal A Normally Closed N C switch is required to hold this line to a LOW grounded condition for normal operation of the system 46 10 2000 7 WIRING SUPO0270 02 NOTES INDEX 10 FEB 2000 INDEX Acceleration Time 27 17 Base 27 Command Bit Output Register 29 Command Word Output Registers 26 Commands E 31 Available 31 Glear Erf rsu Aus a 31 Decelerate and 37 Find Origin Up Find Origin Down 32 Immediate Stop 38 Jog Up Jog Down 33 Move 35 Move Relative and Move Absolute 34 Repeat
14. 0 mA 2 5 VDC min Direction Output High 20 mA 2 5 VDC min Step Output Low 20 mA 0 5 VDC max Direction Output Low 20 mA 0 5 VDC max GENERAL SPECIFICATIONS Required Power Steady State 26 0mA 5VDC CE Rating See 0005 Required Power Inrush Re in UL Pending u Relative Humidity 5 to 95 Non Terminal Type Spring Clamp condensing Removable Operating Temperature 0 to 60 Celsius Weight 9 5 oz 270 g Storage Temperature 40 to 85 Celsius kk rating of this product As measured at the PLC OCS 100 200 or RCS210 Shielded cables must be used for the discrete inputs to this module pins 1 7 to obtain immunity protection specifed by the EN50082 2 92 Failure to do so subjects the equipment to Criterion B failure and voids the CE 1 INTRODUCTION 10 2000 11 50 0270 02 1 5 Signal Descriptions 1 5 1 Isolated Inputs Emergency Stop Home Low Limit High Limit and Index are optically isolated using the following circuitry Circuitry inside the dotted line is physically located inside the SmartStack module Home Low Limit High Limit and Index can accept either mechanical switch closures or NPN type proximity switches Normally Open N O switch Isolated Ground Figure 1 1 Isolated Input Schematic Home Low Limit High Limit and Index are active low signals A Normally Open N O switch is required to switch these lines to gro
15. D STATES In no event whether as a result of breach of contract warranty tort including negligence or otherwise shall HE APG or its suppliers be liable of any special consequential incidental or penal damages including but not limited to loss of profit or revenues loss of use of the products or any associated equipment damage to associated equipment cost of capital cost of substitute products facilities services or replacement power down time costs or claims of original purchaser s customers for such damages To obtain warranty service return the product to your distributor with a description of the problem proof of purchase post paid insured and in a suitable package ABOUT PROGRAMMING EXAMPLES Any example programs and program segments in this manual or provided on accompanying diskettes are included solely for illustrative purposes Due to the many variables and requirements associated with any particular installation Horner APG cannot assume responsibility or liability for actual use based on the examples and diagrams It is the sole responsibility of the system designer utilizing the SmartStack Stepper Positioning Module to appropriately design the end system to appropriately integrate the SmartStack Stepper Positioning Module and to make safety provisions for the end equipment as is usual and customary in industrial applications as defined in any codes or standards which apply Note The programming examples sho
16. HORNER APG Supplement for HE800STP100 SmartStack Stepper Positioning Module Second Edition 10 February 2000 SUP0270 02 PREFACE 10 FEB 2000 PAGE 3 SUP0270 02 PREFACE This manual explains how to use the Horner APG SmartStack Stepper Positioning Module Copyright C 2000 Horner APG LLC 640 North Sherman Drive Indianapolis Indiana 46201 All rights reserved No part of this publication can be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form by any means electronic mechanical magnetic optical chemical manual or otherwise without the prior agreement and written permission of Horner APG LLC All software described in this document or media is also copyrighted material subject to the terms and conditions of the Horner Software License Agreement Information in this document is subject to change without notice and does not represent a commitment on the part of Horner APG LLC Cscape SmartStack and CsCAN are trademarks of Horner APG LLC Windows Windows NT Windows 95 and Windows 98 are registered trademarks of Microsoft Corporation For user manual updates contact Horner APG Technical Support Division at 317 916 4274 or visit our website at www heapg com PAGE 4 10 FEB 2000 PREFACE SUPO0270 02 LIMITED WARRANTY AND LIMITATION OF LIABILITY Horner APG LLC HE APG warrants to the original purchaser tha
17. Quadrature 39 Register 24 Register 23 Running Velocity 0 27 Signal 11 10 Up Down Encoder 40 Velocity 2 44 4 26 Velocity Multipliers Examples 26 WINING ates E 43 Isolated Switch Inputs 45 Translator 4 4 43 48 10 2000 INDEX SUPO0270 02
18. TP100 Module OCS Register Summary Error and Status Bit Input Registers Command Bit Output Registers Register Description Register Description l1 Emergency Stop Error Q1 Spare Command future use l2 Low End Limit Error Q2 Spare Command future use 9el3 High End Limit Error Q3 Spare Command future use 4 Illegal Move Error 04 Find Origin Up l5 Motor Stalled Error 05 Find Origin Down 16 Spare Error future use 06 Jog Up 17 Spare Error future use Q7 Jog Down p 9 8 Power Up Watchdog Error 08 Move Relative Current Position Valid Status Q9 Move Absolute Pre empted Move Resumable Status 010 Resume Move Spare Status future use 011 Move Indexed Spare Status future use Q12 Repeat Move Currently at Origin Position Status 013 Set Current Position Motor is Accelerating Status 014 Clear Error s Motor is Decelerating Status 015 Decelerate and Stop Motor is Moving Status 016 Immediate Stop Status Word Input Registers Register Description Minimum Maximum Motor Position Lo Word Motor Position Hi Word 8 388 608 8 388 607 AI3 Encoder Position Lo Word AI4 Encoder Position Hi Word SnaG BNE 23807 Command Word Output Registers Register Description Minimum Maximum AQ1 Destination Position Lo Word _8 388 608 8 388 607 AQ2 Destination Position Hi Word Velocity Divisor 65535
