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DLC Single Axis Control Card for Firmware

1. Rexroth Indramat b DLC A and DLC G DLC Control Card DEA 4 Input Output Car Fig 6 1 DKS DLC Servo System with DEA 4 Installed DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G 6 2 Power 6 3 Cable Routing Installation Start Up 6 3 The DLC receives its power from the digital drive being used Refer to separate manuals listed in Appendix B for power requirements of the other modules power supply servo drive etc For higher reliability the high resolution feedback cables must be shielded and routed away from high voltage power sources to reduce electrical noise Do not route the cables near high amperage type machines like welding equipment which produce strong magnetic field interference Suppress inductive loads such as solenoids and motors that are switched ON and OFF during DLC system operation with R C networks AC or diodes DC Correct grounding is essential for trouble free operation The ground connection must be made by observing strictly the branching conditions shown in the wiring diagram
2. A 1 Normal Folge beaten etre irem ttn Eis A 1 Homing Without Using the Homing A 2 Homing chine Gi 2 Homing to the Marker tented A 3 Homing Routine at Start of User Program A 3 B DLC Display Screen Map sicaseccsiscssicsasssaacnddcueasuicscanceacaweieusdasaacesssncdewcssnntaneannaessaens B 1 C Drawings and Schematics NNEA ERR C 1 C 1 DKS DLC A MDD Interconnection Sheets 1 10 C 2 C 2 RS 232 Data Interface C 12 SOT DLC RS485 Interconnection esses C 13 C 4 Timing Diagram for DLC with DKS DDS or 14 D Installation Drawings aeann DOOR MAE dU M ICON MN Ud D 1 Did DIMENSIONS ii irae eonun e ed D 2 D 2 Keyboard and Cabinet Cutout 5 D 3 D 3 CTA 04 Keyboard and Cabinet Cutout Dimensions sse D 4 D 4 IDS and Cabinet Cutout Dimensions D 5 0 5 10 Keyboard and Cabinet Cutout Dimensions sse eene D 6 D 6 CTA DLC Interconnection D 7 E DLC Type
3. 4 34 Parameter A126 Position Window as of software version 1 04 5 4 35 Parameter B000 Enable Axis 2 DG software 4 36 Parameter B001 System Inputs DG software 4 37 Parameter B001 Serial Jog Enable DA software only 4 38 Parameter B002 User I O As of software version 1 04 07 01 04 07 4 39 Parameter B003 Serial 4 40 Parameter B004 Serial 4 41 Parameter B005 Memory 4 42 Parameter B006 Start Task 2 amp 3 4 43 Parameter B007 Display Language Decimal Place Keypad 4 44 Parameter B008 M Function Inputs and Outputs DLC G only sse 4 46 Parameter B009 M Function Timer DLC G only 4 47 Parameter BOTO Fre iiie ere eiue aaa ea 4 48 Parameter B011 Manual 4 49 Parameter B012 Program Interrupt Vector Jump on 4 50 Parameter B013 Velocity Override as of software version 1 1 1 04 00 4 51 Paramete
4. 5 5 5 8 Command SUMMA i Lee dette era rax ei EL o oa aee dates Era ee dani 5 5 Positioning COMMANAS MET 5 6 Position Support Commands 5 7 Branch Commands esccain 5 8 5 8 Auxiliary FUNCIONS occ tesssettvecshe eaten 5 9 5 9 RR RR x ERR nu qun Ge ERR a RR d 5 9 Other etit itat taa edat rd luba tu ah a n d i 5 9 5 9 Command Descriptions 5 10 Acc Acceleration Change miissen an aiin oca ertet faced 5 11 AEA Auxiliary Output 5 12 Rexroth Indramat DOK CONTRL DLC A DLC G AWOS AE P 12 99 DLC A and DLC G Table of Contents V AKN Acknowledge Single Input 5 13 Acknowledge Parallel Input 5 14 APE Activate Parallel Outputs 5 15 APJ Activate Parallel Output then Jump 5 16 ATS Acknowledge Output Status 5 18 BAC Branch And COUNT iet udin Eden er dictions 5 19 BCA Branch Conditiona
5. 7 6 CHECKSUM Calculations 7 6 Sending Information to the DEG e et tte eade erts 7 7 Sending Program Blocks to the DLC 7 7 Sending Parameters to the DLC 7 8 Alphabetical Listing of 7 9 Inrormation Bequest eie ie ee x no 7 11 Requesting a Program Block from the 7 11 Requesting a Parameter from the 7 11 Requesting System Status from the DLC 7 12 Status 51 User Inputs Hexadecimal 7 19 Status 52 User Outputs Hexadecimal 7 19 otatus 53 s System Ce poema et dc a ete 7 19 Diagnostics And Troubleshooting 8 1 Digital AC Servo Drive Normal Operating Diagnostics 8 1 DLC System Error Code And System Error Messages sss 8 2 Serial Communication Errors 8 9 G Code Programming Errors rie 8 12 Rexroth DOK CONTRL DLC A DLC G AWOS AE P 12 99 Indramat VIII Table of Contents DLC A and DLC G A Programming INOUGS A 1 AX Axis Homing forthe DEG OR etter el A 1 Ee nlrme
6. 1 8 Programmable UU 1 8 Control Machine System I O 1 8 HONN a seater 1 8 Registratio nis O R 1 8 RS 232 485 Serial 1 8 CTA Remote 1 8 Optional IDS Module noe E RE ER Pra yu Fass 1 9 Optional Station Operator Terminal SOT and Screen 1 9 MotionManager eim 1 10 Optional 10 User Interface roter ee Centre ri ene pet nei dan 1 10 Standard Configuration Of DKS With DLC Control Card DEA 4 Input Output Card 1 11 Standard Configuration Of DKS With DLC Control Card DEA 4 Input Output Card And Optional DEF 1 Incremental Encoder Interface 1 13 fere HH 1 14 Physical Specifications Operating Environment 1 14 Control Specifications e RE 1 14 MOP MAS ACC 1 14 Spam ahaa eee 1 15 Controls and Indicators vi p brun On 2 1 8
7. 8 s 4 78 General Description 2 4 78 M Selection of M 4 79 Table Set Up i die 4 80 4 7 Parameter Data Sheets cc cccccssssecsessnsecseseesecsesensecsesensecsesnsecsesensecsesensecsesenseseesenseseesensessesenaeess 4 81 A Parameter Input 4 81 B Parameter Input 4 82 Parameter Input Sheet euet cene 4 83 5 P og MmMing 5 1 EE o mE 5 1 5 2 Auxiliary Inputs Outputs eccentric erste ra e da apa ca Le rte eaae Di dde e cue VE Lauda 5 2 Programming Inputs OUtDpUlts fetes dentes aree eene oet teenie ideae te LEER Lud e pea 5 2 Inputs Outputs Signal 5 2 5 9 Multi HASHING 5 4 5 4 Start of the Programie adia eedan araida aiian NEAR daa 5 4 b 5 Progra eee ete ee Cea ran nd 5 4 5 6 Programming Mode eee a Den eb e puc etg cu ctc Pn raa dd 5 4 S7 Genaral Forma
8. 6 8 Position Data Scaling at the Analog Output Degrees 10V 6 8 Velocity Data Scaling At The Analog Output 10 6 8 Parameter cfe m acad 6 9 FRO GUMMY eir 6 10 Axis Jogging in Manual 6 10 Automatic Moda Operation 2 dece etate bnt a t lec eu ett o ere a eg 6 11 Serial SACS uoo oder petii LI RU 7 1 Connector Wiring DB 9 iu Irene tide bee to Rente eire E idee 7 1 Signal Level Requirements 7 2 Serial Cable Configurations 7 2 Data a tes 7 3 Wad EET 7 3 Parity CHECK iain EE 7 3 Baud Rate otra iia tise eater 7 4 IMTS ACE Mode 2 7 4 DEG Control String Protocol eret d go rea dela 7 4 First 1 Control String Character Transmission Type 7 4 Second 2 Control String Character DLC Unit Identifier 7 5 Third 3 Control String Character Information Type 7 5 Other Important Control 7 5 Information
9. 16 through through user defined 3 Auxiliary Output Flags 44 59 See Table 5 1 in Chapter 5 for use as software flag user defined as software flag A through user defined as software flag Auxiliary Output 60 76 See Table 5 1 in Chapter 5 for use as software flags user defined as software flag through N user defined as software flag Auxiliary Output 81 88 89 94 95 96 See Table 5 1 for specific use and warnings user defined as software flag through 88 user defined as software flag 89 94 function set in firmware as follows 1 indicates Manual Mode 1 indicates Automatic Mode not currently defined used not currently defined used Warning 0 indicates a system Fault function set in user program to provide specific function as follows Monitoring Window Axis 1 turned OFF 1 ON 0 not currently defined used Auxiliary Output 97 99 Monitor See Table 5 1 for specific use and warnings not currently defined used 1 Axis 1 motion is interrupted not currently defined used Figure 2 2 Output Signal Display Legend AR co 9 EX DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Counter Screen Controls and Indicators 2 13 The Counter screen shows the current status of the counter now executing in the selected block number Any counter programmed in blocks 0000 2999 can be monitored using this displ
10. Carriage Return Line Feed Requesting a Parameter from the DLC It is not necessary to be in Parameter Mode to request parameter data The computer Sends a Request in the format as follows yy xXx _ CR LF The following describes each part of the command string K Send parameter to host yy Parameter Set XX Parameter Number CrLf Carriage Return Line Feed The DLC responds to the requested parameter in the following format K_yyxx dddddddd_ hh CRLF DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat 7 12 Serial Interface Examples DLC A and DLC G The following describes each part of the command string Sending parameter to host yy Parameter Set XX Parameter Number dd gt dd Parameter Data End of block check sum may follow hh Check sum if enabled in parameter B004 CrLf Carriage Return Line Feed Parameter Set Code yy Parameter Number xx General parameter BO 00 to 15 Axis 1 parameter A1 00 to 25 Drive parameter CO 00 to 12 Tool correction value DO 01 to 19 M Function MH or ML 00 to 63 Query K B003 Serial Interface Reply K B003 19200181 Query K A108 Feed Constant axis 1 Reply K A108 00100000 Requesting System Status from the DLC Rexroth Indramat The following System Status Information can be reque
11. Fig 9 1 DLC CTA 4 Figure D 6 CTA DLC Interconnection Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat D 8 Installation Drawings DLC A and DLC G Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G DLC Type Code Descriptions E 1 E DLC Type Code Descriptions E 1 DLC Hardware Type Code Description Hardware Type Code Designation DLC X X Indramat Position Control Designation DLC Hardware Version Number 1 1 Original Version 2 1 With I O bus card connector E 2 Software Type Code Description Software Type Code Designation Indramat Position Control Designation ______ Software Standard R Feed to Length G G Code Programming Corresponding DLC Hardware Version Number 01 1 Original Version Software Revision Number Supported with Documentation Software Minor Revision Number Not Supported with Documentation E 3 IDS Hardware Type Code Description Hardware Type Code Designation IDS X Product Ids Hardware Version Number IDS Hardware Revision Number Number of Digits to the Right of the Decimal Point 0 to 3 These decade switches will be in Red as opposed to Black Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat E 2 DLC Type Code Descriptions E 4 DLC A and DLC G IDS Software Type Code Descriptio
12. Brown Black Green 0 5mm Red OVDC Supply voltage of the isolated Green 0 5mm2 24VDC In Outputs x Yellow Green Shield Cable Type IKS 711 All relays must be equipped with protective diodes Fig 9 2 DEA 4 Figure 3 1 DEA 4 X17 Input Output Connector and Pin Designations Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 3 X32 Connector Green Black Grey Pink Green Red Yellow Black Green Blue Red Blue Yellow Brown Green Brown White Red White Pink White Black Pink Brown White Y ellow White Green White Blue IN DO 4 Plug in location U3 Outputs 12 1 14 15 16 17 18 19 20 21 22 23 24 25 26 27 White Grey White Violet Yellow Pink Blue E 1 lt a Yellow Grey ink Green Yellow Pink Brown Blue Brown Green Yellow Blue Yellow Red Brown Red Brown Black Brown Black Grey 0 5mm2 Red Supply voltage of the isolated Green 0 5mm 24VDC In Outputs Yellow Green Shield Cable Type IKS 711 All Relays must be equipped with pro
13. Error Message Code M Wheel P False 01 10 This error will occur when requesting Status 46 Length Counter and Status 47 Actual RPM MW without having a measuring wheel activated in the DLC parameters Refer to Chapter 4 for more information on how to enable External Encoder operation Error Message Code Param illegal 01 07 The parameter number transmitted to the DLC was too large Rexroth Indramat 8 10 Diagnostics And Troubleshooting Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Rexroth Indramat DLC A and DLC G 1 Verify that the parameter number transmitted to the DLC is between the following A100 A125 for Axis parameters B000 B023 for System parameters C000 C012 for Drive parameters 001 D19 for Tool Correction data MLOO ML63 for M Functions Low Byte MH63 for M Functions High Byte 2 Referto Chapter 7 Section 7 6 2 for the proper format Error Message Code RS Block Wrong 01 01 The program command being requested transmitted to the DLC has an invalid block number Verify that the block number is between 0000 and 2999 Error Message Code RS Block Data Error 01 03 The
14. 0 Measuring wheel Note When A 0 If the measuring wheel option has not been set in parameters 009 and B 010 the error message M Wheel will be sent instead of Status 46 20212345 6 7 8 _ nh hn Cr Lf X_46 Status 46 A axis number 1 measuring wheel 0 d Direction 12345 678 Length selected axis has fed between the programmed ON and OFF of the command FUN in input units Status 47 Actual RPM Measuring Wheel X 4 7 Cr LE d1234 56_ hh Cr Lf X_47 Status 47 d Direction Measuring Wheel axis 1234 56 Actual RPM of the Measuring Wheel Note If the measuring wheel option has not been set in parameters B 009 and 010 the error message 10M Wheel False will be sent instead of Status 47 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat 7 18 Serial Interface Request Format Response Format Request Format Response Format Rexroth Indramat DLC A and DLC G Status 48 Axis Current Motor RPM X 48 Cr Lf X 4 8 1 d1234 56 x yzzzz zz ShhcCr Lf X 48 Status 48 1 axis number 1 d Direction 1234 56 Actual RPM of axis 1 X Not Used y Not Used ZZZZ ZZ Not Used Status 50 System Inputs and Outputs Hexadecimal E x 50 Cr Lf X 50 5
15. ALL DIMENSIONS NOTE bm 1076 wmf Figure D 2 CTA Keyboard and Cabinet Cutout Dimensions Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat DLC A and DLC G imensions D 3 CTA 04 Keyboard and Cabinet Cutout D D 4 Installation Drawings IM xeu arvo YLO 101 wag xeu YLO 401 Fig 8 1 DLC CTA 4 0ex in ui SMI quiessy WLU ss uyoiy 9 30u JouIqey 260 9 ON 70 YLO 0 9 Hed YLO vor SLL YW pnis xew DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Figure D 3 CTA 04 Keyboard and Cabinet Cutout Dimensions Rexroth Indramat DLC A and DLC G Installation Drawings D 5 D 4 IDS and Cabinet Cutout Dimensions Connector assignment 40 Figure D 4 IDS and Cabinet Cutout Dimensio
16. Lf Four system inputs Hexadecimal a Four system outputs Hexadecimal 1 Hexadecimal Conversion Table Weight 2 2 2 2 0 0 0 0 0 0 0 0 1 1 0 0 1 0 2 0 0 1 1 3 0 1 0 0 4 0 1 0 1 5 0 1 1 0 6 0 1 1 1 7 1 0 0 0 8 1 0 0 1 9 1 0 1 0 1 0 1 1 B 1 1 0 0 1 1 0 1 D 1 1 1 0 E DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Serial Interface 7 19 2 Status 50 Example 007400F 9 amp h h CR LF 0000 0111 0100 0000 0000 1111 System Inputs System Outputs In this example e System inputs 3 5 6 and 7 are at 24 volts e System outputs 1 4 5 6 7 and 8 are at 24 volts Status 51 User Inputs Hexadecimal Request Format e X 51 CR LF Response Format X 51 5 LF Input numbers user input hexadecimal code 36 32 28 24 20 16 12 8 4 23 35 3L 27 23 19 15 11 7 227 34 30 26 22 18 14 10 6 2 3133 329425 21 17 13 9 E L s 0 is transmitted for all other inputs that not exist in hardware Status 52 User Outputs Hexadecimal Request Format 52 LF Response Format X_52_aaaaaaaaaaaaaaaaaaaaaaaasS HhCR LF Output numbers a user output hexadecimal code 96 92 88 84 80 76 72 68 64 60 56 52 48 44 40 36 32 28 24 20
17. The AKP command is used to verify the status of a specific bank or group of ten auxiliary inputs Stepping to the next program block takes place after all inputs have met their programmed status simultaneously Note Input 00 of Bank 0 does not exist Program this input with a Don t Care 2 status No error diagnostic is issued if this input is programmed with anything besides a Don t Care condition Note The standard DLC A or DLC G with the DEA 4 system auxiliary I O card has a maximum of 7 auxiliary inputs that are physically accessible to the user The DLC A or DLC G with the DEA 5 expansion I O card has expanded auxiliary input capability of 22 inputs The DLC A or DLC G with the DEA 5 amp DEA 6 expansion I O cards has expanded auxiliary input capability of 37 inputs The following is an example use of the AKP command The AKP command waits until all the specified aux inputs 10 19 have achieved the indicated status shown by the data field 0110201222 0044 AKP 0110201222 1 1 1 1 2 3 4 5 6 2 NT NT 0 0 13 14 15 16 1 0 1 1 0 2 0 1 2 2 2 Inputs 10 13 and 15 are checked for condition OFF Inputs 11 12 and 16 are checked for condition ON Inputs 14 17 18 and 19 are not checked for a condition Don t Care Example 0000 NOP 0001 01 1 Turn ON output number 1 0002 1 0110201222 Scan inputs 10 19 until programmed sta
18. 20 Button Keypad Figure 2 1 CTA Display Keypad Module 2 2 Data Entry Keys Rexroth Indramat CL CR This section describes the general function of each key on the CTA keypad The use of these keys is further described throughout the manual for specific functions Clear Use to clear the displayed hard or soft fault message if the fault can be cleared cause of fault has been corrected It also clears parameter entry errors See Store key for additional uses Carriage Return When changing data values press this key before pressing the Store key to cancel the change and leave the data as previously stored clear entry In all display screens which show a flashing cursor allow editing data fields use this key to move the cursor to the first position of the data field press again to move to a previous data field on the display Continue pressing to move the cursor to home position of the display and allow scrolling to different display screens with the arrow keys Store Press to store save entered data to the DLC user memory when programming or editing program from the Edit display screen Pressing the CR key changing to another block number or other display screen without first pressing the Store key cancels data changes and data returns to that previously stored Plus and Minus Use in programming from Edit screen to specify the feed direction When on the Edit screen or Counter Display screen
19. Error Message Code M CommandStatus Illegal 20 An M Function was called for in the program but M Function are not properly set up in parameter B009 When M Functions are set up in the DLC parameters parameter B009 requires an input and an output number be specified as the first output used and the first acknowledgment input used If no input and output are specified such as the input or output number is 00 when you call for an M Function the DLC gives you this error Refer to Chapter 4 Section 4 6 for a complete description of M Functions and how they can be used Error Message Code M Command M0 1 21 An M Function acknowledgment was programmed but M Function acknowledgments are not properly set up in parameter B009 When M Functions are set up in the DLC parameters parameter B009 requires an input number be specified as the first acknowledgment input If no input is specified as the starting input such as the input number is 00 when you call for an acknowledgment in an M Function the DLC has not been told what input to monitor and therefore gives you this error Refer to Chapter 4 Section 4 6 for a complete description of M Functions and how they can be used Error Message Code Malfunction 501 Command 22 The Tool Correction register number specified in the current program is not between 01 19 The amount of the correction value to be stored exceeds the val