19. The STP100 can be configured for one of three encoder types None Quadrature or Up Down Absolute encoders and resolvers are not compatible with the STP100 If the Encoder Type is None the Encoder Position Status Word registers AI3 and AI4 need to be ignored and the Motor Stalled Error bit 945 never goes ON Otherwise if the Encoder Type is configured for Quadrature or Up Down the Encoder Position Status Word registers are updated as a result of feedback pulses from the Encoder to the STP100 thus allowing Motor Position validation and Motor Stall detection Figure 7 1 Typical Encoder Disk A typical Optical Encoder contains a glass or plastic disk in the Encoder Assembly The encoder is mechanically attached to the motor such that the encoder disk and motor shaft turn together Typically an optical sensor fits over the edge of the encoder disk As the disk turns the sensor generates the A and B pulses which are amplified to TTL or RS 485 levels and then are sent to the STP100 through short cables 6 2 1 Quadrature Encoder The Quadrature Encoder is the most common position feedback device used in motion control This type of encoder outputs two square wave signals A and B which are 90 out of phase with each other The STP100 determines the direction of motion based on which signal lags behind the other as shown in Figure 7 2 below Phase 1112131011121 Phase 1112131011121 1 1 1 i i A A leads A l
20. ags B Figure 7 2 Quadrature Encoder Signals As can be seen in Figure 7 2 there are two possibilities of signal timing A leads B and A lags B These two possibilities are set by the direction of the motor For example if the motor is moving in the forward direction then A leads B If the motor is moving in reverse then A lags B 40 10 2000 6 USING ENCODERS SUPO0270 02 The STP100 counts these encoder pulses to verify how far the motor has traveled If A leads B then the count is incremented If A lags B then the count is decremented Also a Quadrature Encoder s resolution can be effectively doubled or quadrupled by the STP100 s quadrature decoding hardware A Quadrature Encoder can also provide a third signal called a Marker This signal usually generated once per revolution of the motor s shaft can be used by the STP100 as a reference position when connected to the STP100 s Marker Input This also requires that the STP100 s Marker Input be configured as the Origin Source to allow the Marker Input to be used as a reference during Find Origin Up and Find Origin Down commands 6 2 2 Up Down Encoder The Up Down Encoder also provides A and B signals but not both at the same time Typically if the motor is turning clockwise the A output is active If the motor is turning counterclockwise the B output is active The STP100 increments the position count when A is active and decrements the position count when B
21. anslator DIR Direction Pin 16 Figure 7 3 Interfacing to a Translator Drive Using Negative 5VDC Signals 7 3 Encoders Encoders are optional devices The STP100 is compatible with encoders which produce either differential signals or 5 VDC positive going TTL compatible signals Note that the Encoder signals are not isolated from common ground HES00STP100 Pin 11 ENCA gt Pin 12 Encoder ENCB Pin 13 Marker MARK Pin 9 optional MARK 7 gt Pin 10 Figure 7 4 Interfacing to an Encoder with Different Outputs HES00STP100 Pin 11 Encoder gt Pin 13 GND Pin 8 19 Marker MARK 72 gt Pin9 optional GND gt Pin 8 or 19 Figure 7 5 Interface to an Encoder with Positive 5VDC Signals 7 WIRING 10 2000 45 SUPO0270 02 7 4 Isolated Switch Inputs The STP100 accepts several different isolated switch inputs Pin mereng II Isolated Common Isolated Common ESTOP Emergency Stop Active High Open 24VDC pull up LOLIM Low Limit Active Low Closed 24 VDC pull up HILIM High Limit Active Low Closed 24 VDC pull up HOME Home Active Low Closed 24 VDC pull up INDEX Index Active Low Closed 24 VDC pull up Isolated Common Isolated Common All switch inputs are optically isolated to 500 VDC This is accomplished by the following circuit inside the STP10
22. d Figure 3 6 Stepper Module Configuration Screen Under Mode be sure that Normal is selected Test is used for production and quality control testing and has no use in field applications Under Origin Source select either Marker or Home Switch If Marker is selected the STP100 uses the encoder s Marker signal or the user provided Marker input as the Origin input If Home Switch is selected the STP100 uses the externally supplied Home signal as the Origin input 22 10 2000 3 CONFIGURATION SUPO0270 02 In the Find Origin box select either the Normal Method or the Simple Method With the Simple Method when a Find Origin command is issued the STP100 moves the motor until the Origin position is located and then stops With the Normal Method the STP100 moves the motor quickly until the Origin position is located then backs up and re approaches the Origin position at a slower rate The Simple Method assumes the motor is initially moving slowly enough such that it does not overshoot the Origin position Checking the Limit Switch Qualified box causes the Find Origin command to first search for a limit switch before searching for the Origin This is especially useful when an encoder marker is being used as the Origin Source Under Encoder Configuration select Encoder Type None Quadrature or Up Down Absolute encoders and resolvers are not compatible with the STP100 With Quadrature selected Encoder A and Encod
23. ection is unchecked no error is generated if the motor fails to move If the application will be using Indexed Moves check the Enable Indexed Move box The state of this box must match that of the Index Move box in the Stepper Move element in the Cscape ladder program Note that Indexed Moves require the presence of a user supplied Index Input signal If no Index Input signal is supplied an Indexed Move behaves exactly like a Relative Move When the Enable Indexed Move box is checked the STP100 module requires 14 AQ registers instead of just 7 Be sure to check the modules I O register assignment if this box is changed If the STP100 is not the only SmartStack module installed or the last SmartStack module installed all subsequent modules find their register addresses shifted if the Enable Indexed Move box is checked 4 REGISTERS 10 2000 23 SUPO0270 02 CHAPTER 4 REGISTERS 4 1 General Chapter Four defines the OCS registers used by the STP100 module and describes how they are used For this discussion it is assumed that the STP100 module is installed as the first SmartStack module in the OCS In this case the STP100 uses OCS registers starting with 9el1 Q1 and AQ1 If the STP100 is not the first SmartStack module the actual registers that are used are determined by the type and position of the other SmartStack modules installed on the OCS Table 4 1 summarizes STP100 register usage Table 4 1 S
24. egisters are summarized in Table 4 1 above 4 2 2 1 Motor Position and AI2 The first 2 status words AI1 and 96AI2 are treated as a single 32 bit signed integer value representing the current Motor Position Motor Position is continuously updated up or down based on step pulses sent by the STP100 to the stepper motor translator drive Note that at power up or after a watchdog timer reset this value is set to zero and is considered invalid This is reflected by the fact that the Current Position Valid Status bit l9 is OFF The Motor Position continues to be invalid until a Find Origin Up Q4 Find Origin Down Q5 or Set Current Position Q13 command is executed successfully Until this happens the STP100 does not obey the Move Absolute command 96Q9 4 2 2 2 Encoder Position AI3 and Al4 If an encoder is attached to the STP100 and if it is properly configured via Cscape the AI3 and AI4 status words are treated as a single 32 bit signed integer value representing current Encoder Position Encoder Position is continuously updated up or down based on feedback pulses sent by the encoder to the STP100 Note that at power up or after a watchdog timer reset this value is set to zero and is considered invalid This is reflected by the fact that the Current Position Valid Status bit 19 is OFF If the STP100 is properly configured see section 6 3 Encoder Position tracks Motor Position Note that when Encoder Pos
25. er B accept phases A and B respectively from an encoder that supplies quadrature outputs With Up Down selected Encoder A and Encoder B accept Up and Down signals respectively from an encoder that supplies Count Up and Count Down outputs When Encoder Type is not None the other Encoder Configuration items Multiplier Divisor Tolerance and Stall Detection all become available for configuration Enter suitable numbers into the Multiplier Divisor and Tolerance boxes and if desired check the Enable Stall Detection box Multiplier and Divisor are used to tell the STP100 about the number of encoder pulses per revolution versus the number of step pulses per revolution For many applications some small amount of positioning error is acceptable Setting the Tolerance to some non zero value causes the STP100 to compare the encoder feedback value with the desired motor position If the result of the comparison is less than the Tolerance value no error is generated If the result of the comparison is greater than the Tolerance value the Current Position Valid status bit is set False If Tolerance is set to 0 zero the comparison is not made and no error is indicated If the Enable Stall Detection box is checked the STP100 verifies that encoder feedback pulses are being received after a move is requested If encoder pulses are not received the STP100 assumes that the motor is not turning and sets the Motor Stalled error bit True If Enable Stall Det
26. he first module the one installed next to the main body of the OCS is Module 1 Module 1 is always assigned to l01 Q01 AI01 and 96AQO01 in any combination required by the SmartStack module The addressing of subsequent modules is determined by the addressing of those modules before it This assignment is automatic and makes the most efficient use of I O register space For example assume that Module 1 is a HE800DIM210 This module requires eight 8 l registers no Q registers no Al registers and no AQ registers Its l registers are 901 through 9408 inclusive Now assume that the STP100 is Module 2 The STP100 require sixteen 16 l registers Because of the previously installed DIM210 the STP100 s l registers are 909 through 96124 inclusive Since no other installed modules have yet required Q or the OCS assigns the STP100 s registers to 001 through Q16 and AI01 through 104 The STP100 requires either seven 7 or fourteen 14 96AQ registers depending on how the module is configured Since no other installed modules have yet required a AQ register the OCS assigns the STP100 to AQ01 through AQ07 AQ01 through AQ14 depending on the configuration This can be summarized by checking the module Map dialog box as described in Chapter 3 The dialog box indicates the addressing and size of the required I O register space This setup is assigned by the OCS and can not be changed 18 10
27. il it reaches its programmed target position However at the operators option the footswitch can be released causing a Decelerate and Stop command to be issued There are a number of reasons why the operator might decide to do this such as to make a mechanical adjustment or to manually reposition the material being moved Then when the operator is ready the footswitch can be pressed again sending a Resume Move command to the STP100 to complete the motion 5 COMMANDS 10 2000 37 SUPO0270 02 5 3 8 Set Current Position Command Command Bit Q13 Status Bits Required 11 through l8 and l16 must be OFF Status Bits Affected I9 Status Words Required None Status Words Affected through AI4 Command Words Required AQ1 and 2 This command is used to manually set the current position When the Set Current Position command is issued Destination Position 1 and AQ2 is copied into Motor Position AI1 and AI2 and Encoder Position AI3 and AI4 and the Current Position Valid Status bit l9 is turned On This command can be used in conjunction with the Jog Up and Jog Down commands as an alternative to the Find Origin Up and Find Origin Down commands for finding and setting a reference position There is no motor movement associated with this command 5 3 9 Decelerate and Stop Command Command Bit Q15 Status Bits Required None Status Bits Affected 96110 96113 through 116 Statu