20. H IlOUxaiu 300W INSOMNIA SILVWOLNY daddv 5 BV3N L3N AjaLvavdas 38 GISNI ANd LHM b1162 3 wmf Figure C 3 DKS DLC A MDD Interconnection Sheet 3 of 10 DOK CONTRL DLC A DLC G AW03 AE P 12 99 Rexroth Indramat DLC A and DLC G Drawings and Schematics C 5 TES IL HOFFMAN REXROTH INDRAMAT 20 21 AUX INPUT 3 AUX INPUT 4 AUX INPUT AUX INPL GRN BLK PARATELY WRAPPED WITH SHOULD BE SEI SED WIRES oF UNU b1162 4 wmf Figure C 4 DKS DLC A MDD Interconnection Sheet 4 of 10 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat DLC A and DLC G C 6 Drawings and Schematics 00 OL LON ISN B3WOLShO 1N3An200 SIL xnv 1 Off LDdNI XN NY8 734 318 734 vivdis 3H GINOHS S G3SNNN 30 50 3 590 3dvl 101010 b1162 5 wmf Figure C 5 DKS DLC A MDD Interconnection Sheet 5 of 10 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat DLC A and DLC G Drawings and Schematics C 7 HOFFMAN ES REXROTH INDRAMAT b1162 6 wmf Figur
21. 12345 678 Branch If Position Has Been Reached BZP 345 2 12345 678 Branch if Target Position Exceeds Position Limit CID 345 1 0 1234567 Change Instruction Data CIO 0 01 23 4 Copy Input Output to Output CLA 1 Clear axis Absolute Encoder Value CLC 345 Clear Counter 1 07 001122 360 Cam Output Control CON 1 0 999 07 Continuous Operation ON OFF COU 12345 12 123456 Count CPL 1 Clear Position Lag CST 1 1 Change Subroutine Stack Pointer 12 Tool Correction Memory Selection 1 11 234567 Factor All Motions All Positions by X FOL 1 2 1 234567 axis Synchronization on off FUN 2 2 1 2222 Functions DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat 7 10 Serial Interface Rexroth Indramat DLC A and DLC G _12345678________ Feedrate command for G Code Functions G01 1 12345678 99 _ G04 1234 Linear Feed with M Functions Dwell Time G40 Deactivate Tool Correction G43 Add Tool Correction to Command Position G44 Substract Tool Correction to Command Position G60 Position with Exact Stop G61 Begin Velocity Rate Optimization Profile Q74 1 Reference Home Axis G90 Begin Absolute Positioning G91 Begin Incremental Positioning HOM 1 Home axis JMP 345 Unconditional Jump to
22. 185232 CTS 52321 ATS 195495 Rx Tx RS 485 CONFIGURATION SHIELD Ax Tx GROUND Ra Tx DLC X31 C NNECT OR Fig 7 1 DLC X31 Connector Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 e Indramat 7 2 Serial Interface DLC A and DLC G Signal Level Requirements Figure 7 2 illustrates the signal level requirements for the different communications RS232 485 for the DLC Control Card To minimize signal degradation over long cable runs the serial device driver should provide the following levels e RS232 15 50 ft maximum run e RS 422 5 Vdc 1000 ft maximum run e RS 485 5Vdc 3000 ft maximum run The length of the transition for each word T is set in the serial interface parameter B003 The current hardware version is capable of 300 to 19200 baud LOGICAL RS 232 5 85 485 15 VDC 5 5 VDC LDGICAL 1 Fig 7 2 Signal Level Requirements Serial Cable Configurations For RS 232 serial communications you should note that the connector on the serial card in your computer can vary in configuration Figure 7 3 illustrates two common serial connections for interfacing from the RS 232 port of a computer to the DLC COMPUTER COMPUTER 9 pin to 25 pin 9 pin to 9 pin D connector D connector Fig 7 3 RS 232 Serial Cable Configurations Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G 7 2 Data Format LOGICAL 1i LOGICAL 8 Wo
23. 2 32 16 x 12 386 0 inches second For an Accel Decel rate of 1G enter parameter data lt 00003860 gt Multiply or divide this number for a rate of 2G 1 2 G etc Use similar procedures to program in factors other than G force Note Parameter A117 Knee Point can be programmed to select a second acceleration deceleration rate based on velocity Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 10 Parameters DLC A and DLC G Parameter A103 Position Gain KV Factor Position Gain A103 0000 01 00 0000 Not Used set to 0000 01 00 Position Gain Minimum 0 01 Maximum 10 00 This is the axis position gain of the system The standard machining Kv Factor 1 Entering a larger number higher gain will yield a tighter system less following error Entering too large a number can result in overshoot oscillation and or high wear on the system parts bearings chains gears etc Set this parameter for optimum high performance not necessarily maximum for your system Input is specified to two decimal places Hint A gain of 3 to 5 is typical when the motor is matched to the load inertia This entry sets the amount of velocity command given to the amplifier per a given position error deviation The following error deviation while feeding is inversely proportional to the KV selected v Vel E Vel 1000 x FE 1000x KV Where e Vel velocity is in IU minute e following error is
24. Rx Tx Notes 1 When only one station is in use not using IKB0001 a matching resistor must be installed in the interface cable Matching resistances 300R 470R 2 Data transfer cables may not be laid in parallel to power cables Fig 9 6 DLC RS485 fig906 wmf Figure C 12 SOT DLC RS485 Interconnection with up to 32 Stations Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat C 14 Drawings and Schematics DLC A and DLC G C 4 Timing Diagram for DLC with DKS DDS or DDC Input Output Enabled Bb DC Bus Dynamic Braking E STOP Power OFF Clear Power ON Antrieb DLC Drive UD Contact Power Torque On o Automatic Mode Cycle Stop a Cycle Start Automatic Program running O O O fF O BFPO fF O fF O O 0 approx 5s for DKS approx 300ms for DDC and DDS with TVD gt 200ms after locking the UD contact and if Bb 17 the drive torque falls 25ms 220ms 210ms 2300ms after locking the UD contact and if Bb 1 the program can be started t Maintain gt 800ms minimum interval between CLEAR and START after an AF ON internal DLC drive enable for the drive controller When AF ON is activated the drive torque falls These timing diagrams enable po
25. Section 8 3 describes the serial communications errors and suggests possible solutions to the error condition Digital AC Servo Drive Normal Operating Diagnostics Error Message Code Drive Enabled 102 The digital drive has powered up properly and the DLC Control card has enabled the servo system The DLC system can now be operated in Automatic or Manual mode Not Required Error Message Code Drive Halt 103 The DLC Control card has detected an error The digital drive will stop with the maximum torque available The digital drive will then maintain zero velocity with torque still applied to the motor and remain in a closed position loop Check the DLC display to determine the DLC error detected Then consult the Solution section under that specific diagnostic Error Message Code Drive Ready 101 Control voltage and main power are present DC bus voltage is present Drive is ready to be enabled If the DLC Control Card has an error the digital drive is typically displaying this diagnostic Check the DLC display to determine the error in the DLC Then consult the Solution section under the diagnostic explanation Not Required Error Message Code Operation Ready 100 The digital drive is ready to have 3 phase power applied Not Required Error Message Code Safety Interlock 104 This diagnostic will occur when the AS inpu
26. Selection M function root idus 5 64 N P No Operation Blank rea cc 5 65 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat VI Table of Contents DLC A and DLC G PBK Positioning scscesasdscadechteacaanlatecucadsauseahsenteuesslalssasgeeuedanduaadecssetteredsinadewsgearadedduacdeneyetes 5 66 PFA Absolute Position Feed To Positive Stop 5 67 PFI Incremental Position Feed To Positive Stop 5 68 POA Positlon Absolut o accetti md DUNS 5 69 Poston INCFEMONT 5 70 POM Position On Memory Requires IDS 5 71 PSA Position Absolute With In Position Signal 5 72 PSI Position Incremental With In Position Signal sese 5 73 PSM Position On Memory with In Position Signal Requires IDS Setup 5 74 SEE ri 5 75 REF Referencing Detect Registration Mark Input 5 76 REP Conditional Jump if Search Distance is Exceeded Referenced to REF Command 5 77 RMI Registration Mark 222 eaaa Naa NAANA T n EO E densa assu DES 5 79 RSW 5 82 RTS Return from SUBrOULI
27. WARNING If the automatic cycle is interrupted by a low on the Feed Interrupt line all motion is suspended Once this signal is restored high the cycle will immediately resume The work area should not be entered if the motion has stopped as a result of this signal Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 3 14 Functional Description of DEA 4 I O Connections DLC A and DLC G Special Functions Rexroth Indramat Inputs e Detect Registration Mark e Enable Measuring Wheel Operation and Dual Encoder Option An auxiliary input Detect Registration Mark can be assigned in the REF command to cause the DLC to search for a registration mark on the material To provide this input signal use a sensor which detects a printed mark or stamp on each piece of material A high signal must be present on this input when a reference mark is present under the sensor The accuracy and duration of this signal is essential to the proper operation of position correction especially if the mark needs to be detected at high speeds The DLC can detect a registration input signal in 1 millisecond Refer to the REF program command in Chapter 5 for additional information on using this feature For External Encoder operation an optional encoder input card must be installed in the Indramat Digital Drive Product Also the external encoder option must be enable in parameters A123 B016 through B022 These parameters enable the external e
28. 0 Not Used 1 Homing type 0 No homing disable homing function 1 Homing using a single turn feedback Incremental 2 Multi turn absolute feedback 05 Search velocity max velocity 01 99 of A100 in 1 increments 5 to 10 is normal for power up homing 00 When multi turn absolute feedback selected no search velocity is required 0 Not Used 0 Linear rotary operation select 0 Standard operation 1 Rotary operation with shortest path 2 Rotary operation follows programmed direction forward reverse The last digit of this parameter allows using the DLC for rotary table applications If a single turn absolute feedback is used with this function homing is required because of the absolute measuring system The rotary table option also must be activated by entering a gear ratio in parameter A116 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 18 Parameters DLC A and DLC G Parameter A111 Homing Offset Homing Offset 111 0000 000 In many cases some position other than the home position such as the center line of the slide is used as the reference position This parameter defines the distance in input units and the direction from the home switch that you want to use as the reference position After the homing routine is completed the offset distance programmed in this parameter will be inserted as the current axis position The axis will not physically move to this
29. 1347 PFI 1 00020 000 999 Rexroth Indramat 1 Axis 1 00020 000 Incremental position feed to a positive stop in input units to 2 or 3 decimal places depending on the setting in 007 999 feed rate 00 1 99 9 of the maximum velocity set parameter A100 The PFI command is used in conjunction with the MOM command The PFI command will incremental position the axis to a positive stop and the MOM command will determine the percentage of maximum torque during the move to the positive stop and the maximum torque at the positive stop When using the PFI command the positive stop must be within the software overtravel limits set in parameters A113 and A114 The incremental position programmed in the PFI command must be greater than or equal to the exact distance to the positive stop otherwise the positive stop cannot be reached The programmed incremental position can be greater than the software overtravel limits Only PFI command can be active at one time The program flow continues immediately after one or both of the following conditions e f positive stop is not reached the next block in the program is executed The next block is typically a unconditional jump JMP command to a error routine to notify the operator that the positive stop was not reached e f the positive is reached the program flow will jump over the block immediately after the PFI command Refer to the MOM command in
30. A121 entry for 2000 RPM motor is Max Speed RPM 121 2000 0000 Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 29 Parameter A122 Monitor Window Monitoring 122 0 0 00 0 010 0 Error Reports 0 Error reports Drive Runaway Encoder Error active Excessive Position Lag or 8 Error reports deactivated 0 Monitor window delay in delay x 100 milliseconds O OFF 1 9 delay 00 This output is set if the positional deviation is greater than the allowable deviation An entry of 00 no output programmed Note The output that is programmed here is only set if the error reports have been deactivated and the error occurs Deactivation by entering 8 in the first screen position of this parameter or by setting flag 95 in the program 0 Unassigned 010 Allowable position deviation in percent In the normal case a value of 10 20 is input here Entry range 001 100 Output Position error gt Maximum allowable deviation The DLC1 continuously monitors position control To do this the DLC uses a mathematical model to recognize an error immediately Drive Runaway occurs if the current position of the encoder exceeds the target position of the model Excessive Position Lag occur if the current position of the encoder is less than the position expected by the model The maximum allowable deviation between the actual position and t
31. Actual count titttt Target count Status 05 Software Version Request Format dc d db Response Format X 05 h hber Lf V Software version as displayed on the CTA display Example DAO1 1 03 02 Status 06 Input Status Request Format 06 Cr Lf Response Format X 06 b eeeeeeeeeeeeeeee 3S hhcCr Lf 16 inputs are always represented bz Bank number Input range 0 System Inputs 1 8 DEA 4 1 card 1 Aux Inputs 1 7 DEA 4 1 card 2 Aux Inputs 08 22 DEA 5 1 card 3 Aux Inputs 23 37 DEA 6 1 card e State of each of 15 inputs in sequence as follows 0 OFF 0 Vdc 1 ON 24 Vdc Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Request Format Response Format Request Format Response Format Serial Interface 7 15 Status 07 Output Status X 0 7 b Cr Lf X 0 7 b _ShhCr Lf 16 outputs are always represented b Bank number Output range 0 System Outputs 1 5 1 Aux Outputs 1 16 2 Aux Outputs 17 32 Aux Outputs 33 48 4 Aux Outputs 49 64 5 Aux Outputs 65 80 6 Aux Outputs 81 96 7 Aux Outputs 97 99 a State of each of 16 outputs
32. Function Input Clears the Hard or Soft Fault status of the DLC 24 Vdc momentary Clears the Soft Fault status of the DLC or Clears the Hard Fault status and re initializes the DLC 0 Has no effect Once a fault occurs the DLC displays a diagnostic message refer to Chapter 8 The operator must then physically correct the problem Next the operator can press the Clear key on the CTA keypad or the Clear pushbutton on the user s control panel to clear the diagnostic message This signal is typically wired to a normally open push button switch on the user control panel Auxiliary Inputs 1 Through 7 Rexroth Indramat DEA 4 Connector X17 pins 9 through 15 Function Input Defined by the machine builder in the DLC parameters and program 24 Auxiliary input is on high 0 Auxiliary input is off low The DEA 4 auxiliary inputs 1 7 are defined by the machine builder in the DLC parameters and or program DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 19 3 4 DEA 4 Output Signal Descriptions System Fault Indicator Manual Mode Indicator DOK CONTRL DLC A DLC G AWO3 AE P 12 99 This section describes the system auxiliary outputs from the DEA 4 I O card for the DLC control system The Input and Output signal lines of the DEA 4 I O card are optically isolated from the internal bus structure to mini
33. If no input is programmed 00 then the call up of an M function with input acknowledgment in the user program leads to the error message M Command MO 1 If no output is programmed 00 then the call up of an M function in the user program leads to the error message Mz Command The input and output specified in this parameter become the starting point for the user defined M function I O Example f Aux Output 4 is entered here as the First M Function output then output 5 becomes the second M function output etc These input output designation changes remain true for the I O sets configured for high and low bytes in the M function parameters See Section 4 6 for a complete description of M Functions and how they are used DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Parameters 4 47 Parameter B009 Function Timer pLc G ony Function Timer B009 aa00tttt aa Output used to signal Timer is running 00 Notused set to 00 tttt Timer for M function Timer is entered in seconds between 0 000 to 9 999 This timer controls the ON time for each M Function output turned on See Section 4 6 for a complete description of M Functions and how they are used Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 48 Parameters DLC A and DLC G Parameter B010 Free Free B010 00000000 0000000 Not used must be set to 0000000 Parameter 10 Free is currently undef
34. Indramat Axis 1 2 Override input selection 0 switched OFF or override in accordance with Parameter B013 2 Override via Binary value at Inputs 1 7 Significance input 1 20 input 7 27 3 Override via value in Gray Code in inputs 4 7 as in B013 4 Programmed Override requires entry in 456 override velocity factor 5 Override via measuring wheel encoder 1 pulse frequency 3 Override update 0 Read the Override input value every program cycle 1 Reads Override value only once each time the command is executed 456 Override velocity factor Velocity factor to 3 decimal places 001 999 This factor is significant only if 4 is selected in the second digit Subsequent feeds are reduced by this factor 999 99 9 050 5 0 7 Function 0 Override as factor Override input value represents a factor to determine the resulting velocity All subsequent feeds will be scaled 1 Override as limiting Override input value represents a limiting factor Position commands that have lower velocity than this are not affected Activation of an override function using the VEO command has precedence over any activation in parameter B013 The Binary or Gray scale might be used in conjunction with a PLC The limiting sector is typically a internal software switch in the user program Programmed override is a means of scaling or limiting the velocity of the subsequent process after the command
35. It tells the control when to read the next command line see PSI PSM in chapter 5 and to turn ON the auxiliary output The first two digits specify the output number that will turn ON when the axis is in position You can use this output to turn on a light buzzer or as an internal flag If no output is needed a 00 can be programmed or an output that is not physically accessible 46 to 72 can be programmed Note The auxiliary output number must be unique to all other parameter selected auxiliary outputs The remaining digits are the switching threshold position tolerance entered in input units A typical setting is 5 thousandths of an inch The second half of the entry would be lt 000005 gt The following sketch shows an example of switching threshold Position Tolerance in input units at this point program l reads in next block Position Tolerance The Aux Output will turn back OFF momentarily if an overshoot exceeds this amount axis Direction gt overshoot if any gt Commanded Position Note A properly tuned system does not overshoot See A102 and A103 If overshoot occurs the acceleration rate and or gain may be set too high Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 14 Parameters DLC A and DLC G Parameter A107 Position Pre Signal Pos Presignal A107 14 0 2 123 4 14 auxiliary output number to be turned on 00 not activated 0 2 time in 0 1 seconds 0
36. Jog Forward 3 17 3 18 Parameter Mode Select 3 15 Installation Start Up 6 1 Interface Descriptions 3 1 Axis Homing 3 8 Fault Diagnostic Monitoring 3 12 Feed Monitoring Program Interruption 3 13 Manual Operations 3 11 Normal Operation Signals 3 7 Operating Mode Selection 3 5 Safety Interlocks 3 6 Special Functions 3 14 L Linear or Rotary Operation 4 5 M Map of DLC Control Panel Display Screens 2 5 Mounting Cabinet 6 1 Optional IDS 1 9 Output Signal Descriptions Automatic Cycle Running Indicator 3 20 Automatic Mode Indicator 3 20 Auxiliary Outputs 1 Through 11 3 20 Manual Mode Indicator 3 19 Parameter Mode Indicator 3 20 System Fault Indicator 3 19 P Parameter Descriptions 4 6 A100 Maximum Velocity 4 7 A101 Jog Velocity 4 8 A102 Acceleration Rate 4 9 A103 Position Gain 4 10 A104 Encoder Resolution 4 11 A105 Free 4 12 A106 Position Tolerance 4 13 A107 Position Pre Signal 4 14 A108 Feed Constant 4 15 A109 Direction of Operation 4 16 A110 Homing Setup 4 17 A111 Homing Offset 4 18 A112 Homing Acknowledgements 4 19 A113 Travel Limit Minimum Value 4 20 A114 Travel Limit Maximum Value 4 21 A115 Special Functions 4 22 A116 Rotary Axis Gear Ratio 4 23 A117 Second Acceleration Rate 4 24 A118 Brake Release 4 25 A119 Free 4 26 A120 Feed Angle Monitoring 4 27 A121 Maximum Motor Speed 4 28 A122 Monitor Window 4 29 A123 Fo
37. Note Auxiliary Output 00 of Bank 0 does not exist Program this aux output with a Don t Change 2 status No error diagnostic occurs if this output is programmed with anything besides a Don t Change condition Note The standard DLC A or DLC G with the DEA 4 system auxiliary card has a maximum of 11 auxiliary outputs that are physically accessible to the user The DLC A or DLC G with the DEA 5 expansion I O card has expanded auxiliary output capability of 27 outputs The DLC A or DLC G with the DEA 5 amp DEA 6 expansion I O cards has expanded auxiliary output capability of 43 outputs The following is an example of the APE command The aux outputs in Bank 1 aux outputs 10 19 will be programmed to the states designated in the data field 210012201 1 respectively E 0044 APE i 2100122011 1 1 1 1 1 1 1 1 1 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2 1 0 0 1 2 2 0 1 1 Aux Outputs 12 13 17 are programmed for an OFF state Aux Outputs 11 14 18 and 19 are programmed for an ON state Aux Outputs 10 15 and 16 are programmed with a Don t Change condition This causes the output to remain in its previous state Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 16 Programming DLC A and DLC G APJ Activate Parallel Output then Jump E 0304 APJ 1000 1 2100221011 1000 Target block 0000 2999 1 Bank number 0 9 group o
38. Parameter C007 is only effective in conjunction with a multiturn encoder When using a single turn encoder C007 is overwritten with O after the drive is powered up again Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 70 Parameters DLC A and DLC G Parameter C008 Error Reaction as of software version DAO1 1 01 6 Rexroth Indramat If there is a drive fault during motion this parameter determines the drive s error reaction to the fault Error Reaction C008 00000002 0000000 Not used must be set to 0000000 2 Error Reaction 0 The drive switches itself to velocity control and defaults to a RPM setpoint of 0 The brake engages after maximum 400 msec and it disengages after another 100 msec DDS Error report to the power supply package reaction DDS Error report to the internal power supply Failure of power system protection 1 Same as error reaction 0 but no error report to the power supply package reaction or to the power supply 2 The drive disengages immediately If there is brake it engages immediately No error reaction no package reaction The drive Switches itself to velocity control and defaults to a RPM setpoint of 0 DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 71 Parameter C009 Current Loop Proportional Gain as of software version DAO1 1 01 6 Current Loop P_Gain C009 000120 00 000 Not used must be s
39. REF Move at a set velocity until a registration mark is detected REP Maximum search distance for REF command branch if exceeded RMI Registration mark interrupt high speed SAC Set Absolute position reference SIN Sinusoidal oscillation SO1 Read inputs to program a distance and velocity into memory Velocity change absolute vcc Velocity change during a profile VEO Velocity override binary gray code override WRI Write current position to a target block Teach Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 5 8 Programming Branch Commands Jump Commands Rexroth Indramat DLC A and DLC G These are commands for conditional program flow control used to direct the actions of the control based on events that can be monitored by the DLC BAC Branch when the item count is met up to 99 999 counts BCA Output dependent conditional branch 1 to 99 BCB Binary inputs conditional branch 16 or 256 possible targets BCD BCD input conditional branch 100 possible targets BCE Input dependent conditional branch 1 to 37 BIC Branch conditional on inputs 1 to 37 BIO Branch if Input Output mask matches compares 10 bits BMB Binary output conditional branch compares any of outputs BPA Parallel output conditional branch compares 10 outputs BPE Parallel input conditional branch compares 10 outputs BPT Branch on position reached must be at position BZP Branch if at or past a positio
40. There is a parameter table available for the definition of the 64 pre defined M function Output of one of the M functions corresponding to this table can be programmed in the command G01 The M function programmed in a G01 block is set after the programmed position has been reached within the limits set by A106 Position Tolerance If GO1 is programmed within a G61 contouring mode the M function is set so as to allow optimum speed Please see Section 4 6 of Chapter 4 for further information on M Functions and their use With the G01 command program block execution continues immediately after achieving the programmed position within the position window A106 DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 47 G04 Dwell Time E 1000 G04 tt tt tt tt Wait time in seconds This command causes a delay in further execution of the program It corresponds to the WAI command Program block execution is delayed by the programmed dwell time Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat DLC A and DLC G 5 48 Programming G40 Tool Correction Deactivated Rexroth Indramat E 1000 G40 This command disables Tool Correction within the process path in the programmed feed command G40 is effective upon entering automatic operation The register selected remains selected even after deactivating the Tool Correction with G40 If a G43 or G44 command is issued after a G40 is issued the
41. in parameter B007 e The acceleration rates specified in parameter A102 will be used as defaults unless they are changed with the ACC command prior to the motion e Select either Constant acceleration or Knee Point acceleration profile e Motion can be independent or simultaneous e Axis can be programmed for Rotary motion rotation resetting to zero after one revolution DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 7 Position Support Commands The following commands are used either in conjunction with a positioning command or by themselves to achieve the specific result Acc Change acceleration deceleration rate 0 1 to 99 9 of A102 CLA Clear absolute position buffer set to zero coc Cam Output Control CON Constant velocity command sets axis to a continuous speed CPL Clear Position Lag D Tool Correction Memory Selection FAK Factor all position distances by a set ratio FOL Axis synchronization factor master slave mode FUN Functions Feedrate command for G Code Functions G40 Deactivate Tool Correction G43 Add Tool Correction from commanded position G44 Subtract Tool Correction from commanded position G74 Reference home axis G90 Begin Absolute Positioning G91 Begin Incremental Positioning HOM Execute a homing routine KDI Copy a position difference to a target block Torque Reduction PBK Position break axis immediate stop PST Position test turn output ON OFF based on position
42. the Indramat Digital Drive to accept the Master Encoder Measuring Wheel Input The Follow Axis parameter A123 is used to configure the axis to follow a master encoder input or as a measuring wheel encoder to verify the axis has been positioned properly The Following Operating Modes available are Normal Feed Axis 00000000 Following Mode Axis follows Master Encoder 21000000 Measuring Wheel Version 1 3100XXXX Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 32 Parameters Rexroth Indramat DLC A and DLC G Measuring Wheel Version 2 4100XXXX When parameter A123 Follow Axis is programmed with all zeros the axis is a normal feed axis When using the Follow Axis Measuring Wheel Version 1 or 2 the following parameters must be programmed External Encoder 1 Parameter B016 External Encoder 1 Lines Rev Parameter B017 External Encoder 1 Constant Parameter B018 External Encoder 1 Offset Parameter B019 When the Follow Axis parameter A123 is programmed with 21000000 the axis will follow the master encoder input in Automatic or Manual Mode When the Follow Axis parameter A123 is programmed with 3100XXXX the Measuring Wheel Version 1 is selected In Automatic Mode the Measuring Wheel Version 1 will close the position loop on the measuring wheel encoder Any slight difference between the load and motor position will be compensated for during the position move When the Follow Axis paramet
43. use these keys to page through the block numbers the cursor must be on the first line Use in parameter mode to scroll through parameters numbers within each parameter set Numerical Keys Use for entering data values DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Controls and Indicators 2 3 2 Left and Right Arrow Use to move the cursor to the left or right one position at a time From certain display screens ones without a cursor the right and left arrow keys select additional display screens see next section Up and Down Arrows Use to scroll through display screens see next section or to change parameter sets see Chapter 4 in parameter mode Use to scroll through program commands when on the Edit screen With the cursor positioned next to the command mnemonic i e NOP press these keys to step through the program commands in alphabetical order Note All displays illustrated in this manual use an underline character to represent the cursor Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 2 4 Controls and Indicators DLC A and DLC G 2 3 CTA Display Screens The CTA uses its liquid crystal display for several screens The operating mode and keyboard selections determine the resulting display When the DLC is in Parameter Mode data for each parameter can be viewed entered or edited While in Automatic or Manual Mode other display screens show the control s
44. 0 complete 0157 JMP 0150 to Block 0150 Example Main Program Before It Writes In the New Position Block 0000 JMP 0015 0015 PSA 1 00000 000 500 0016 AEA 01 1 0017 WAI 00 50 0018 AEA 01 0 0019 PSA 1 00000 000 500 0020 AEA 02 1 0021 WAI 00 50 0022 AEA 02 0 0023 JMP 0015 Procedure for Using the WRI Command in Manual Mode 1 In Manual mode home the axis 2 Jog the axis to the first position desired Example First position desired L P 1A 00010 000 1 Turn Auxiliary Input 42 on and off 2 Jogthe axis to the second position desired Example Second position desired L P 1A 00005 000 1 Turn Auxiliary Input 42 on and off 2 Now blocks 15 should change to the first position desired Blocks 19 should change to the second position desired Example Main Program After It Writes In the New Position Block Number 0015 1 00010 000 999 Always writes in velocity of 99 9 0016 AEA 01 1 Use VEO or VCC to change it 0017 WAI 00 50 0018 AEA 010 0019 POA 1 00005 000 999 Always writes in velocity of 99 9 0020 AEA 02 1 Use VEO or VCC to change it 0021 WAI 00 50 0022 AEA 02 0 0023 JMP 0015 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 99 5 10 Tool Correction 0 G40 G43 G44 Tool Override Dnn 00010 00 nn Number of the Tool Correction Register to be used 00000 00 Tool Correction value to 2 3 decimal places
45. 0 at 20 feedrate Jump to block 0000 and stop program A new value for the factor has no effect on the positioning currently being executed The FAK factor takes affect on the next position command Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 44 Programming FUN Functions E 1234 FUN 0 0 1 1000 0 0 4 4 0 0 0 Sig Unassigned set to 0 Unassigned set to 0 DLC A and DLC G Feed length measurement measuring wheel 0 off 1 on Feed length measurement axis 1 0 off 1 on Unassigned set to 0 Unassigned set to 0 Unassigned set to 0 ignificance of the inputs Temporarily store measured value and then clear Clear the measurement value start new measurement A temporarily stored value is retained No change Status 46 is used to request the temporarily stored measurements via the serial interface The feed length traversed by the axis is to be determined after 10 events Example 0000 NOP 0001 01 1 0002 FUN 000 1000 0003 010 0004 011 0005 BAC 0007 0000 0009 0006 JMP 0009 0007 0005 01 0 0008 JMP 0007 0009 AKN 011 0010 FUN 0000000 Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Feedrate Programming 5 45 E 1000 F 010000 00 010000 00 Feedrate in units min to 2 or decimal places depending on setting in B007 Range of values 0 F max Fmax Pa
46. 0000 through 2999 The Indramat MotionManager Program Development Tool provides an efficient method of creating and editing the user program for the DLC control It is a software package that runs on any DOS based computer It provides several benefits over programming the DLC from its control panel It also includes enhanced features for creating and editing program that are not possible from the DLC control panel Refer to Publication IA 74733 for specific information on using this software program This chapter begins by describing some basic information that should be considered before creating a program for the DLC It then describes the methods to enter the user program directly into the CTA keypad and display It further describes the programming commands and their function in a user program Two types of positioning can be selected in the system absolute and incremental All positioning is done in the units of your choice and are referred to as Input Units IU Input Units are the user s desired units of measure i e inches mm radians degrees etc In absolute positioning all movements of the slide are made some absolute distance from the machine reference point Thus if the slide is at 2 inches from home and an absolute position command to move 3 inches is executed a one inch feed in the positive direction will result In incremental positioning all movements of the slide are made in the commanded direction to the dis
47. 0000 to 2999 In mode 3 5 Number of the correction memory 01 to 19 The SO1 command is used to read in length information via decade switches or from a programmable logic controller PLC DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 87 The information entered is cleared after a fault Emergency Stop when powering up the DLC and when entering Parameter Mode Malfunction S01 Command occurs if 1 The Tool Correction register number is not between 01 19 2 The amount of the correction value to be stored exceeds the value 99999 99 or 9999 999 In the following example aux input 04 is the least significant digit Enter 04 for the ee entry Input 05 is 04 1 ee 1 Input 07 is the most significant digit ee 3 The DLC must read in all decimal places one after the other A SO1 command is required for each decimal place The resulting information is converted to position and velocity and stored in one of the following position commands POI PSI POA PSA VCC programmed in the target block Additional Examples A Hardware Connect for an external decade switch array 4 decades Aux Outputs One an decade n decade E Aux Inputs 5 a 5 6 E 8 Figure 5 2 Decade Switch Array The inputs are switched using the APE command The inputs are read using the SO1 command At the beginning of statement 0300 is POI 1 123456 78 999 Rexroth
48. 001 00000 Minimum 00001000 Maximum 50000000 This parameter sets the feed constant which is the ratio of slide movement per motor revolution The number entered equals the distance the axis will travel per one revolution of the encoder to four or five decimal places Set the decimal resolution B007 before entering this parameter Note This parameter defines the input units used in the parameters Rotary Note Enter the amount of travel for one revolution of the table device one revolution of the gearbox output The DLC will internally calculate the motor feed constant Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 16 Parameters DLC A and DLC G Parameter A109 Direction of Operation Direction A109 0 1 000000 This parameter allows changing the axis direction through software in the DLC 0 Not used set to 0 1 Direction 0 Direction of operation remains unchanged 1 Reverse motor direction 000000 Not used set to all zeros Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 17 Parameter A110 Homing Setup Homing Setup A110 01010500 This parameter specifies the search direction and speed for the zero reference point See Section 3 2 5 for homing function description and Appendix A for additional application information 0 Not Used 1 Search direction for home switch 0 Search Forward 1 Search Reverse
49. 01 07 SYSTEM OUTPUTS gt OUTPUT 1 16 j OUTPUT 33 48 OUTPUT 49 64 1 ONLY SHOWS WHEN USING 65 80 DEA 5 1 I O CARD OUTPUT 81 96 OUTPUT 97 99 2 ONLY SHOWS WHEN USING DEA 5 1 DEA 6 1 I O CARDS NOTE NOTE INAUTOMATIC ROW E ONLY DISPLAYS THIS SCREEN M PROGRAM STATUS TASK XXXX AKN TASK 2 XXXX BCE TASK 3 XXXX ATS MANUAL AI INIT A PROGRAM STATUS TASK 1 XXXX AKN TASK 2 XXXX BCE TASK 3 XXXX ATS E EDIT PROGRAM Figure 2 2 Map of DLC Control Panel Display Screens Row A Refer to the Display in Figure 2 2 When power is applied and no errors occur the DLC will display the Drive Diagnostic Screen in Automatic or Manual Mode this display shows the drive status code and diagnostic By pressing the right arrow key the DLC control status is displayed By pressing the right arrow key again the DLC hardware and software screen will be displayed This screen will show the current version of DLC hardware along with the current DG software version installed on the DLC control card Use the right left arrow keys to scroll around to different screens Drive Diagnostic System is Ready DLC 1 1 102 Drive Enabled DG 01 1 XX XX Drive Diagnostic Screen DLC Status Screen Hardware Software If a servo fault is present at power ON then the servo status message will appear first Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 9
50. 1 Transformer Heat Dissipation The incoming 3 Phase power must be ground referenced Use an isolation transformer with secondary if this cannot be confirmed Refer to TVD TVM KDV DKS or appropriate manual for additional information If a transformer is needed for operation exercise caution on its location Do not install the transformer in the same cabinet as the modules unless a sufficient method of cooling is applied 6 4 Hardware Installation See Appendix D for mounting hole dimensions and location of the CTA keypad and display module the cut out dimensions for the remote keypad keypad gasket and mounting holes and cut out dimensions for the optional IDS The mounting dimensions and cabinet cut out data for the TVD DDS or DKS are located in the units respective support manuals The method of mounting the MDD Digital AC servomotor is dependent upon the application Additional information and a drawing package for the MDD servomotor is available on request from Indramat 6 5 Electrical Installation There are many variations of wiring techniques used to connect the DEA 4 System Auxiliary I O card to the machine builder s equipment The Interconnect Drawings supplied with this manual see Appendix C show an example of the connections to a typical machine Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 6 4 Installation Start Up DLC A and DLC G 6 6 DLC DEA 4 1 Connectors This section describ