28. is turned OFF during a move the current move will still complete normally but it will not be repeated 5 3 7 Resume Move Command Command Bit Q10 Status Bits Required 11 through l8 and 16 must be OFF 96110 must be ON Status Bits Affected 11 through 9415 96110 and 96113 through 96116 Status Words Required None Status Words Affected through Al4 Command Words Required None This command can be used to resume a previously pre empted Relative Move or Absolute Move If a Move Relative or Move Absolute command was previously pre empted by a Decelerate and Stop command Q15 and no other commands have been issued since then the Pre empted Move Resumable Status bit is ON In this case the Resume Move command can be issued to restart the pre empted move from where it left off Of course this action turns the Pre empted Move Resumable Status bit back OFF Note that the resume logic is such that a move can be pre empted and resumed any number of times until one of the following occurs 1 The move reaches its originally programmed relative target position 2 An error occurs such as End Limit or Emergency Stop 3 Some command other than 010 is issued after a move is pre empted The Resume Move command is especially useful for manually assisted programmed moves For example the machine operator can trigger a Move Absolute command by pressing a footswitch If the footswitch continues to be pressed the move continues unt
29. ition doesn t match Motor Position exactly a position validation error has been detected There are several possible causes for this error see section 6 3 2 Some position validation errors can t be avoided which is why the STP100 supports an Encoder Tolerance configuration parameter 26 10 2000 4 REGISTERS SUPO0270 02 423 Command Word Output Register Details AQ1 7 or AQ1 AQ14 By default the STP100 uses seven 7 registers If the Enable Indexed Moves box is checked on the STP100 s Module Setup screen then the STP100 uses at total of fourteen 14 registers The AQ command words act as qualifiers for the Q command bits Typically the AQ command words are set to appropriate values and then one of the Q command bits is changed from OFF to ON Normally after the STP100 starts executing a command the AQ command words be changed to prepare for the next command without affecting the command in progress The exception to this rule is that the Destination Position 1 and AQ2 must not be disturbed during a Find Origin Up or Find Origin Down command until either an error occurs or the Current Position Valid status bit goes ON 4 2 3 1 Destination Position 1 and 2 The first two command words AQ1 and AQ2 are treated as a single 32 bit signed integer value representing the Destination Position For the Find Origin Up Find Origin Down and Set Current Position com
30. lues PAGE 6 10 FEB 2000 PREFACE SUPO0270 02 PREFACE 10 FEB 2000 PAGE 7 SUP0270 02 TABLE OF CONTENTS PREPAGE coincidir 3 LIMITED WARRANTY AND LIMITATION OF LIABILITY 4 ABOUT PROGRAMMING 5 4 2444444440 4 1 20 9 NESCIRE ENT 9 152 su tr Ses NM Min din Minim Min UN 9 1 9 A ae 9 1 10 AE MS audi 11 1 5 1 Isolated teil taal eel Seca dona cet dona ee 11 1 5 2 Differential Inputs 11 1 5 3 Differential 12 126 INACIO tito 12 df Motion 12 CHAPTER 2 1 5 4 4 00 15 2 1 CEDE 15 2 2 EE A 15 2 35 External WIND oi a Em 16 24 ATEOS Or 17 CHAPTER 3 CONFIGURATION 2 dara aliadas 19 9245 oes coe uoc eni p PII I I ca LES 19 9 2 Sontig ratloh iia 19 3
31. mands the Destination Position is the value to be loaded into Motor Position and Encoder Position when the command completes successfully For the Move Absolute command the Destination Position is the absolute position to move to For the Move Relative and Move Indexed commands the Destination Position is the relative distance to move above or below the current position 4 2 3 2 Velocity Divisor AQ3 This command word determines the resolution multiplier of the Base Velocity 4 and the Running Velocity AQ5 command words The velocity multiplier My ranges from 01 pulses per second to 30 pulses per second and is calculated as follows 600 AQ3 v Pulses per second Table 4 3 shows some useful AQ3 settings along with their resulting velocity multipliers and corresponding maximum velocities Table 4 3 Example Velocity Multipliers Velocity Divisor Velocity Multiplier Maximum Velocity Pulses Per Second oe My My x 8191 245 730 0 81 910 0 gt CTI 4 REGISTERS 10 2000 27 SUPO0270 02 4 2 33 Base Velocity AQ4 This command word determines the velocity the STP100 starts at when executing one of the motion commands Q4 through 96Q1 1 A typical move starts at the Base Velocity and accelerate to the Running Velocity Then if the move ends normally it decelerates from Running Velocity to Base Velocity and then stops Also near the end of a Find O
32. mmands are issued by setting the appropriate bit in the Command Bit Output registers Commands can be issued only under strict conditions as described in the individual command descriptions that follow The STP100 does not accept commands if any of the Error Status bits are ON The exception is of course the Clear Errors command 014 If an error occurs the only command that can be issued is the Clear Errors command Note that immediately following a power up or reset the Power Up Watchdog Error bit is ON Thus the first command issued after a power on or reset must be the Clear Errors command This is a safety feature which prevents the STP100 from running until the application program is in control and specifically issues the Clear Errors command 5 3 Available Commands 5 8 1 Clear Error s Command Command Bit 014 Status Bits Required None Status Bits Affected through l8 Status Words Required None Status Words Affected None Command Words Required None This command is used to clear errors previously detected by the STP100 When this command is issued all Error bits 911 through 968 are cleared turned OFF Note that when an Error bit is ON the STP100 does not obey any other commands till the error is cleared via the Clear Error s command The Power Up Watchdog Error bit 9618 provides a safety interlock This bit is ON immediately after power ON reset or watchdog timeout The Stepper Controller does not