51. 1 1 1 999 0 Velocity Override Command WAI 01 00 Time Delay Wait WRI 345 011 Write in Absolute Position teach command DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Serial Interface 7 11 Information Request Program Parameter and System Status can be requested from the DLC This allows a host device to discern the status of the DLC and access the following information e Request Program Block e Request Parameter e Request Status Information Each is fully described in the following sections Requesting a Program Block from the DLC A request for a program block begins with and ends with CrLf a checksum is not required Request format is as follows Nbbbb CR LF The following describes each part of the command string N Send program block to host bbbb Block Number 0000 2999 CrLf Carriage Return Line Feed The DLC will send the requested program block in the following format refer to Table 7 1 for illustration of the data format for each command LF Nbbbb c dddddddddddddddd S hnhCR The following describes each part of the command string Sending program block to host bbbb Block Number CCC Command Mnemonic dd gt dd Program block Data End of block check sum may follow hh Check sum if enabled in parameter 42 CrLf
52. 43 DEA 5 amp DEA 6 80 Software Flags 44 99 Table 5 1 Output Definitions Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Outputs and Flags 1 to 72 Output Flags 73 to 80 Output Flags 81 to 88 Output Flags 89 to 94 89 90 91 92 93 94 Output Flags 95 to 99 95 96 97 98 99 Warning Warning DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Programming 5 3 are cleared set to 0 volts when e DLC is first powered up or if there is loss of power e there is a system fault hardware or program are cleared set to 0 volts when e the DLC is first powered up or there is a loss of power e anE Stop error occurs or the DLC is switched to Parameter Mode are retained in RAM battery backed they can only be cleared e if they are turned ON OFF in the user program e ifthe battery is disconnected or fails are set in firmware and can be queried by the user program 1 indicates Manual Mode 1 indicates Automatic Mode currently not used currently not used currently not used 0 indicates a system fault are set within the user program to provide specific actions they are cleared when the DLC is first powered up or loses power x Monitoring Window is turned OFF 1 or ON 0 see Warning below X currently not used X currently not used 1 axis 1 motion is interrupted see Warning below X currently not used If the Monitoring Window
53. A121 00 125 0 K CONSTANT POSITION WINDOW 126 may be changed only with permission from the machine drive manufacturer Notes 1 To get to the other parameter sets either press the Store key or use the up and down arrow keys 2 increment or decrement through the parameters in each set use the or keys 3 move the cursor in the data field use the right or left arrow keys DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat 4 82 Parameters B Parameter Input Sheet Rexroth Indramat USER I O B002 5 B004 M EMORY DISPLAY B005 00000000 START TASK 2 amp 3 B006 LANGUAGE B007 M FUNCTION I O B008 0000 FREE B010 0000000 0 MANUAL VECTOR B011 0 0 DLC A and DLC G 000000 EXTE CONSTANT 022 1 To get to the other parameter sets press the Store key or use the up and down arrow keys 2 To increment or decrement through the parameters in each set use the or keys 3 To move the cursor in the data field use the right or left arrow keys DOK CONTRL DLC A DLC G AW03 A
54. Change Command 0411 VCC 12345 678 999 0000 0001 0002 0003 0004 0005 0006 VCC VCC VCC ATS WAI JST 1 Axis 1 12345 678 Path to be traversed before the velocity change to 2 or 3 decimal places depending on the setting in B007 999 Speed in 96 00 1 99 9 of the maximum velocity set in parameter A100 The VCC command is used to alter the current rate of velocity at some point along a path Multiple VCC commands can be used to create a step effect in the velocity profile Stepping to the next block takes place after the path specified in the VCC command has been traversed This function is designed to work in conjunction with the position commands POA POI and POM Note If the path specified here is longer than the previous position command the DLC will step to the next block after the axis reaches the position tolerance see Parameter A106 Example 00100 000 999 Move axis 100 inches at 99 9 max 00050 000 250 Change after 50 inches to 25 0 max 00020 000 500 Velocity Change after 20 more inches to 50 0 max 00010 000 100 Velocity Change after 10 more inches to 10 0 max 5 1 Acknowledge the axis is in position A106 01 00 Dwell for 1 second 0000 Jump and stop at program block 0000 Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 94 Programming DLC A and DLC G VEO Velocity Override Command E 0035 VEO 12 3 456 7 Rexroth
55. DLC G D Tool Correction Memory Selection Rexroth Indramat nn Number of the correction memory selected 00 19 An activated tool correction is effective for all feed commands G01 POA POI POM PSA PSI and PSM Registers 001 019 can contain values up to seven digits The eight digit is designated as the sign digit either or Register DOO deactivates Tool Correction and unselects any active register After a D 00 block in order to activate Tool Correction you must re select a Tool Correction register using the D command See Entering Tool Corrections Section at the end of Chapter 5 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 43 FAK Factor All Motions E 0210 FAK 1 1 999999 Global position correction factor all feeds 1 Axis 1 1 999999 Multiplication Factor 0 000000 to 1 999999 This programmable factor is used to multiply the feed length or position in feed commands The feed rate is not changed At the start of Automatic operating mode the factor 1 0000 until it is changed by the command FAK The factor remains in effect until a new value is read with the command FAK during program execution Example E 000 PSI 1 00010 000 200 Position Axis 1 10 0 inches at 20 feedrate E 001 WAI 01 00 Wait 1 00 seconds 002 FAK 0 500000 Multiply position by 0 5 003 PSI 00010 000 200 Position Axis 1 5 0 inches 0 5 x 10
56. Encoder When two external encoders are used simultaneously the system selection in parameters 016 and 020 must not be identical These functions are activated in parameter A123 Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 59 Parameter B021 External Encoder 2 Pulses Revolution as of software version DAO1 1 01 2 Ext E 2 Impulse B021 000 05000 Note For incremental encoder only Requires DEF card 000 Not Used 05000 Encoder line count pulses per encoder revolution 100 to 10000 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 60 Parameters DLC A and DLC G Parameter B022 External Encoder 2 Feed Constant as of software version 01 1 01 2 Note Requires DEF card Ext Enc 2 B022 050 00000 Feed constant of external encoder 2 in input units The distance per encoder revolution Entry range From 000 0 1000 to 500 0 0000 in input units Entry resolution 4 or 5 digits after the decimal point see parameter B007 Also see parameter A108 Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 61 Parameter B023 Offset Dimension External Encoder 2 Note Requires DEF card Ext Enc 2 Offset B023 00000000 00000000 Not used must be set to 00000000 This parameter is currently under development Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 62 Para
57. Measuring Wheel Encoder Position Screen When the Measuring Wheel option is selected the System Information and Actual Speed screens are expanded to include the Measuring Wheel Encoder Position Screen The Measuring Wheel Encoder Position screen displays the current measuring wheel encoder position current axis position and the difference between them L MR 00059 990 1 00059 690 Diff 00000 300 Current Measuring Wheel Position Display Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Mode Tasks Screens Controls and Indicators 2 15 Line 1 MR Measuring Wheel Encoder Position Line 2 1 Axis Position Line 3 Diff Difference Between The Measuring Wheel Encoder Position and Axis Position If the DLC is in Automatic Mode an A appears on the screen along with the status of Task 1 2 and 3 If the DLC is in Manual Mode two screens are available On the first screen appears on the screen along with the status of Task 1 2 and 3 Use the left right arrow keys to toggle between this screen and the Axis Enabled screen Each display screen is further described below Task Screens Manual Mode M Program Status Task 1 0091 BCE Task 2 1366 AEA Task 3 2901 BCE Manual Mode Task Screen This display shows the current block number and related command mnuemonic for each task Task 3 runs when the DLC is in manual or automatic mode The information keeps changing as each b
58. O signals involved and section where each signal is individually described then describing the general function of the signals Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 3 2 Functional Description of DEA 4 I O Connections DLC A and DLC G X17 C t onnector Inputs Parameter Mode Select Automatic Mode Select Emergency Stop Drive Enable Cycle Start Cycle Stop Jog Forward Jog Reverse Clear Aux Input 1 Aux Input 2 Aux Input 3 Aux Input 4 Aux Input 5 White Green Aux Input 6 aA ARS Release White Blue Aux Input 7 DG1 04VRS Green Black Grey Pink Green Red Yellow Black Green Blue Red Blue Yellow Brown Grey Brown White Red White Pink White Black Pink Brown White Yellow OO IN OO 4 Outputs System Fault Manual Mode Automatic Mode Parameter Mode Auto Cycle Running Aux Output 1 Aux Output 2 Aux Output 3 Aux Output 4 Aux Output 5 Aux Output 6 Aux Output 7 Aux Output 8 Aux Output 9 Aux Output 10 Aux Output 11 Grey Green White Grey White Violet Yellow Pink Blue Yellow Green Pink Green Yellow Pink Brown Blue 5 w 2 E 1 5 i m e lt m a Brown Green Yellow Blue Yellow Red Brown Red Brown Black
59. Parameter B005 Memory Display Note For service use only Memory Display BOOS 00 000000 This parameter is for use by the Indramat Service Department Set to 00 000000 Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 43 Parameter 006 Start Task 2 amp 3 Start Task 2 amp 3 B006 1500 2000 1500 Starting block number for second task 0001 2999 Any Block number except 0000 or a block number of another task 0000 Task 2 program disabled 2000 Starting block number for third task 0001 2999 Any block number except 0000 or a block number of another task 0000 Task 3 program disabled Task 1 always starts at block 0000 This parameter allows running separate programs at the same time As soon as the DLC is switched to Manual or Automatic mode Task 3 begins running As soon as Cycle Start is activated in Auto Mode Task 1 and 2 start running Also the system output Automatic Cycle Running Connector X17 pin 20 will turn on Note Do not access the same routine by two tasks at the same time within 1 millisecond or a system fault will occur The user program must be in place for task 3 before leaving the parameter mode because task 3 will start running immediately If the task 3 program is not in place you will see ERROR INVALID BLOCK 7 Warning Do not use task 3 for servo commands Task continues running in Manual Mode and during an E Sto
60. Schematics DLC A and DLC G C 2 RS 232 Data Interface Interconnection IBM Compatible RS 232 Data Interface IKS 046 Brown White 1 1 7 max 15m DLC 1 Plug In Card Plug In Location U1 D Sub 9pole D Sub 9pole Decade Switch Unit X31 Connector RS 232 Data Interface IKS 047 Brown White Yellow Grey 0 5 mm Pink 0 5 mm2 20 DLC 1 Plug In Card Plug In Location U1 Connector assignment z B X3 5 DKS 5 Pole Fig 9 5 RS 232 Figure C 11 RS 232 Data Interface Interconnection Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Drawings and Schematics C 13 SOT DLC RS485 Interconnection Cable Cable Cable IKB0001 IKB0001 IKB0001 Connector Housing Shield Station Station Station 32 FT D Sub 9 Pole D Sub 9 Pole D Sub 9 Pole 2 Cable 50166 customer supplied External Control Unit cable i b SOT only for DLC with plastic front plate Shield GND Rx Tx
61. Southern Sales Region INDRAMAT GmbH RidlerstraBe 75 D 80339 M nchen Phone 089 540138 30 Fax 089 540138 10 Rexroth Indramat Austria G L Rexroth Ges m b H Gesch ftsbereich INDRAMAT RandlstraBe 14 A 4061 Pasching Phone 07229 4401 36 Fax 07229 4401 80 Finland Rexroth Mecman OY Riihimiehentie 3 SF 01720 Vantaa Phone 0 848511 Fax 0 846387 Italy Rexroth S p A Divisione INDRAMAT Via G Di Vittoria 1 1 20063 Cernusco S N MI Phone 02 92365 270 Fax 02 92108069 Spain Goimendi S A Divisi n Indramat Jolastokieta Herrera Apartado 11 37 E San Sebastion 20017 Phone 043 40 01 63 Telex 361 72 Fax 043 39 93 95 Russia Tschudnenko E B Arsenia 22 153000 Ivanovo Russia Phone 093 22 39 633 Belgium Mannesmann Rexroth N V S A INDRAMAT Division Industrielaan 8 B 1740 Ternat Phone 02 5823180 Fax 02 5824310 France Rexroth Sigma S A Division INDRAMAT Parc des Barbanniers 4 Place du Village F 92632 Gennevilliers Cedex Phone 1 41475430 Fax 1 47946941 Italy Rexroth S p A Divisione INDRAMAT Via Borgomanero 11 1 10145 Torino Phone 011 7712230 Fax 011 7710190 Sweden AB Rexroth Mecman INDRAMAT Division Varuv gen 7 S 125 81 Stockholm Phone 08 727 92 00 Fax 08 64 73 277 Customer Service in Europe Eastern Sales Region INDRAMAT GmbH BeckerstraBe 31 D 09120 Chemnitz Phone 0371 3555 0 Fax 0371 3555 230 Southwester
62. The function of the line control is to convey commands and to receive information via I O connections from the DLC Digital AC Servo System The DLC requires an I O card be plugged into the U2 slot of the DKS The DEA 4 card provides 15 inputs 8 system 7 auxiliary and 16 outputs 5 system 11 auxiliary Optional cards can increase the auxiliary inputs to 37 and the auxiliary outputs to 43 In many applications the DLC DEA 4 with an Indramat Digital Controller Module can provide sufficient machine control without the use of an external line control Other information such as programs parameters and system status can be communicated two way between the DLC and a host device such as a computer programmable controller or Indramat SOT via a multi format serial communications port DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G General Description 1 3 PC or SPS DKS DLC 9 Configuration 0104 Cable IKS 745 max 30 m CTA not illuminated 10 m illuminated CTA 8 System Inputs 7 Open Inputs 5 System Outputs 11 Open Outputs Power Connection Actual Positio JL Motor Feedback Cable 5 Motor Power Cable IKE eed es Fig 1 1 DLC System Figure 1 2 Block Diagram Rexroth DOK CONTRL DCL A DLC G AW03 AE P 12 99 Indramat 1 4 General Description DLC A and DLC G 1 1 DLC Configuration Rexroth Indr
63. a 2 1 Data Entry incase acs sila ee ed ants alee 2 2 Display Screens Em 2 4 Scrolling Through Display Screens 2 4 Parameter Mode Display Screens 2 8 Drive Diagnostic DLC Status DLC Hardware Software Version Display Screens 2 8 Tool Correction Data Screen DLC G only 2 9 System Auxiliary I O Status Screens 2 10 Rexroth DOK CONTRL DLC A DLC G AWOS AE P 12 99 Indramat Il Table of Contents DLC A and DLC G Counter Soreenm dodici ode e Pda adc Ru dea Madde 2 13 Axis Information Sereen 2 14 MOde TaSkS SCreens 2 15 Edit SCTE m 2 16 3 Functional Description of DEA 4 I O Connections 3 1 31 Signal 3 1 3 2 Interface 3 1 Operating Mode 3 5 Safety INnterloCKS edu scenes 3 6 Normal Operation Signals 3 7 AXIS arerb L 3 8 unrestricted at bee tete cede
64. a Correction Memory D E 1000 D nn nn Number of the correct memory selected 00 19 An activated tool correction is effective for all feed commands G01 POA POI POM PSA PSI and PSM Registers 001 019 can contain values up to seven digits The eight digit is designated as the sign digit either or Register DOO deactivates Tool Correction and unselects any active register After a D 00 block in order to activate Tool Correction you must re select a Tool Correction register using the D nn command Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 102 Programming DLC A and DLC G Activating Tool Correction Rexroth Indramat G43 Tool Correction Activated E 1000 G43 Adds the contents of the active Tool Correction register to the programmed destination The sign of the value in the Tool Correction register is considered in this computation Example If the value in the register is 1 this command will add 1 to the programmed destination If the value is 1 this command will add 1 to the programmed destination G44 Tool Correction Subtracted E 1000 G44 Subtracts the contents of the active Tool Correction register to the programmed destination The sign of the value in the Tool Correction register is considered in this computation Example If the value in the register is 1 this command will subtract 1 to the programmed destination If the value is 1 this c
65. block line number the three letter mnemonic for the command and relative data fields This manual principally describes hardware versions DLC 1 1 and DLC 2 1 with software version DG01 1 XX X The software has parameter selected two or three decimal place precision in the commands that involve positioning and position related parameters See Parameter B007 Each command requires specific data All places for required data in a user program block which contains illegal characters a space or an undefined character not a number or the sign are replaced by the asterisk character in the display This enables the user to easily recognize which points a command data needs be programmed A program block has the correct syntax when it contains no asterisk characters in the display The following sections fully describe the use and data field entry requirements of each command DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 11 acc Acceleration Change E 0001 ACC 1 750 1 Axis 1 750 Acceleration in percentage of the acceleration rate set in parameter A102 Min 00 1 Max 99 9 One decimal place precision i e 750 75 0 The ACC command allows the acceleration rate to be changed in the user program The desired rate is programmed as a percentage of the acceleration entered in parameter A102 Stepping to the next block takes place immediately after the block is read in If you
66. block store key 2 or 3 times to store program blocks with the new decimal place settings Press the reset key to clear the error Error Message Code RTS Nesting 0C This nexting error occurs when an RTS command is encountered in the DLC program without a matching JSR command 1 Verify in the DLC program that a JSR command appears before the RST command is encountered 2 Refer to Chapter 5 for information on the use of JSR and RTS commands Error Message Code Software Combination 18 This error will occur if the drive software in the DSM module is incompatible with the DLC software Contact Indramat Service Department Error Message Code System Fault IRQOVL Interrupt 11 This error is an internal software fault in the DLC The DLC card could not process all requested data within the 1 millisecond time slice allowed Contact the Indramat Service Department Error Message Code System Fault Stack Overflow 10 This error is an internal software fault in the DLC Contact the Indramat Service Department Error Message Code TC Memory Lost When power to the DLC is turned off and the battery does not have sufficient power to retain its memory or is disconnected this error occurs when power is re applied It signifies that the tool correction register data that was stored in memory is no longer in memory This error may also
67. dependent on the value in parameter B003 A sign bit must be added Positive correction is the default Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 100 Programming Input Rexroth Indramat DLC A and DLC G The tool length correction consists of a tool correction memory with 19 selectable Tool Correction registers 001 019 DOO is effective upon entering automatic operation and is active once the program is started Inputting of correction values is possible on line through the CTA keyboard or through the serial interfaces Tool Correction register values can be entered in manual and automatic mode External Tool Correction data input is also possible through parallel inputs using the SO1 command see Chapter 5 for a complete description of the SO1 command It is possible to use the Tool Correction register for a variable memory however only one correction value can be selected and calculated per programming command Each correction value memory can accept a seven digit correction value The eighth digit is the mathematical operator The commands G43 and G44 enable the selected Tool Correction register lts value is then added or subtracted from the destination programmed according to the mathematical operator Tool correction is disabled with the command G40 or by selecting the register DOO DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 101 Selecting
68. different screens and how to interpret and change data on the screens The CTA keypad and display module Figure 2 1 attaches to connector X30 on the DLC via 04 0745 shielded ribbon cable The system input output connections via DEA 4 1 I O card are described in Chapter 3 The connections are further described in Chapter 6 for installation 2 1 Keypad and Display The CTA keypad display panel consist of a keypad with pressure sensitive membrane type keys and a liquid crystal display LCD which shows up to four lines of 16 alphanumeric characters each The number of lines and characters showing depends on the selected display mode and the current operating status of the control The display informs the operator of the operating status of the DLC system and displays all diagnostic messages It is also used when entering or editing program or parameters from the keypad The keypad contains all the keys required for data entry cursor movement clearing fault error messages entering program and parameter data etc The following sections describe the keypad and display functions The keypad and display module must be remotely mounted The standard length for the IKS745 ribbon cable is 8 feet Different lengths must be specified when ordering this cable The maximum cable length is 90 feet Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 2 2 Controls and Indicators DLC A and DLC G Liquid Crystal Display
69. if the system experiences a power loss In Parameter Mode the display shows the parameter name number and data value of the parameter selected as illustrated below Max Velocity A100 00050 000 When selecting Parameter Mode the display shows the first parameter of the A set of parameters A100 unless a fault exists as described later in this section The parameter display appears with the cursor on the first digit of the parameter data field Use the right left arrow keys to move the cursor in the field Enter or change a parameter s data by writing over any previous data stored Press the Store key to save the data change The display automatically changes to the next parameter number in the parameter set The following conditions will cause a parameter data change to revert back to the values last saved if performed BEFORE pressing the Store key 1 Pressing the CL key clear entry 2 Scrolling to another parameter 3 Exiting Parameter Mode Always maintain an accurate listing of your parameter entries for reference when troubleshooting or changing parameters for a different application To select other parameters to display first move the cursor onto the parameter number by pressing the CR key If the cursor is within the data field pressing CR once will cause it to move to the beginning of that field Press it again to move the cursor to the beginning of the parameter number The left and right arrow keys will
70. in IU input units e KV Velocity in IU minute per thousand IU of Following Error Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 11 Parameter A104 Encoder Resolution Encoder A104 00 000000 002 Encoder resolution sets maximum number of allowable motor turns 00 Default setting 465 536 motor turns 12 12 bit resolution 524 288 motor turns 13 13 bit resolution 262 144 motor turns 14 14 bit resolution 131 072 motor turns 15 15 bit resolution 65 536 motor turns 000000 Not Used set to 000000 Note This applies to single turn high resolution feedback only Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 12 Parameters DLC A and DLC G Parameter A105 Free Free A105 00000000 Parameter A105 Free is currently undefined Rexroth Indramat DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Parameters 4 13 Parameter A106 Position Tolerance Position Tol A106 01 000 010 01 Auxiliary output number to be turned on when position reached 000 010 Position tolerance to two or three decimal places Set the decimal resolution in 007 before entering this parameter i e lt XX000010 0 010 IU gt This parameter sets the axis positional band tolerance It is defining a window in which the DLC will consider the axis in position Adjusting this tolerance does not affect the accuracy of the move
71. in sequence as follows 0 OFF 0 Vdc 1 ON 24 Vdc Status 08 Current Block for all Tasks X 08 Cr Lf X 08 1100 1200 1300 1400 1500 160 5h heer Lf 1100 Task 1 Current block number 1200 Task 1 Main program block number 1300 Task 2 Current block number 1400 Task 2 Main program block number 1500 Task 3 Current block number 1600 Task 3 Main program block number The DLC returns the current block number of each task It also will return the main program block number if a given task is in a sub routine first level of the JSR stack pointer If not in a sub routine the current block number is repeated for the main program return block If a task has not been activated spaces will be returned in the appropriate locations Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 7 16 Serial Interface Request Format Response format Request Format Response Format Request Format Response Format Request Format Response Format Rexroth Indramat DLC A and DLC G Status 09 Measuring Wheel Motor Encoder Position Readings e 09 ee Lf 09 12345 678 12345 678 S hhcCr Lf X 09 Status 09 Reserved not used at present X A Axis 1 has been homed _ Axis 1 has not been homed 12345 678 First Position Axis 1 in EGE if Measuring Wheel
72. is detected Homing Routine at Start of User Program 0000 0001 0002 0003 0010 0011 BCE HOM ATS JMP NOP 005 1 21 0010 21 1 Branch if axis 1 is already homed Home axis 1 figure 2 1Wait for axis 1 Homed output Start of Program Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat A 4 Programming Notes DLC A and DLC G Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G DLC Display Screen Map B 1 B DLC Display Screen Map This page is included for illustrative purposes only Refer to chapter 2 section 2 3 for description of using this map and how to interpret the information on the screens of the DLC control panel display em HARDWARE VERSIO A DRIVE DIAGNOSTIC DLC STATUS e TOOL CORRECTION B REGISTERS amp VALUES DLC G only OUTPUT 17 32 OUTPUT 33 48 OUTPUT 49 64 OUTPUT 65 80 OUTPUT 81 96 OUTPUT 97 99 c SYSTEMINPUTS INPUTS 01 07 gt SYSTEM DL INPUTS 08 22 h 2 1 ONLY SHOWS WHEN USING DEA 5 1 I O CARD 2 ONLY SHOWS WHEN USING D COUNTERS DEA 5 1 DEA 6 1 I O CARDS POSITION MOTOR E INFORMATION SPEED NOTE IN AUTOMATIC MODE ROW E ONLY DISPLAYS NOTE d THIS SCREEN M PROGRAM STATUS MANUAL AI INIT A PROGRAM STATUS E TASK 1 XXXX AKN TASK 1 XXXX TASK 2 XXXX BCE TASK 2 XXXX BCE TASK 3 XXXX ATS TASK 3 XXXX A
73. is read and will remain in effect until it is changed The Override via measuring wheel encoder 1 pulse frequency can be activated only if the axis in parameter A123 is configured as a Normal Feed Axis The measuring encoder 1 must be configured correctly in parameters 016 through 019 Otherwise indexing to the next statement is executed The feed constant and number of lines per revolution are calculated so the maximum axis velocity is equal to the measuring wheel velocity This velocity can be adjusted by using the Follow command FOL If the axis achieves a velocity greater than 1 25 times the axis maximum velocity the error message Override A1 will be displayed The VEO command is used to override programmed velocity for all programmed commands DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 95 1 With the function Override as factor the override velocity factor is multiplied by the programmed speed of the commands 2 With the function Override as limiting the override is multiplied by the programmed speed parameter Vmax parameter A100 This multiplied value is then valid as the max speed limit Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 96 Programming WAI Wait Time Delay Rexroth Indramat DLC A and DLC G E 0420 WAI 00 50 00 50 Dwell time 00 01 99 99 seconds Examples of how a time delay is programmed 00 01 10 milliseconds the
74. is to follow Rexroth Indramat Hexadecimal 3F The DLC interprets this character received via the RxD channel as a Request for Information when followed by the proper requesting codes the DLC will transmit the desired data via the TxD channel Hexadecimal 23 This character signifies a block of Information to be Stored into memory The data that follows will be read into the proper memory location Hexadecimal 21 This character signifies a System Parameter or Control Command is to follow DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Serial Interface 7 5 Second 2 Control String Character DLC Unit Identifier This character is only present if communicating in the RS 485 mode It is used to identify the DLC unit to receive the current message If communicating in RS 232 mode this character will be a space Hex 20 Space RS 232 Mode 1 DLC 1 RS 485 Mode H DLC 17 RS 485 Mode 2 DLC 2 RS 485 Mode DLC 18 RS 485 Mode 3 DLC43 RS 485Mode J DLC 19 RS 485 Mode 4 DLC 4 RS 485 Mode K DLC 20 RS 485 Mode 5 DLC45 RS 485 Mode L DLC 21 RS 485 Mode 6 DLC46 RS 485 Mode M DLC 22 RS 485 Mode 7 DLC 7 RS 485 Mode N DLC 23 RS 485 Mode 8 DLC 8 RS 485 Mode O DLC 24 RS 485 Mode 9 DLC 9 RS 485 Mode P DLC 25 RS 485 Mode A DLC 10 RS 485 Mode Q DLC 26 RS 485 Mode B DLC 11 RS 485 Mode R DLC 27 RS
75. is turned OFF the DLC will have no way of detecting if a motor has Drive Runaway or Excessive Position Lag If motion is interrupted by setting flags 98 ON it will resume automatically when the output is turned OFF Rexroth Indramat 5 4 Programming 5 3 Multi Tasking DLC A and DLC G The DLC is capable of operating one motion program and two background PLC programs simultaneously when multiple tasks are programmed see next section This allows a single DLC to operate one motion program and two background processes at the same time or utilize multi tasking in a single process 5 4 Start of the Program When the DLC is first powered up or an error is cleared the program block pointer is set to block 0000 for Task 1 If Tasks 2 and 3 are used they will start at their assigned starting point as user defined in parameter All programs must start at their assigned starting points Task 1 must start at block 0000 Blocks of numbers of programming will be followed sequentially unless a jump or branch instruction is encountered If block 2999 is executed and it is not a jump command all motions are stopped and an error code is displayed Typically the last command block you enter will be a jump command to return to the start of the next cycle or to return from a sub program routine 5 5 End of the Program Take extreme care to control the flow of the program This is especially important when using multi tasking Most
76. last selected Tool Correction register prior to the G40 command will be used as the selected value DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 49 G43 Tool Correction Added E 1000 G43 Adds the contents of the active Tool Correction register to the programmed destination The sign of the value in the Tool Correction register is considered in this computation Example If the value in the register is 1 this command will add 1 to the programmed destination If the value is 1 this command will add 1 to the programmed destination Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 50 Programming DLC A and DLC G G44 Tool Correction Subtracted Rexroth Indramat E 1000 G44 Subtracts the contents of the active Tool Correction register to the programmed destination The sign of the value in the Tool Correction register is considered in this computation Example If the value in the register is 1 this command will subtract 1 to the programmed destination If the value is 1 this command will subtract 1 to the programmed destination which means it will add 1 to the programmed destination DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 51 G60 Exact Stop E 1000 G60 If this command is invoked prior to 201 command all subsequent G01 commands are processed with exact stop i e with Lag finishing This means the execution
77. list each entry Note Should the displayed message appear in a language other than the language desired by the user enter the B Parameter Set and scroll to 007 Change the display to the desired language as explained for parameter B007 in this chapter field entry of 01xxxxxx will cause a display in English The DLC checks the parameter values each time it is powered ON as well as each time parameters are read in If there are parameters that are incorrect or missing an appropriate error message will be displayed Upon exit from the Parameter Mode if any parameters have been changed internal buffers that are dependent on parameter values will be re calculated During that time the display will show the message Please Wait If you have entered a value higher or lower than the limits of the parameter the display will show the error message Is INVALID The invalid parameter description and number will display Is INVALID Parameter A100 Max Velocity By switching back to Parameter Mode the invalid parameter will be displayed Enter correct values for the parameter within limits This manual describes a DLC software version that has programmable decimal positions This version has two or three decimal places in the commands that involve positioning Specific decimal places allowed for parameters and commands are listed in their specific description in Chapters 4 and 5 The number of decimal digits can be up to 5 depe
78. minimum dwell time programmable 00 50 0 5 seconds The DLC waits in the program block until the specified time has elapsed After the time delay the program steps to the next block See the NOP command for related function when require less than 10 milliseconds dwell time DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 97 WRI Write in Absolute Position Teach Command E 0042 WRI 1234 001 1234 Target block number 0000 2999 00 Command type 00 POA command 01 PSA command 1 Axis 1 Use this command to write in teach an absolute positioning command in the user program Note that an absolute positioning command requires that the axis must be homed Otherwise an Axis 1 Not Homed error occurs The entered target block number specifies where to install the absolute positioning feed command s The next entry digits specify which absolute position command is to be programmed in the target block POA Absolute positioning command stepping to the next block occurs immediately after it is read in PSA Absolute position command stepping to the next block occurs after positioning is completed This command is used to teach or update a position into a functional program The axis is typically jogged into a desired position then a predefined teach routine is run that will teach this position into all the appropriate blocks The teach routine can be written as a manual vector or as p
79. occur if the firmware is removed or if different DLC firmware is installed 1 If this error occurs every time the DLC is powered up replace the backup battery 2 Verify that every DLC tool correction register has valid data in it The DLC tool correction registers might contain asterisks indicating invalid data has been entered Refer to Chapter 5 for information on how to enter the DLC tool correction values Error Message Code WRITE Command OF The WRI command tried to write into a target block which did not contain a POA or PSA command Check the DLC program and refer to Chapter 5 to determine if the WRI command is used properly DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Diagnostics And Troubleshooting 8 9 8 3 Serial Communication Errors Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Serial communications errors are not displayed on the CTA display but the serial communication error code and error message will be transmitted from the CLM to a host device SOT computer etc The correct format must be used when information is transmitted to the DLC from a host device If the format is not correct the DLC will transmit an error
80. of the IDS board The IDS board is enabled in parameter B003 Serial Interface 1 The cable between the IDS board and the DLC connector X31 is not installed properly 2 The DLC serial communication port is defective 3 The IDS board is defective Error Message Code IDS Format Error 14 This error will occur if the optional IDS board is enabled but the DLC does not detect the connection of the IDS board The IDS board is enabled in parameter B003 Serial Interface DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat 8 6 Diagnostics And Troubleshooting Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Rexroth Indramat DLC A and DLC G 1 The cable between the IDS board and the DLC connector X31 is not installed properly 2 f the IDS board is connected then the wiring and its layout to the decade switch should be checked Maximum cable length is 15m Error Message Code Invalid Block The program contains a combination of offset jump distance and BCB BCD commands that causes the DLC program to jump to a program block greater that 2999 If Task 3 is being used enter the program for Task 3 in the appropriate program block location before enabling Task 3 in parameter B006 You must do it this w
81. only the task display is available on this row An A appears on the screen Automatic Mode along with the status of Task 1 2 and 3 A Progr Status Task 1 0091 BCE Task 2 0366 VCC Task 3 0901 BCE Automatic Mode Task Screen Row G Refer to the Display Map in Figure 2 2 From any screen in Row F press the down arrow key to display the Program Edit screen in Row G Notice the E in the upper left corner of the screen easily identifies it as the Edit display screen Edit Screen Note From Row G press the down arrow key to wrap to a display screen in Row A From Row A press the up arrow key to display the Edit screen in Row G Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 2 8 Controls and Indicators DLC A and DLC G Parameter Mode Display Screens When the DLC is in Parameter Mode data for each parameter can be viewed entered or edited The top line of the display indicates the title of the parameter number The following display shows Parameter A100 Maximum Velocity for Axis 1 Max Velocity A100 00050 000 A100 indicates parameter number 00050 000 indicates data for parameter When Parameter Mode is selected the parameter display appears with a flashing cursor on the third digit of the parameter number Use the right left arrow keys to move the cursor in the field Type over existing data to change and press the Store key to save the change Appendix D provides blank p