33. move as follows Q8 Performs a relative move 09 Performs an absolute move Both of these commands perform a programmed move in the up or down direction to a relative target position If doing a relative move 08 the relative target position is taken directly from Destination Position 1 and AQ2 and it is not necessary for the Current Position Valid Status bit 19 to be On The direction of the move is determined by the Destination Position sign for move up or for move down If doing an absolute move Q9 the relative target position is calculated as the difference between Destination Position AQ1 and 2 and Motor Position and AI2 and therefore it is necessary for the Current Position Valid Status bit l9 to be On The direction of the move depends whether Destination Position is higher move up or lower move down than Motor Position Normally the move starts at Base Velocity and accelerates to Running Velocity until it is time to decelerate back down to Base Velocity and then stop This type of move is said to have a trapezoidal velocity profile If it is time to start decelerating before accelerating to Running Velocity has completed the motor starts decelerating at that point In this case the acceleration and deceleration times are decreased and the velocity profile becomes triangular Optionally the End Limit Inputs can be used to start relative and absolute moves The High Limit Input
34. n ESTOP Emergency Stop Active High Open 24VDC pullup LOLIM Low Limit Active Low Closed 24 VDC pullup HILIM High Limit Active Low Closed 24 VDC pullup HOME Home Active Low Closed 24 VDC pullup INDEX Index Active Low Closed 24 VDC pullup Isolated Common Isolated Common Common Connected to internal Bus Common MARK Encoder Marker Positive Input MARK Encoder Marker Negative Input ENCA Encoder Channel A Positive Input Encoder Channel A Negative Input ENCB Encoder Channel B Positive Input ENCB Encoder Channel B Negative Input DIR Direction Positive Output DIR Direction Negative Output STEP Step Positive Output STEP Step Negative Output Common Connected to internal Bus Common 2 INSTALLATION 10 2000 17 SUPO0270 02 2 4 Addressing The STP100 module requires sixteen 16 digital input registers l sixteen 16 digital output registers Q four 4 analog input register Al and seven 7 or fourteen 14 analog output registers AQ depending on how the module is configured The location of these registers within OCS I O register space is determined by the type number and location of any installed SmartStack modules The OCS automatically assigns the register space based on the physical position of the SmartStack Module T
35. n control SmartStack module for use with Horner APG Operator Control Station OCS products The STP100 is capable of interfacing to a wide variety of stepper motors limit switches and encoder feedback devices 1 3 Features Single axis motion controlled by application ladder program Up to 245 730 steps or micro steps per second Programmable position velocity acceleration and deceleration Automatic ramp down deceleration calculation Moves can be specified as absolute relative or indexed Relative and indexed moves can be auto repeated Automatic find origin functions Manual jogging functions Home and over travel inputs Emergency stop input Incremental encoder feedback inputs Power watchdog timeout safety interlock 10 SUP0270 02 1 4 Specifications 10 FEB 2000 CH 1 INTRODUCTION Table 1 1 Stepper Input and Outputs ISOLATED INPUTS LOWLEVEL 2mA ISOLATION Emergency Stop ES Emergency Stop ES Home HO Home HO Index IN 0 9 Index IN 500 VDC min High Limit HI High Limit HI Low Limit LO Low Limit LO DIFFERENTIAL INPUTS Encoder Frequency 0 1 0 MHz Differential 0 2 VDC min reshold Low Encoder Single Ended 1 2 1 6 VDC Encoder Differential 0 2 VDC max Threshold Threshold High DIFFERENTIAL OUTPUTS Step Frequency 0 245 KHz Direction Output Setup Time 2 ms max Step Output High 2
36. nen Base Velocity per Second Time Figure 1 4 Trapezoidal Motion Profile 1 INTRODUCTION 10 FEB 2000 PAGE 13 SUPO0270 02 For a given set of programmed Acceleration and Deceleration Times a particular move can be too short to allow the motor to accelerate all the way up to Running Velocity lf it is time to start decelerating before accelerating to Running Velocity has completed the motor will start decelerating at that point In this case the acceleration and deceleration rates in pulses per second are preserved but the acceleration and deceleration times are decreased When this happens the velocity profile becomes triangular as shown in Figure 1 5 below Start Position End Position hie nec Running Velocity Base Velocity 4 Figure 1 5 Triangular Motion Profile 14 10 2000 1 INTRODUCTION SUPO0270 02 NOTES 2 INSTALLATION 10 2000 15 SUPO0270 02 CHAPTER 2 INSTALLATION 2 1 General Chapter Two describes the installation of the STP100 module on the Operator Control Station OCS chassis 2 2 Installation WARNING The STP100 must not be installed while power is applied to the OCS or when the cables to the motor drive are attached to the SmartStack I O connector Always ensure that the motor is disconnected and that power to the OCS is OFF The power to the OCS must be unplugged The STP100 can be placed in any Sma
37. obeys the command only when the module sees the command bit transition from OFF to ON The STP100 can require more than one OCS logic scan to detect a command bitbut takes no more than 2 mS to start executing the command The command bit must then be turned OFF for at least 2 mS before the next command or the same command can be again issued The Jog Up and Jog Down commands are level sensitive The Jog commands start when the OFF to ON transition is recognized and remain running so long as the command bit stays ON The Jog commands decelerate and stop when the ON to OFF transition is recognized The Power Up Watchdog Error Status bit 18 is always ON immediately after Power On or reset Therefore the first command issued must be the Clear Errors command 014 Also some commands are ignored depending on the state of other status bits For example if the Moving Status bit 96116 is ON the only legal commands are Decelerate and Stop 015 and Immediate Stop Q16 If more than one command bit goes active during any one CPU Scan Time the command with the highest bit number takes priority Note that this gives the Immediate Stop command Q16 the highest priority 30 10 2000 4 REGISTERS SUPO0270 02 NOTES 5 COMMANDS 10 2000 31 SUPO0270 02 CHAPTER 5 COMMANDS 5 1 General Chapter Five describes the commands available for the STP100 and their operations 5 2 Issuing Commands Co