82. parameter 01 99 increments 1 00386 0 Second acceleration Input Units second units second second to zero or one decimal place above the knee point velocity Set the decimal resolution in B007 before entering this parameter The first acceleration below the knee point velocity is programmed in parameter A102 This function is effective in Automatic operation as well as in Manual operation for instance jogging The only limitation for the user programming is that the command ACC change of acceleration is not effective as long as this parameter is switched ON can use one or other CAUTION Since the second acceleration may be greater than the first acceleration the greater of the two values is to be considered the maximum acceleration Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 25 Parameter A118 Brake Release as of software version DA1 04VRS and DG1 03T03A Brake Release A118 xx yy 0000 To be functional this parameter must be enabled in Parameter C013 XX Input Brake release 00 External brake release function disabled yy Output Brake released 00 No output programmed The output is functional only if the input Brake release is also programmed Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 26 Parameters DLC A and DLC G Parameter A119 Free Free 119 00000000 Parameter A119 Free is cur
83. plugs into either the U3 or U4 slot The DEF 1 card can be used as either a master encoder input or measuring wheel input DLC Control Card DEF 1 Incremental Encoder Interface Card Optional DEA 4 Input Output Card Figure 1 8 Standard Configuration of DKS with DLC Control Card DEA 4 I O Card and Optional DEF 1 Incremental Encoder Interface Card Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 1 14 General Description 1 5 Specifications DLC A and DLC G The following sections provide full specifications for the DLC Control and options Note Performance specifications can vary depending on the mechanical limitations of the equipment Physical Specifications Operating Environment Cooling Allowable Ambient Temperature Range Storage and Transport Temperature Range Maximum Operating Altitude at Rated Values Control Specifications Position Feedback Measuring Wheel Feedback Feed Length Resolution Feed Rate Jogging Programmable Dwell Time Programmable Counters CTA Key
84. programs are designed so they will loop back to the start of each task and wait for the proper sequence of events before starting again Make sure that each task will not interfere with another task 5 6 Programming Mode Rexroth Indramat The DLC must be in either Automatic or Manual mode to accept program entry edit from the front panel It is recommended that the DLC be placed in manual mode when editing the program especially when this involves changing a command or several blocks Warning Program entry in Automatic Mode while the unit is in operation will be accepted as soon as the Store key is pressed The next time the block is scanned in the program the updated data will be executed It is recommended that the DLC be placed in Manual Mode when editing the program Complete and verify the program changes before returning to Automatic Mode Have accurate listings of the program and parameters when editing to reduce the possibility of errors DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 5 5 7 General Format The general format shown on the CTA display during program entry edit is as follows E _0000 ABC DATA E shows the display is in the program edit mode 0000 block number displayed command or data can be viewed or edited You can select any block number 0000 2999 to display To scroll through the block numbers first press the CR key to locate the cursor in the to
85. report Illegal Command is generated when this command is called e The default delay time for indexing to the next statement is 1 millisecond Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 35 CLC Clear Counter E 0037 CLC 0123 0123 Counter block number 0000 2999 Use this command to clear set to zero the actual value of the counter at the indicated block number If the indicated block does not contain the count command COU or BAC this block is only scanned The default delay time for indexing to the next statement is 1 millisecond Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 36 Programming DLC A and DLC G coc Cam Output Control E 0020 COC 1 05 110022 090 1 Axis 1 05 Number of the first of six aux outputs to be set 110022 Status of the 6 aux outputs starting with the first resets output to Off 1 sets output to On 2 output remains unchanged 090 Test position of axis in Input Units to zero or one decimal place can be or If BOO7 is set for 2 decimal places 007 xx02xxxx the test position has no decimals i e 360 360 If B007 is set for decimal places 007 xx03xxxx the test position has one decimal i e 360 36 0 The COC command sets a bank of six aux outputs relative to the axis position in degrees The DLC waits for the programmed axis to reach the test position before setting th
86. results 00 Transmission Delay For RS485 Communication In Milliseconds 00 No Delay 02 2 msec use for CTA10 or SOT This parameter allows the integration of the calculation of the check sum into the interface The DLC will perform a bit count comparison from one operation processing If a 0 is not programmed in the first bit a check sum is not required for communication i e instead of Checksum CR LF CR LF is sufficient If it is important that the data sent to the DLC is received correctly it is recommended that the checksum be turned ON The host device must be programmed to calculate and send the checksum with each transmission to use this option Transmission Acknowledgment when active returns a Y CR LF from the DLC to the Host Device This occurs after any command transmitted to the DLC that does not require any other response from the DLC The Transmission Delay For RS485 Mode in milliseconds is used to define a time delay for switching between the transmit and receive mode In RS485 mode when the last character is received it switches immediately to transmit mode This immediate switching can cause problems with some PC RS485 driver cards if they are not fast enough to switch to receive mode The transmission delay allows the PC drivers to switch from transmit to receive mode without communication errors Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 42 Parameters DLC A and DLC G
87. same feed program cannot be used for the cutting process because the possibility that the perforation will drift to the edge cannot be excluded Because of this reason cutting is done depending on the reference hole The reference hole can be detected by means of a light barrier initiator or similar device Notes e Cannot be used simultaneously with a REF command e Will be ignored in the case of re start e The RMI works correctly only with feeds and offset feeds in positive direction e g PSI 1 e n Task 2 RMI program there should be no other feed except for the offset e After the RMI command RMI 0 XX has been called up masking hole is no longer possible e Recognition of an additional registration mark prior to the command RMI 1 XX is not possible The velocity that can be changed by means of the offset feed is returned to its old value when the program resumes The interruption feed monitoring and override functions may be used DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Sample program Task1 Stamp1 Stamp2 Task2 Tool DOK CONTRL DLC A DLC G AWO3 AE P 12 99 PSI 1 000050 00 999 JSR stamp1 PSI 1 000025 00 999 JSR stamp2 JMP task1 AEA 01 1 WAI 00 20 AEA 01 00 RTS AEA 02 1 WAI 00 20 AEA 02 0 RTS RMI 0 01 PSI 1 000015 50 500 JSR tool RMI 1 01 JMP task2 AEA 03 1 WAI 00 25 AEA 03 0 WAI 00 20 RTS Programming 5 81 stamping with s
88. shows how it would be calculated After all characters are added together the High byte is added to the Low byte then the compliment of the two is taken This number should immediately follow the character Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Serial Interface 7 7 Fig 7 5 CHECKSUM Example Calculation 7 6 Sending Information to the DLC The DLC is capable of receiving new program block and parameter data from a host device using the set of protocols described in the following sections They use the key characters defined in sections 7 3 to 7 5 and a set data field to transfer the required information To get an acceptable transmission it is very important that all characters including all spaces are used in the exact described format when sending to the DLC If there is any type of discrepancy the DLC will respond with an error message describing the type of format error that was found and the current data will not be changed Sending Program Blocks to the DLC A program block sent to the DLC must follow this format Nbbbb ccc dddddddddddddddd ShhCRLF The following describes each part of the command string N Send program block to DLC bbbb Block Number 0000 2999 ccc Command Mnemonic dd gt dd Data 16 characters in the proper format for a given command End of block check sum may follow hh Check sum if enabled in paramete
89. software flag is turned ON or OFF as the user program executes the block containing the command Chapter 3 describes the functional use of each system input output as well as many programming and parameter entries specifying input or output connections Several I O are available for use as flags in the user program Certain output flags are set in firmware and can be queried by the user program Table 5 1 list the hardware outputs that can be used in the program to electrically signal an external component It also lists the output software flags that can be used internally in the program It defines the output flags which are set in firmware Refer to this table when programming an output Inputs Outputs Signal Definition There are two states that system inputs outputs auxiliary inputs outputs could hold The ON or High state means that there is a 24 Vdc signal present at the input output The OFF or Low state means that there is a O Vdc signal at the input output A signal line is described as Active High when its associated action is initiated by a High 24 volts signal level It is described as Active Low when its function is initiated by a Low signal 0 volts An active low signal must remain in the high state to allow normal operation Refer to Chapter for further description of I O signals DLC with DEA 4 Hardware Outputs 1 11 DLC with DEA 4 amp DEA 5 Hardware Outputs 12 27 DLC with DEA 4 Hardware Outputs 28
90. that line for the input number top line input of fos Acknowledgement 96 Table 4 2 Input assignments Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 52 Parameters DLC A and DLC G Parameter B014 Restart Vector as of software version DA1 1 03 03 DG01 1 03 03 Re Start Vector B014 0210 2700 02 Input Begin restart 00 Restart function not enabled 00 Output Restart possible 00 No output 2700 Starting block for the Restart Vector program 0001 2999 0000 No restart program set Status will be reestablished immediately lt gt 0000 Starting block for the Restart Vector program Complete status reestablished at end of restart program Note Use this parameter only if the system is equipped with a multi turn feedback This parameter is used to define the starting block for the Restart Vector routine If a program is interrupted by a power loss system error or mode change the status of outputs absolute target position and velocity are temporarily stored in memory Based on the type of error and system configuration it may be possible to restore the status of the DLC as before the interrupt Note The temporarily stored absolute target position will only be resume if the axis is equipped with an absolute encoder Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 53 Parameter B015 Cycle Time as of soft
91. the condition is not met at the programmed input stepping to the next block takes place One use of this command is to allow selecting different routine programs to run for making different parts by turning ON a different switch on the control panel In the following example the main program runs then branches and executes the routine program indicated by the first input that is high ON The last block of the routine can jump back to the first block of the main program for continuous operation It can jump back to the beginning of the main program block 0000 and branch to the respective block for the input that is high Example 0000 NOP 0001 BCE 0600 01 1 Branch to block 0600 if input 01 is high 0002 BCE 0700 02 1 Branch to block 0700 if input 02 is high 0003 BCE 0800 03 1 Branch to block 0800 if input 03 is high 0004 BCE 0900 04 1 Branch to block 0900 if input 04 is high 0005 JMP 0000 Jump to beginning of cycle at block 0000 scan inputs 1 4 again Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 25 Branch Conditional On Binary Inputs E 0801 BIC 0300 20 15 3 0 0300 20 15 Block Offset 0000 2999 Length Of Jump Starting Auxiliary Input Number 01 37 Number of Consecutive Auxiliary Inputs Required 1 8 Mode 0 Binary Mode 1 9 Future Options The BIC command executes a jump which has been defined by the binary state of the selected
92. the machine such as maximum and minimum feed lengths jog acceleration and deceleration rates units of feed measurement RS 232 485 serial communication characteristics etc This allows one single type of DLC control to handle the mechanics of various types of different machines Thus plant personnel need be familiar with only one control system Generally parameters are entered once when setting up the system then changed only if the configuration changes or if different types of operations are required The factory installed DLC executive program interprets the parameters to match the DLC Digital AC Servo System to the machine and translates operator entered commands into motion control signals coordinating the feed motion with the parts of the other machinery Complicated system programming is not required Fully Self Diagnostic System protection is paramount The DLC detects normal operating status operator errors errors in the control itself and machine faults Both fault and normal status messages can displayed on the DLC s optional CTA interface in the user selected language Thus the operator is informed of the current operating status of the system and is alerted to any condition that causes a fault This helps the operator quickly locate and correct problems The DLC processor models and predicts the motion profile and continuously compares it with the actual response of the servo controller thereby detecting irregul
93. via outputs 09 to 16 3 Fault code via outputs 17 to 24 4 Fault code via outputs 25 to 32 5 Fault code via outputs 33 to 40 6 Fault code via outputs 41 to 48 If the function is enabled an appropriate fault code is outputted via the programmed output when there is a fault The fault code consists of 2 hex digits Fault code assignment 00 to General disturbance 40to6F Disturbance axis 1 For a complete list of fault codes and explanations see chapter 8 Diagnostics and Troubleshooting Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 45 45 Lock out feature 00 Allows program entry storage from the CTA keypad 45 Inhibits storage in memory of program blocks which are entered via the CTA keypad 55 Command data but not commands can be altered as of software version DA1 04VRS Note Programming can still be accomplished via the RS232 485 serial interface such as by downloading from MotionManager program development tool The lock out feature prevents accidental or unauthorized changes via the CTA keypad Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 4 46 Parameters DLC A and DLC G Parameter 008 Function Inputs and Outputs DLC G only Rexroth Indramat M Function I O B008 0000aaee 0000 Not used set to 0000 aa First M function output ascending ee First acknowledgment input ascending
94. when program space is limited Refer to section 5 8 Command Summary for alternatives Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 58 Programming DLC A and DLC G JSR Jump to Subroutine Rexroth Indramat E 0250 JSR 1567 1567 Start block of the subroutine Subroutines can be called up at any time The maximum permissible number of nested subroutines is 127 A subroutine must end with the command RTS program jumps back to the block following the JSR command If an RTS command is not programmed at the end of a subroutine the programmed lines following the end of the subroutine will be executed This can result in unexpected axis movement Invalid Program Command diagnostic etc Note Additional program flow control is possible by using the Change Subroutine Stack command CST with the JSR RTS commands for advanced programming DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 59 JST Jump and Stop E 2600 JST 1678 1678 Target Block Number This command causes the program to jump directly to the target block and stop in that block The DLC will issue a software Cycle Stop and stop the program waiting in the target block for a new start impulse at system input Cycle Start The start impulse will cause the DLC to continue processing the program beginning with the target block A JST command executed in Task 1 will cause the program running in Task 2 to ha
95. zero and sets the Homed Flag high This completes the homing process for a given axis 0000 0800 0801 0802 0803 0804 0805 0806 0807 0808 BCA BCE CON AKN PBK NOP REF ATS CLA JMP 0800 0805 1 0 23 0000 21 L 0 Branch if axis 1 has not been homed 050 050 00 01 Branch if axis 1 is not on the home switch Sets axis 1 in direction at 5 max velocity Waits for axis 1 home switch to open Stops axis 1 motion Sets axis 1 in REV direction at 5 max velocity waits for home switch to close then ramps to a stop and reverses to the point the switch first closed Waits for axis 1 to be in position Initializes axis 1 position buffer to zero Homing to the Marker Pulse When the DLC Servo System is first powered up it knows where the motor pulse is located The DLC can tell the axis to home to the marker pulse This is very useful for single revolution applications where the rotating mechanisms are directly attached to the motor shaft rotary knife print drum This type of operation is enabled when the home switch input is set to 00 in parameter A112 The homing routine can be activated by an input in manual mode or through a short series of commands in automatic mode This home sequence in either mode starts with the axis performing the following steps 1 The axis moves in the desired direction CW CCW at the velocity set in parameter A110 until the marker pulse
96. 0 Positive 1 Negative The PSM command is an incremental or absolute positioning command with position acknowledgment The programmed position distance and velocity are stored in a single memory location by an Indramat IDS decade switch option Note that the axis can be controlled by the PSM command but given a single memory location only one value can be stored at one time Stepping to the next block takes place after positioning is complete The In Position aux output is programmed in Parameter A106 Position Tolerance When using the IDS decade switch option enable this option in Parameter 003 If the decade switch option is not enabled this block is scanned and no positioning takes place Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 75 PST Position Test E 340 PST 1 05 12345 678 1 Axis 1 05 Auxiliary output number 12345 678 Test position value to 2 or 3 decimal places depending on setting in B007 This command is used to check for a position and control an output based on current position status At the execution of this block the designated auxiliary output is turned ON if the actual position of the axis is less than the test position value If the actual position is equal to or greater than the test position value the auxiliary output is turned OFF Stepping to the next block takes place immediately after the block has been read in Please note tha
97. 0 XX 0 20 XX 0 0 Jump to program block 0900 and start a new read the Toggle input 1 to output the next digit Return from subroutine Rexroth Indramat 5 92 Programming vca Velocity Change Absolute E 0410 VCA 12345 678 999 Rexroth Indramat 0000 0001 0002 0003 0004 0005 0006 POA VCA VCA VCA ATS WAI JST 1 Axis 1 DLC A and DLC G 12345 678 Absolute position to be reached before the velocity change to 2 or 3 decimal places depending on the setting in B007 999 Speed in 00 1 99 9 of the maximum velocity set in parameter A100 The VCA command is used to alter the current rate of velocity at some point along a path Multiple VCA commands can be used to create a step effect in the velocity profile Stepping to the next block takes place when the absolute position has been reached This function is designed to work in conjunction with the position commands POA POI and POM Example 1 00100 000 1 00050 000 1 00075 000 1 00090 000 15 1 01 00 0000 999 250 500 100 Position axis to 100 inches at 99 9 max Velocity change at 50 inches to 25 0 max Velocity change at 75 inches to 50 0 max Velocity change at 90 inches to 10 0 max Acknowledge axis is in position A106 Dwell for 1 second Jump and stop at program block 0000 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 93 Velocity
98. 0 to prevent the program from executing any position commands The DLC will process all program blocks not containing any position commands If there is no signal at the assigned input the program continues to execute until it processes to a block containing a position command The DLC will stop in this block until there is a signal at the input If the input signal turns OFF during a feed the feed will be stopped and an error message will be displayed An auxiliary input Feed Interrupt Feed Hold can be assigned in parameter A120 to prevent the program from executing any position commands The DLC will process all program blocks not containing any feed lengths If the input is low the program continues to execute until it processes to a block containing a feed length The DLC will stop in this block until the assigned input goes high If the input goes low during positioning the positioning will be stopped Positioning will automatically resume as soon as the signal goes high An example of use for this signal is in conjunction with a material loop Material is fed from an uncoiler into a looping pit with an optical sensor in the pit tied to the Feed Interrupt line If the material pulls too tight the signal goes low and the cycle is interrupted As soon as an adequate amount of material is fed into the looping pit the signal returns high and the cycle immediately resumes See Chapter 4 for further information on this parameter function
99. 00 500 0000 Jumps to block 0053 axis 1 absolute positioning to 48 125 in at max feed rate Jump to block 100 if output 20 is ON ON in this example Jump to block 200 if aux output 20 is OFF Program execution could progress to here if output 20 turns ON after block 0054 executes scan output 20 again axis 1 absolute position to 45 25 in at 75 596 max feed rate Jump to beginning of cycle at block 0053 and stop axis 1 absolute position to 0 0 IU at 5096 velocity Jump to beginning of cycle and stop Rexroth Indramat 5 22 Programming DLC A and DLC G BCB Binary Conditional Branch Inputs E 0800 BCB 1000 121 Aux Input Binary Significance Decimal Significance Aux Input Binary Significance Decimal Significance Aux Input Binary Significance Decimal Significance Rexroth Indramat 1000 Block Offset 0000 2999 12 Length of jump 1 Auxiliary input bank selection can be 1 2 or 3 This determines the location of the Binary inputs The BCB command executes a jump which has been defined by means of the Binary Inputs at the aux inputs 1 to 8 relative to input bank selection The target block is calculated as follows Target Block Offset Binary Input Value x Length of Jump The Binary Input Value should be converted to a decimal value to calculate the target block The Binary input location can be selected from the following Input Bank S
100. 0000 used to detect if either axis has been previously homed If not the homing routines at blocks 0800 will be executed as required The homing program starts by branching to the CON command which causes the program to wait until the home switch input is activated The PBK command causes the axis to ramp to a stop at the current acceleration rate The distance traveled past the switch is a function of both the selected velocity and the acceleration rate The ATS command waits for the axis to be fully stopped in position before the CLA command is executed The CLA command sets the axis position buffer to zero and sets the Homed flag high This completes the homing process 0000 BCA 0800 21 Branch if axis 1 has not been homed 0001 Start of Program 0800 CON 1 1 050 00 Sets axis 1 in direction at 5 max velocity 0801 AKN 1 2 Waits for axis 1 home switch to close 0802 PBK 1 Stops axis 1 motion CON off could also be used 0803 ATS 23 1 Waits for axis 1 to be in position 0804 CLA 1 Initializes axis 1 position buffer to zero 0805 JMP 0000 Example 2 Illustrates the use of the REF command which causes the axis to back up to the point where the home switch was first closed before setting the position buffer to zero Otherwise it will function similar to example 1 0800 REF 1 1 050 01 Sets axis 1 in REV direction at 5 max velocity waits for home switch to close then ramps to stop and reverses to the point the swi
101. 01 00001 000 Min 00000010 IU Max 05000000 IU This parameter specifies the maximum velocity that the axis can be jogged in manual mode It is specified in input units second to two or three decimal places Set the decimal resolution in B007 before entering this parameter You specify this velocity in the same manner as in A100 but define the velocity to be used for jogging rather than the maximum velocity Hint Start at 1096 of A100 entry then increase or decrease as required for the application Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 9 Parameter A102 Acceleration Rate Accel Rate 102 0000386 0 The axis accelerates and decelerates at the rate specified by this parameter This parameter provides a protection for the machinery as it can limit the amount of torque produced during speed changes The amplifier drive system must be capable of acceleration at the rate specified here If not an overshoot or an error message may occur during a speed change 2 The parameter value is specified in input units second units second second in whole units 0 decimal places or to one decimal place Set the decimal resolution in 007 before entering this parameter For example To program the machine in the force of 1G assuming your Input Units are programmed in inches 2 1G 32 16 feet second Convert to inches input units inches used in this example
102. 03 This error occurs when the Emergency Stop input to the DLC DEA 4 X17 pin 3 goes low or is lost 1 The machine E Stop button has been pushed 2 The Emergency Stop circuit has been interrupted Consult the machine wiring diagrams to determine the cause 3 The 04 0123 I O cable is not connected to the DEA 4 card 4 24 Vdc must be applied to DEA 4 X17 pins 36 amp 37 Also the reference 0 Vdc must be applied to the DEA 4 X17 pins 34 amp 35 Error Message Code Encoder Fault 4C This error will occur when the percentage of deviation between the external encoder position and the axis position is exceeded The percentage of deviation is defined in parameter A123 1 The External encoder Lines Rev and Feed Constant parameters B017 amp B018 are incorrect Verify that the external encoder parameters are correct B016 through B018 2 Verify that the axis Feed Constant A108 is correct 3 The percentage defined in the Follow Axis parameter A123 is too small 4 Verify that the External encoder direction parameter B016 is correct 5 Slippage between the external encoder and the material or coupling Try a lower acceleration to reduce the slippage 6 The external encoder is wired incorrectly Error Message Code Excess Pos Lag 1 43 The DLC uses a mathematical model to calculate the normal following error expected This diagnostic will occur when the actual follo
103. 0360 0 0000360 0 Degrees 10V 0000000 1 1474560 0 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 66 Parameters DLC A and DLC G Parameter C004 Velocity Data Scaling at Analog Outputs AK1 and AK2 as of software version DAO1 1 01 6 Velocity Data Scaling A Output C004 00002000 000 Not used must be set to 000 02000 Degrees 10V 00002 65000 Rexroth Indramat DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Parameters 4 67 Parameter C005 Velocity Loop Monitoring as of software version DAO1 1 01 6 Velocity Loop Monitoring C005 00000001 0000000 Not used must be set to 0000000 1 Monitoring Circuit for Velocity Loop 0 OFF 12 ON Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 4 68 Parameters DLC A and DLC G Parameter C006 Position Velocity Window as of software version DAO1 1 01 6 Position Velocity window C006 0005 0000 0005 0000 RPM 0000 0000 0005 0000 Parameter C006 is only effective in conjunction with a multiturn encoder When using a single turn encoder C006 is overwritten with 0 after the drive is powered up again Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 69 Parameter C007 Absolute Encoder Reference Position as of software version DAO1 1 01 6 Absolute Encoder Ref Position C007 0000 0000 0000 0000 Degrees 0000 0000 0359 9000
104. 09 Direction of 4 16 Parameter A110 Homing 4 17 Parameter A111 Homing Offset eene nnne nennen 4 18 Parameter A112 Homing Acknowledgements 4 19 Parameter A113 Travel Limit Minimum Value eeesesssseseeeeeennnennenennnnn nennen nns 4 20 Parameter A114 Travel Limit Maximum Value eeesssssseseeeeennnnnnnnnnnnn nennen nnnm 4 21 Parameter A115 Special Functions Disable Following Error Velocity Achieved Master Encoder Averaging Velocity Feed Forward 4 22 Parameter A116 Rotary Axis Gear 4 23 Parameter A117 Second Acceleration 4 24 Parameter A118 Brake Release as of software version DA1 04VRS and DG1 03T03A 4 25 Parameter A119 Eree de near seats eta coa RE eR Rea n 4 26 Parameter A120 Feed Angle Monitoring Feed 4 27 Parameter A121 Maximum Motor 8 4 28 Parameter A122 Monitor 4 29 Parameter A123 Follow Axis Measuring Wheel Mode Requires DEF 4 31 Parameter 124 4 33 Parameter 125 Jerk Constant as of software version DA1 04VRS
105. 1 2000 Target block for the stored position difference 1000 Compare position block number 1 0 2 Actual position minus the compared position 12 Compared position minus the actual position The Compared Position is the difference between the Actual Absolute Position and an Absolute Position at a specific program block i e block 1000 as shown above The KDI command will copy the position difference between the actual absolute position and the absolute position at a specific block number Compare position block number The position difference is then stored in the target block The amount of time to process the KDI command can be up to 100 ms The program will advance to the next block after the position difference is stored in the target block The actual position is either subtracted from the compared position or the compared position is subtracted from the actual position In order for the KDI command to function properly the following conditions must be met 1 Axis 1 must be homed If the axis is not homed when the KDI command is encountered in the program then the error message Axis 1 Not is displayed 2 The compare position block number must contain an absolute position command POA PSA If the program block is not an absolute position command then the error message Invalid Prog will occur 3 The target block must contain an incremental position command POI PSI If the target block is
106. 1 9 9 in 0 1 increments 00 2 output as a constant signal which stays on until next feed or a command AEA output ON OFF 123 4 Pre signal distance in Input Units zero or one decimal place to the target position Set the decimal resolution in B007 before entering this parameter The Pre Signal feature is used to turn ON an aux output at a specified distance prior to the completion of a feed command Typically the Pre Signal is used when anticipation of the end of a feed is needed so other processes can be initiated ahead of time The Pre signal applies to each feed command POI PSI POA POM PSA PSM After the initiation of the motion if the Current Distance to travel is less than the Pre signal Distance programmed in this parameter the Pre Signal output is switched ON The Pre Signal output will be ON for either the programmed period of time or until the next move dependent on the parameter settings Pre Signal Distance Pre Signal Off Begin Motion Pre Signal ON Target Position For Programmed Time If the Target Position is equal to or less than the Pre Signal distance the Pre Signal output is switched ON at the start of the feed motion for the specified amount of time Begin Motion Target Position Pre Signal ON For Programmed Time Rexroth Indramat DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 DLC A and DLC G Parameters 4 15 Parameter A108 Feed Constant Feed Constant A108
107. 16 12 8 4 23 95 91 87 83 79 75 71 67 63 59 55 51 47 43 39 35 31 27 23 19 15 11 7 3 2 94 90 86 82 78 74 70 66 62 58 54 50 46 42 38 34 30 26 22 18 14 10 6 2 21 93 89 85 81 77 73 69 65 61 57 53 49 45 41 37 33 29 25 21 17 13 951 20 Status 53 System Fault Request Format X 5 3 a Gr Lt Response Format X ogd mnmn 4 A amp 1 5 Cr Lf nn error code hexadecimal t Fault message text Fault message texts and error codes are listed in detail in chapter 8 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 7 20 Serial Interface DLC A and DLC G Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Diagnostics And Troubleshooting 8 1 8 Diagnostics And Troubleshooting 8 1 Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution DOK CONTRL DLC A DLC G AWO3 AE P 12 99 This chapter is divided into three sections The first section 8 1 describes the normal operating diagnostics of the digital drive If an error is displayed which is not described in Section 8 1 consult the Indramat Digital AC Servo Drive Manual for more information Section 8 2 describes the system error codes and messages for the DLC Control Card and suggests possible solutions to the error conditions
108. 250 Diadema SP Caixa Postal 377 BR 09 901 970 Diadema SP Phone 011 745 90 65 011 745 90 70 Fax 011 745 90 50 China Rexroth China Ltd 1430 China World Trade Centre 1 Jianguomenwai Avenue Beijing 100004 P R China Phone 010 50 50 380 Fax 010 50 50 379 Japan Rexroth Co Ltd INDRAMAT Division Building Nakamachidai 4 26 44 Tsuzuki ku Yokohama 226 Japan Phone 045 942 72 10 Fax 045 942 03 41 Customer Service in Asia Australia and the Far East Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat Customer Service Locations Europe Austria G L Rexroth Ges m b H Gesch ftsbereich INDRAMAT H gelingasse 3 A 1140 Wien Phone 1 9852540 400 Fax 1 9852540 93 England Mannesmann Rexroth Ltd INDRAMAT Division 4 Esland Place Love Lane Cirencester Glos GL7 1YG Phone 01285 658671 Fax 01285 654991 France Rexroth Sigma S A Division INDRAMAT 270 Avenue de lardenne F 31100 Toulouse Phone 61499519 Fax 61310041 Spain Rexroth S A Centro Industrial Santiago Obradors s n E 08130 Santa Perpetua de Mogoda Barcelona Phone 03 718 68 51 Telex 591 81 03 718 98 62 Switzerland Rexroth AG Geesch ftsbereich INDRAMAT GewerbestraBe 3 CH 8500 Frauenfeld Phone 052 720 21 00 Fax 052 720 21 11 Germany Central Sales Region INDRAMAT GmbH Bgm Dr Nebel Str 2 D 97816 Lohr am Main Phone 09352 40 0 Fax 09352 40 4885
109. 34 Target Block Number 0000 2999 1 Bank number 0 9 group of 10 aux outputs 1111000022 Output State each of 10 as listed below the output will be checked for condition Off 1 the output will be checked for condition On 2 the output will not be checked Don t Care This command represents an expansion of the command BCA It can be used to check if a condition is being met at 10 auxiliary outputs The condition can be specified separately for each output The jump to the target block takes place only if all 10 aux outputs meet their programmed condition If not stepping to the next block takes place DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 29 BPE Branch on Parallel Inputs E 1500 BPE 0345 6 1111000022 0345 Target Block 3 Bank number 0 3 group of 10 aux inputs 1111000022 Input State each of 10 as listed below the input will be checked for condition OFF 1 the input will be checked for condition ON 2 the input will not be checked Don t Care This command represents an expansion of the command BCE It can be used to check simultaneously if a condition is being met at 10 auxiliary inputs The condition can be specified separately for each input The jump to the target block takes place only if all 10 inputs meet the programmed condition If not stepping to the next block takes place Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 30
110. 4 1 Description of Parameter Sets 4 1 4 2 Parameter LISb ue uic erben cce as ce e do eyed ded dvd rette 4 2 4 3 Entering the b ee a t c ERE unde a e ERR ua 4 3 Displaying of Decimal t ce 4 4 Auxiliary Inputs Outouts Ge ee ee 4 4 Unit of Measuremaont 4 5 4 4 Linear or Rotary 4 5 4 5 Parameter 4 6 Parameter A100 Maximum 4 7 Parameter 1 409 Velocity cot eget 4 8 Parameter A102 Acceleration Rate 4 9 Parameter A103 Position Gain KV 4 10 Rexroth Indramat DOK CONTRL DLC A DLC G AWOS AE P 12 99 DLC A and DLC G Table of Contents III Parameter 104 Encoder Resolution 4 11 Parameter A105 Frb 4 12 Parameter A106 Position 4 13 Parameter A107 Position Pre Signal 4 14 Parameter A108 Feed Constant na ean 4 15 Parameter 1
111. 485 Mode DLC 12 RS 485 Mode 5 DLC 28 RS 485 Mode D DLC 13 RS 485 Mode DLC 29 RS 485 Mode E DLC 14 RS 485 Mode U DLC 30 RS 485 Mode F DLC 15 RS 485 Mode V DLC 31 RS 485 Mode G DLC 16 RS 485 Mode W DLC 32 RS 485 Mode Third 3 Control String Character Information Type This character is used to identify the type of information to be sent N Hexadecimal 4E Identifier for a program block The information which follows this character will be stored as a program block 0000 2999 Hexadecimal 4B Identifier for a system parameter The information which follows this character will be stored as a parameter Hexadecimal 58 Identifier for DLC status The status type requested will be sent back to the host device Other Important Control Characters The following are additional control characters required for proper protocol CR LF Hexadecimal 24 Identifier for check sum The two characters following this character represent the check sum of the information transmitted This check sum must be transmitted along with every transmission Hexadecimal OD Hexadecimal OA These two characters CR Carriage Return and LF Line Feed form the end of every transmission X ON Hexadecimal 11 X OFF Hexadecimal 13 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat 7 6 Serial Interface DLC A and DLC G Serial transmission can be controlled using handshaki