38. ove 1 sss 36 5 3 8 Set Current Position 37 5 3 9 and Stop 2 37 5 3 10 Immediate St p Command 38 PAGE 8 10 FEB 2000 PREFACE SUPO0270 02 CHAPTER 6 USING 5 4444 0000 00 ness nnns snas nnn nnn 39 SEDE CITATI CIMA 39 6 2 Adding an Encoder en eo 39 6 2 1 Quadrature 39 6 2 2 Up Down 40 6 3 Configuring the 2 40 6 3 1 Configuring Step Pulse to Encoder Feedback 40 6 3 2 Configuring Encoder 2 41 6 3 8 Configuring Motor Stall 42 CHAPTER 7 WIRING isaer 6122 etie Fete 43 7 1 NN 43 7 22 Translator 43 o ee E 44 7 4 Isolated Switch Inputs o RR RR HER agora aaa 45 1 INTRODUCTION 10 FEB 2000 PAGE 9 SUPO0270 02 CHAPTER 1 INTRODUCTION 1 1 General Chapter One provides a brief overview of the SmartStack Stepper Positioning Module HE800STP100 1 2 Overview The SmartStack Stepper Positioning Module STP100 is an intelligent programmable motio
39. p Jog Down Commands Command Bits Q6 and Q7 Status Bits Required 9el1 through l8 and l16 must be OFF Status Bits Affected through l5 and 113 through l16 Status Words Required None Status Words Affected through AI4 Command Words Required AQ3 through AQ7 These commands are used to perform manual jogging as follows Q6 Starts a manual jog move in the Up direction Q7 Starts a manual jog move in the Down direction When one of the Jog Command bits goes ON the motor starts in the selected direction at the Base Velocity and accelerates to the Running Velocity The motor continues to move at Running Velocity until the Jog Command bit goes OFF again At that time the motor decelerates from Running Velocity back down to Base Velocity and then stop If the Jog Command bit transitions from ON to OFF before the motor reaches Running Velocity the motor acceleration and deceleration times is decreased and the velocity profile is triangular 34 10 2000 5 COMMANDS SUPO0270 02 5 3 4 Move Relative and Move Absolute Commands Command Bits Q8 and 09 Status Bits Required 1 through l8 and l16 must be OFF 19 must be ON for Q9 command Status Bits Affected 11 through l5 and l13 through l16 Status Words Required and Al2 used by Q9 command Status Words Affected through AI4 Command Words Required AQ1 through AQ7 These commands perform a relative or absolute
40. r Encoder Multiplier and Encoder Divisor EncoderMultiplier _ Step Re solution EncoderDivisor Encoder Re soloution Where Encoder Multiplier is any value from 1 to 255 Encoder Divisor is any value from 1 to 16 If more than one combination of Encoder Multiplier and Encoder Divisor satisfies the formula choose the combination with the lowest values for Encoder Multiplier and Encoder Divisor reduce the fraction 6 USING ENCODERS 10 2000 41 SUPO270 02 For example Assume that an Encoder Resolution of 1000 lines per revolution is used Further it is assumed the encoder is mechanically connected to the stepper motor shaft and is electrically connected to the STP100 s Encoder A and Encoder B inputs For this example the following table shows the proper configuration settings for Encoder Multiplier and Encoder Divisor for 16 typical Step Resolutions Table 6 1 Example Encoder Multiplier and Divisor Values Step Encoder Encoder Step Encoder Encoder Resolution Multiplier Divisor Resolution Multiplier Divisor 200 1 5 20 000 20 1 400 2 5 21 600 108 5 1 000 1 1 25 000 25 1 2 000 2 1 25 400 127 5 5 000 5 1 25 600 128 5 10 000 10 1 36 000 36 1 12 800 64 5 50 000 50 1 18 000 18 1 50 800 254 5 6 3 2 Configuring Encoder Tolerance If the Encoder Tolerance is set to 0 position validation is disabled Otherwise if Encoder Tolerance is set to a number from 1
41. rately position its rotor For example most stepper motors have an accuracy of 1 part in 2000 which means a Step Resolution greater than 2000 has little affect on accuracy but only contributes to smoother operation 4 The motor missed some step pulses or stalledbecause of low or mid frequency resonance 5 The motor missed some step pulses or stalled because the programmed Acceleration Time or Deceleration Time was too low to properly overcome the mechanical inertia of the system 42 10 2000 6 USING ENCODERS SUPO0270 02 6 Some external force changed the position of the motor For example something caught in the machinery does not let the motor move the load as requested 6 3 3 Configuring Motor Stall Detection If desired Motor Stall Detection can be enabled by checking the Enable Stall Detection checkbox on the STP100 s configuration screen When this option is enabled the STP100 monitors Encoder Feedback pulse velocity to determine whether or not the motor has stalled In particular if the measured move velocity falls to less than 1096 of the theoretical move velocity then a Motor Stalled error has been detected When this happens the STP100 stops sending step pulsesand turns the Motor Stalled Error Status bit 15 ON 7 WIRING 10 2000 43 SUPO0270 02 CHAPTER 7 WIRING 7 1 General Chapter Seven provides example wiring diagrams for interconnection between the STP100 and external
42. rigin Up or Find Origin Down command the motor moves at a constant Base Velocity while searching for the exact Origin Position Actual Base Velocity Vg depends on the Velocity Divisor AQ3 and is calculated according to the following formula 600 AQ3 V 04 AO4X Pulses per second 4 2 3 4 Running Velocity AQ5 This command word determines the maximum velocity the motor moves after the STP100 finishes accelerating The Running Velocity must be greater than the Base Velocity Actual Running Velocity depends on the Velocity Divisor and is calculated according to the following formula 600 V 90AQ5XM 5 R 6AQ Pulses per second Note that if the Destination Position parameter is too short to accommodate the Acceleration Time and Deceleration Time parameters the motor never reaches the Running Velocity and the move becomes triangular 4 2 3 5 Acceleration Time AQ6 This command word determines the maximum time in mS spent accelerating from the Base Velocity to the Running Velocity during a move Note that if it is time to start decelerating before acceleration to the Running Velocity is complete the acceleration time is decreased and the velocity profile becomes triangular Also note that the maximum useful value for Acceleration Time AQ6max is dependent on the Base Velocity AQ4 and Running Velocity AQ5 according to the following formula
43. rtStack slot Caution To function properly and to avoid possible damage do not install more than four Smart Stack Modules per OCS or RCS A Installing SmartStack Modules 1 Hook the tabs Each SmartStack Module has two tabs that fit into slots located on the OCS The slots on the OCS are located on the back cover 2 Press the SmartStack Module into the locked position making sure to align the SmartStack Module fasteners with the SmartStack receptacles on the OCS B Removing SmartStack Modules 1 Using a flathead screwdriver pry up the end of the SmartStack Module opposite of tabs and swing the module out 2 Lift out the tabs of the module Fastener SmartStack Tab Mating Pins OCS Back Cover Figure 2 1 Installing a SmartStack Module on an OCS 16 SUP0270 02 2 3 External Wiring 10 FEB 2000 CH 2 INSTALLATION The STP100 requires user supplied external wiring between the module and the user supplied external equipment such as motor drive limit switches and encoder The STP100 provides nineteen 19 external connection points Not all points are used in all installations When installed on an OCS the STP100 SmartStack appears as the following Figure 2 2 STP100 Attached to an OCS The nineteen pins have the following functions Signal Isolated Common Table 2 1 Pin Out Marking Description Isolated Commo
44. s Words Required None Status Words Affected through AI4 Command Words Required None This command causes the controller to decelerate and stop the motor If the motor is moving when this command is issued the motor decelerates till it reaches the Base Velocity and then it stops If this command pre empts a Move Relative or Move Absolute command the Pre empted Move Resumable Status bit 96110 is turned ON unless an error occurs In this case the original move can be resumed from where it left off by issuing a Resume Move command Q10 38 10 2000 5 COMMANDS SUPO0270 02 5 8 10 Immediate Stop Command Command Bit Q16 Status Bits Required None Status Bits Affected 919 113 through 96116 Status Word Required None Status Word Affected through AI4 Command Words Required None This command is used to cause the motor to stop immediately When this command is issued the motor stops as quickly as possible If the motor was moving the Current Position Valid Status bit 19 is turned OFF 6 USING ENCODERS 10 2000 39 SUPO270 02 CHAPTER 6 USING ENCODERS 6 1 General Chapter Six details the use of optional encoder feedback with the 5 100 6 2 Adding an Encoder The encoder must be of a type accepted for use with the motor selected Read the information supplied with the motor for further instructions on selecting and installing an encoder on the motor
45. s slow enough to prevent overshoot 5 Otherwise just in case we shot right past the Origin the motor is run at Base Velocity in the opposite direction till the Origin Source is active again 6 Motion then continues in the same direction as in step 5 above still at Base Velocity till the Origin Source is inactive for 50 mS 7 Then the direction is reversed again and the motor is moved at Base Velocity till the Origin Source is active at which time the motor stops precisely at the Origin Position 8 Destination Position is copied into Motor Position and into Encoder Position and the Current Position Valid Status bit 19 is turned ON If the Limit Switch Qualified box was checked during configuration step 3 above is changed as follows 3 When the End Limit input for the direction we re moving becomes active motion is stopped immediately NOTE The Limit Switch Qualified variation is most useful when the Origin Source is configured to be the Marker Input Since the Marker on a rotary encoder typically occurs several times during a full stroke move this technique allows the Marker which occurs closest to the Limit Switch to be used as the Origin Position For best results the Marker to Limit Switch relationship needs to be mechanically adjusted such that the Marker occurs at approximately one half of the encoder s revolution away from the Limit Switch 5 COMMANDS 10 2000 33 SUP0270 02 5 3 3 U
46. selected slot showing that the Stepper Controller module has been added It is vital that the module and slot match that of the OCS Mismatched configurations cause an Module Mismatch Error during the power on diagnostics of the OCS 3 CONFIGURATION 10 2000 PAGE 21 SUPO0270 02 3 2 2 Check the Module s O Register Assignments Double click on the picture of the STP100 module s connector or click the Config button to the right of it The tab shows the register locations assigned to this module These values are assigned automatically by Cscape and the OCS These values are not configurable by the user except by installing the Stepper Controller Module in another position in the SmartStack stack If the Stepper Controller is the only module installed on this OCS then there is no way to reconfigure these values HEBE TAO baomer deal bopa Lyi Figure 3 5 Register Assignments from Cscape Write down these values This information is necessary to properly write the ladder program to control this module 3 2 3 Configure the Module Now click on the Module Setup tab a a 20222 EBIEEBIEEISE Select either Home or Fonte rata Marker as the Origin 2 teer fire E Source via the pull pe s m nas down menu Fri Dan mem p TY Im n Y gia bic m nidis z
47. t SmartStack Stepper Positioning Module manufactured by HE APG is free from defects in material and workmanship under normal use and service The obligation of HE APG under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within two 2 years from the date of manufacture or eighteen 18 months from the date of installation by the original purchaser whichever occurs first such defect to be disclosed to the satisfaction of HE APG after examination by HE of the allegedly defective part or parts THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES AND HE APG NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR HEAPG ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS SmartStack Stepper Positioning Module THIS WARRANTY SHALL NOT APPLY TO THIS SmartStack Stepper Positioning Module OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT NEGLIGENCE ALTERATION ABUSE OR MISUSE HE APG MAKES NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY HE APG THE TERM ORIGINAL PURCHASER AS USED IN THIS WARRANTY SHALL BE DEEMED TO MEAN THAT PERSON FOR WHOM THE SmartStack Stepper Positioning Module IS ORIGINALLY INSTALLED THIS WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITE
48. und when the switch is activated Emergency Stop is an active high signal A Normally Closed N C switch is required to hold this line to a LOW grounded condition for normal operation of the system 1 5 2 Differential Inputs The Encoder Inputs Encoder A Encoder B and Marker accept differential inputs Circuitry inside the dotted line is physically located inside the SmartStack module They RS 485 thresholds The inputs are also TTL compatible when connected to single ended encoder outputs of suitable polarity Figure 1 2 Differential Input Schematic 12 10 2000 1 INTRODUCTION SUPO0270 02 1 5 3 Differential Outputs Step and Direction Output Signals have RS 485 drive capability and can be interfaced with TTL level inputs of suitable polarity Figure 1 3 Differential Output Schematic 1 6 Indicators The STP100 provides three 3 LED indicators Table 1 2 LED Indicators Indicator Color Function Red Motor is Stopped Yellow Motor is Accelerating or Decelerating Green Motor has reached Running Velocity 1 7 Motion Profiles For a typical move the STP100 starts at a low Base Velocity accelerates up to the Running Velocity and later decelerates down to the Base Velocity and then stops This is known as the trapezoidal motion profile and is shown in Figure 1 4 below Start Position End Position OR Running Velocity Steps AA II
49. uture use Not Used 96l8 Power Up Watchdog Error Always ON immediately after power on or reset Initially OFF comes ON after successful Find Current Position Valid Status Origin or Set Current Position command set OFF again if motor is stopped suddenly or stalls Pre empted Move Resumable Status Pre empted move can be resumed to completion Spare Status future use Not Used Spare Status future use Not Used Origin Input Marker or Home depending on Currently at Origin Position Status whichever is the configured Origin Source is active Motor is Accelerating Status Motor is accelerating Motor is Decelerating Status Motor is decelerating Motor is Moving Status Motor is moving At power up or after a watchdog timer reset all error and status bits are OFF except the Power Up Watchdog error bit which will be ON If any error or status bit is ON it means the corresponding condition is True Note that if one of the error bits l1 9618 is ON an error has occurred Error bits stay ON till a Clear Error command Q14 is issued No other commands can be issued while an error bit is ON The status bits I9 96116 reflect various other STP100 status conditions and are not affected by the Clear Error command 4 REGISTERS 10 2000 PAGE 25 SUPO0270 02 4 2 2 Status Word Input Register Details AI4 The STP100 used four 4 Analog Input Al registers to indicate position status These r
50. wn in this manual are for illustrative purposes only Proper machine operation is the sole responsibility of the system integrator PREFACE 10 FEB 2000 PAGE 5 SUP0270 02 REVISIONS TO THIS MANUAL This version SUP0270 02 of the SmartStack Stepper Positioning Module Supplement contains the following revisions additions and deletions 1 Added text for new features in Section 1 3 and Section 5 3 6 Auto Repeat of Relative and Indexed Moves 2 Added text for a new feature allowing the optional use of DIR as a move in progress output for indexed moves only in Section 1 3 and in a note contained in Section 5 3 6 3 Incorporated the information contained in Chapter 6 formerly Figuring Parameters into the Chapter 4 Registers Chapter 6 is now replaced by Using Encoders formerly Chapter 7 and Chapter 7 is now replaced by Wiring formerly Chapter 8 Added new table to Chapter 4 and numbered it as Table 4 1 STP100 Module OCS Register Summary Tables and other information have been renumbered throughout Chapter 4 to reflect the incorporation of Chapter 6 material 4 Eliminated the S Curve feature Section 1 3 and 1 7 Replaced Figure 1 5 S Curve Motion Profile with new drawing Triangular Motion Profile 5 Added new figure to Chapter 1 Figure 1 1 and Chapter 7 Figure 7 6 6 Made clarifications and punctuation corrections throughout edition as needed 7 Added Table 6 1 covering example encoder multiplier and divisor va
51. ynchronize motor movement with an external mechanical reference point This reference point or index is provided to the STP100 module via the Index Input The Index Input will only be processed if it occurs during a user specified window When the Index Input is accepted the STP100 then switches to an alternate destination and an alternate deceleration time When the Q11 bit goes ON the motor starts moving just as it would for a Relative Move However during the time the Indexed Window is open determined by AQ11 through AQ14 the STP100 monitors the Index Input If the Index Input becomes active while the Indexed Window is open a new end point for the move is determined This new end point is defined to be N more steps in the same direction beyond the point at which the Index Input became active where N is the Indexed Destination Position 8 and AQ9 value In addition if AQ10 is not zero it sets a new deceleration point called the Indexed Deceleration Time The resulting Indexed Move can be longer or shorter than the default Relative Move The motor must attain Running Velocity before the window is opened If the move does not reach Running Velocity the window won t be opened and the Index Input is not accepted If the Relative Move reaches the point to begin decelerating before the Index Input is activated the window is closed and Index Input is not accepted The STP100 must be specifically configured to accept Indexed Moves
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