112. 6 1 PME LO 6 3 mero r Ai cune 6 3 S MEE Hardware iT m 6 3 6 9 eus ER 6 3 6 6 DLG DEA 4 1 Conn GClorsS ctu adeat ef de eaae de Dr dd ER Ede 6 4 6 7 Pre Operation Start Up 6 4 0 8 COMNGCHONS eitis ru 6 4 6 9 DEA 4 1 Input Connections diit itr Den ied ee RE a caine 6 5 6 10 DEA 4 1 Output Connections ternera o cha eden de ea ed 6 6 6 11 Power teo Sac cts eae aga iei aser iter Greet das cree td cesta LE EE 6 6 6 12 Digital AC Servo Amplifier Parameter 6 6 Changing The Display Language ssssssssssseseseeeene enne enne nnn inttr inrer nnns nnns inneren 6 6 Rexroth Indramat DOK CONTRL DLC A DLC G AWOS AE P 12 99 DLC A and DLC G Table of Contents VII 6 13 6 14 6 15 6 16 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 8 1 8 2 8 3 8 4 NITE P 6 7 Setting the Amplifiers Parameters to Operate with the DLC Control 6 7 Analog Outputs rire rapuere des errare de ee Re a ER Rod etuer ud a 6 7 Bipolar Velocity Limit Value rrr rt terrere RR ERE 6 8 Overload M telo
113. 9 Indramat 2 6 Controls and Indicators DLC A and DLC G Drive Diagnostic 26 Undervoltage Example Drive Diagnostic Screen If no servo fault is present at power ON and a DLC fault is present then the DLC status message will appear EMERGENCY STOP EMERGENCY STOP DLC Status Screen Row B Refer to the Display Map in Figure 2 2 By pressing the down arrow key once from either the Hardware Software Screen or Fault Screen the Tool Correction Screen will be displayed Row B It shows the Tool Correction registers and their respective values Pressing the right or left arrow key causes the cursor to move through the data field and register number field Tool Correction data is entered at this screen Tool Correction Dnn 00010 00 Row C Refer to the Display Map in Figure 2 2 By pressing the down arrow key once from the Tool Correction Screen the System I O Status Screen will be displayed Row C They show the status of each system and auxiliary input and output Pressing the right arrow key from the System Inputs screen causes the status of the Auxiliary Inputs to be displayed Continue pressing the right arrow key to see the status of the System Outputs and Auxiliary Outputs Use the left and right arrow keys to scroll through screens on the same line System Inputs dll System Outputs Outputs 97 99 llis System I O Status Screens Row D Refer to the Display Map in Figure 2 2 Pr
114. A the output bank of 8 outputs shuts off The entire bank of 8 outputs on the DEA card must them be reset by cycling system power off and back on DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Options CTA Remote Keypad Display RS 232 485 Interface Options IDS Module SOT General Description 1 15 An IKS 745 cable allows remote mounting of CTA keypad display to the machine s control panel This standard interface allows remote operation and other data transfer between the DLC and a optional host device such as the IDS SOT computer or programmable controller A remote thumbwheel switch module used for entering feed length and feed rate for operation displays status and fault codes via a two digit LED Station Operator Terminal Used with ScreenManager to create application specific screens for displaying diagnostics entering feed length feed rate viewing input output status etc Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 1 16 General Description DLC A and DLC G Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Controls and Indicators 2 1 2 Controls and Indicators This chapter contains a general description of the DLC control layout plus the following information 1 Description of DLC with optional CTA keypad and display 2 Description of the functions of the keys on the CTA keypad 3 Description of display screens how to scroll through
115. AL D co START STOP TEBE TBE eee Figure 1 5 CTA 10 User Interface Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G General Description 1 11 1 4 Standard Configuration Of DKS With DLC Control Card DEA 4 Input Output Card The DLC Control Card plugs into the U1 slot and the DEA 4 Input Output Card plugs into the U2 slot of the Indramat Digital AC Servo Controller The Indramat Digital Controller being used mounts to the panel of a control cabinet electrical enclosure Installation procedures are described in Chapter 6 mmi DLC Control DEA 4 Input Output Card Figure 1 6 Standard Configuration Of DKS With DLC Control Card DEA 4 I O Card The standard configuration for the DLC DEA 4 with DKS Digital Compact Drive illustrated in Figure 1 5 The DLC with DEA 4 Input Output card has 15 inputs and 16 outputs The first 8 inputs are system inputs and the next 7 inputs are auxiliary inputs The first 5 outputs are system outputs and the next 11 outputs are auxiliary outputs The auxiliary inputs and outputs can be defin
116. Chapter 5 for more information and an example of how the PFI command will operate Note If the positive stop is not reached the maximum torque of the axis and the overload factor of the drive are active Warning When the MOM command is used and while positioning to a positive stop or positioned at the positive stop the overload factor in the drive is internally set to 400 percent The MOM command is the only limit for the percentage of maximum torque DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 69 POA Position Absolute E 2800 POA 12345 678 999 1 Axis 1 12345 678 Plus or minus absolute target position in input units to 2 or 3 decimal places depending on the setting in B007 999 feed rate in 96 00 1 99 9 of the maximum velocity set in parameter A100 The axis must be homed G74 HOM or CLA prior to execution of this command Otherwise an error message will be issued Stepping to the next block takes place immediately after the absolute position has been read into the position buffer Since this command does not wait for the axis to be in position before jumping to the next block the program command following this command will be executed This allows other functions to be executed while the axis is moving toward the end position If multiple POA commands are in sequence the resulting move will in most cases continue and stop at the last POA Target Position issued A
117. Code Descriptions C Vw DU IG E 1 E 1 DLC Hardware Type Code E 1 E 2 Software Type Code Description E 1 E 3 IDS Hardware Type Code E 1 E 4 IDS Software Type Code Description E 2 E SOT Hardware Type 5 E 2 E 6 SOT Software Type Codes E 2 7 DUO CHE ORI l 1 Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G General Description 1 1 1 General Description The DLC is a single axis positioning control card which plugs into the Indramat Digital AC Servo Drives such as the DKS Digital Compact Drive or DDS Digital Drive products The DKS is a self contained power supply and digital drive The DDS is a digital drive which operates with the TVD AC Power Supply The DLC requires a DEA 4 Input Output card or available I O network cards to provide the system inputs and outputs to operate the Digital AC Servo System The DLC plugs into the U1 slot and the I O card plugs into the U2 slot of the Indramat Digital Drive Modules The DLC DEA 4 used with an Indramat Digital Drive Module becomes a multi tasking user programmable unit which provides precise motion control The DLC controls an Indramat maintenance free MDD Digital AC Se
118. DEA 4 Connector Parameter Mode Select Automatic Mode Select Emergency Stop Cycle Start Cycle Stop Jog Forward Jog Reverse pc Clear Auxiliary Input 1 Auxiliary Input 2 Auxiliary Input 3 Auxiliary Input 4 Auxiliary Input 5 Auxiliary Input 6 Auxiliary Input 7 DEA 5 Auxiliary Inputs 8 22 Requires DEA 5 Expanded l O card option Auxiliary Input 8 X32 1 through through Auxiliary Input 22 DEA 6 Auxiliary Inputs 23 37 Requires DEA 6 Expanded I O card option Auxiliary Input 23 X33 1 through 15 a fo fo fo Jo ju CO O N gt p k ol through 15 Auxiliary Input 37 Table 2 1 Input Signal Display Legend Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 2 12 Controls and Indicators DLC A and DLC G Rexroth Indramat CTA Display Signal DEA 4 Connector Position Description System Fault Indicator Manual Mode Indicator Automatic Mode Indicator Parameter Mode Indicator Auto Cycle Running Auxiliary Output 1 11 aN A Auxiliary Output 1 through 11 Auxiliary Output 11 Auxiliary Output 12 27 Requires DEA 5 Expanded I O card see Table 5 1 in Chapter 5 for restrictions and use as software flags user defined through x32 16 through through 16 user defined Auxiliary Output 28 43 Requires DEA 6 Expanded I O card see Table 5 1 in Chapter 5 for restrictions and use as software flags user defined
119. DLC A and DLC G Customer Service Locations Customer Service Locations Americas United States Canada and Latin America USA Rexroth Corporation INDRAMAT Division 5150 Prairie Stone Parkway Hoffman Estates Illinois 60192 Phone 847 645 36 00 Fax 857 645 62 01 Mexico Motorizaci n y Disefio de Controles S A de Av Dr Gustavo Baz No 288 Col Parque Industrial la loma Apartado Postal No 318 54060 Tlalnepantla Estado de Mexico Mexico Phone 5 397 86 44 Fax 5 398 98 88 USA Rexroth Corporation INDRAMAT Division 2110 Austin Avenue Rochester Hills Michigan 48309 Phone 810 853 82 90 Fax 810 853 82 90 Argentina Mannesmann Rexroth S A I C Division INDRAMAT Acassusso 48 41 7 1605 Munro Buenos Aires Argentina Phone 01 756 01 40 01 756 02 40 Telex 262 66 rexro ar Fax 01 756 01 36 INDRAMAT Service Hotlines USA 1 800 860 1055 Canada 1 847 645 3600 request Service Department Latin America US Phone No 847 645 3600 request Service Department Argentina Nakase Asesoramiento Tecnico Diaz Velez 2929 1636 Olivos Provincia de Buenos Aires Argentina Phone 01 790 52 30 Customer Service in the Americas Asia Australia and Far East Australia Australian Industrial Machinery Services Pty Ltd Unit 3 45 Horne ST Campbellfield VIC 2061 Australia Phone 03 93 59 0228 Fax 03 93 59 02886 China Rexroth China Ltd A 5F 123 Lian Shan
120. DLC G Bank 2 Individual Aux Output Number Programmed state Programming 5 17 The following is an example of the APJ command The aux outputs in Bank 2 outputs 20 29 will be programmed to the states designated in the data field 2100122011 respectively The program then jumps to the desired block designated by the data 1000 in the example E 0044 APJ 1000 2 2100122011 1000 After the designated bank of aux outputs have been programmed the program jumps to this block 2 1 0 0 1 2 2 0 1 1 Outputs 22 23 and 27 are programmed for an OFF state Outputs 21 24 28 and 29 are programmed for an ON state Outputs 20 25 and 26 are programmed with a Don t Change condition This causes the output not to change state The aux outputs shown 20 29 only serve as flags if a DLC A or DLC G with DEA 4 is being programmed If the DLC A or DLC G with DEA 4 5 and 6 is being programmed the aux outputs up to 43 are accessible Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 18 Programming DLC A and DLC G ATS Acknowledge Output Status E 0050 ATS 05 1 05 Auxiliary output number scanned 01 99 1 Auxiliary output status 0 output status Off 1 output status On The ATS command scans the status of the programmed auxiliary output Stepping to the next block does not take place until the desired status is present at the specified auxiliary output This command is used to perfor
121. DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 88 Programming B Programming 0900 APE 0100022222 0901 WAI 00 02 0902 SOI 0 2 05 0000 0903 APE 0 0010022222 0904 WAI 00 02 0905 SOI 0 3 05 0000 0906 APE 0 0001022222 0907 WAI 00 02 0908 5010 4 05 0000 0909 APE 0 0000102222 0910 WAI 00 02 0911 SOI 0 5 05 0000 DLC A and DLC G Select 4th decade Wait until level at inputs is stable Read in value of 4th decade Select 3rd decade Wait until level at inputs is stable Read in value of 3rd decade Select 2nd decade Wait until level at inputs is stable Read in value of 2nd decade Select 1st decade Wait until level at inputs is stable Read in value of 1st decade 0912 SOI 1 0 00 0300 Convert information and send to target block 0913 JMP 0900 Start new read in cycle After calling the program the statement 0300 contains 0300 000368 50 999 It is useful to create a program with SO1 commands in Task 3 Notes 1 It is useful to program this type of decade switch query in task 3 2 All numbers which are not read in pseudo nibbles are assumed to be 0 Rexroth Indramat DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G STH Send to Host Programming 5 89 E 0390 STH 0 0019 0 Type of information 00 Status 00 02 03 05 06 07 08 09 10 19 47 48 49 50 51 52 53 1 Counter status of preset and actual number of pieces The block number of t
122. E P 12 99 DLC A and DLC G C Parameter Input Sheet LOG OU 0 0 LOG OU 0 0 PUT 1 000 0 PUT 2 0000 0 0 OAD FACTOR 0000 Uus ERROR REACTION 008 000000 Parameters 4 83 Y LOOP MONITORI 0000000 _ 000 _ Y LOOP I RE HING TIME 0 0 ANDARD ENCODE POSITION BSOLUTE POSITION To get to the other parameter sets press the Store key or use the up and down arrow keys To increment or decrement through the parameters in each set use the or keys To move the cursor in the data field use the right or left arrow keys DOK CONTRL DLC A DLC G AW03 AE P 12 99 Rexroth Indramat 4 84 Parameters DLC A and DLC G Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G 5 5 1 Programming 5 1 Programming Positioning The application program of the system is defined and entered by the user It can be entered directly via the CTA keypad and display or from a remote terminal device interfaced through the RS 232 or RS 485 port The application program flow is similar to a Basic program Three letter mnemonic commands are used There are 3000 programming lines blocks available for user programming numbered
123. Indramat From the C Parameter group pressing the blank key again displays the C100 parameter In this menu the drive parameters can be set to their default values Set Standard Drv Params Over CTA C100 00000000 CODE 00005301 This menu consists of only the parameter C100 The standard parameters are set after entering the number 00005301 and pressing the block store key After pressing the block store key this menu item exits to Drive Parameter C000 If the entry is made incorrectly the menu exits to Drive Parameters without setting the standard parameters i e there is no control monitoring of the entry DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 77 Parameter C101 Set Absolute Position as of software version DA1 04 DG1 04V04 Set Absolute Position C101 00000 00 Input of the Absolute Reference Position in input units Currently available only if Homing Setup is programmed Parameter A110 When Homing Setup is active setting the absolute encoder reference position via the drive parameter is problematic The new DLC Parameter 101 offers a significantly simpler solution by setting the position in input units Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 78 Parameters DLC A and DLC G 4 6 M Functions General Description Pre defined M functions are available to simplify handshaking between the DLC and the line control during program execut
124. Jog reverse 6 Jog forward 5 Immediate stop 4 Start 3 E Stop message 2 Automatic 1 Parameter For all of the system inputs listed above 0 Read in system input via DEA 4 1 1 Read in system input via serial interface 2 Read in system input via Interbus S board DBS2 2 DI software only Set outputs for DEA4 DEA6 via the serial interface or DBS2 1 Read in inputs for DEA4 DEAG via the serial interface or DBS2 1 The assignment of the inputs and outputs is accomplished via parameters B001 and B002 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 38 Parameters DLC A and DLC G Parameter B001 Serial Jog Enable a software oniy Serial Jog B001 00000000 00000000 Enable or disable Serial Jog 00000000 Disabled 01100000 Enabled Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameter B002 User I O As of software version DA1 04V07 DG1 04V07 Parameters 4 39 User I O B002 00123456 00 Not used 1 Outputs A28 A43 DEA 6 2 Inputs E23 E37 DEA 6 3 Outputs A12 A27 DEA 5 4 Inputs E08 E22 DEA 5 5 Outputs A01 A11 DEA 4 6 Inputs E01 E07 DEA 4 For all of the system inputs listed above 0 Read in inputs via DEA X 1 Outputs for DEA X 1 set by the DLC 1 Read inputs via serial interface Outputs for DEA X 1 set by serial interface 2 Read in inputs via Interbus S board DBS 2 2 Outputs for DEA X 1 set b
125. LC A timing diagram for the DLC with DKS DDS or DDC is also included Installation Drawings This section contains a DKS 1 1 dimensional outline drawing as well as CTA and IDS cabinet cutout dimensions for remote mounting DLC Type Code Descriptions This section shows how to interpret the data plate for hardware software options included DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G General Description 1 7 1 3 System Features Superior Performance The system offers high precision motion control with feed resolution of 0 001 inch Note that maximum system performance depends on the mechanical characteristics of the user s system Easy to Operate The user simply and easily operates the control system by entering a simple user program using the optional interfaces Operating status messages appear on the display in the user selected language English French German Spanish Italian or Portuguese Other input and display options are described later in this section The DLC system includes features to make setup quick and easy eliminating time consuming mechanical setup or complex programming when changing parts Parameter Adaptable to Multiple Machines The machine manufacturer or the user easily adapts the DLC to the mechanical and electrical characteristics of an application by entering data into a set of parameters using the DLC s optional CTA keypad and display These parameters define the characteristics of
126. LC A and DLC G STO Send Information To Outputs E 0002 STO 101 1 3 0000 05 Rexroth Indramat For the 0000 10 OMAN OA A OO N Axis number or general data 0 Counter Status 1 Axis 1 Position Not used set to 0 Information Type 1 Absolute Position 2 Counter Status Of The BAC or COU Commands Mode 0 Store Information position or counter 1 Output Stored Information Via Outputs In BCD Format Decimal Position Decimal Significance 1st digit starting from the right 2nd digit starting from the right 3th digit starting from the right 4th digit starting from the right 5th digit starting from the right 6th digit starting from the right 7th digit starting from the right 8th digit starting from the right 9th digit is prefix 0 prefix 24V is output for minus and OV is output for plus For Counter Status Information Type Only Counter Command Block Number Starting Output Number XX with the BCD value see illustration XX 210 corresponding value 1 20 XX 1 211 corresponding value 2 2 XX 2 212 corresponding value 4 2 XX 3 213 corresponding value 8 2 The STO command is used to output either axis position or counter status information via four auxiliary outputs in BCD format Only one type of information can be stored internally at one time either absolute position or counter status The user specifies the type of information number of decimal places counter block
127. LC G SO1 Scanning of Inputs and Modifying a Position Velocity Special Option 1 Rexroth Indramat 1000 501 0 1 0010 0 Read decade switch values 1 Convert input values into a position and store this in the position section of the POI PSI POA PSA VCC PST commands 2 Convert input values into a velocity and store this in the velocity section of the POI PSI POA PSA VCC commands 3 Convert into a length and write to the tool correction memory defined under data target replacing the information contained in this memory 4 Convert into a length and write to the tool correction memory defined under data target adding to the information contained in the selected memory 5 Convert into a length and write to the tool correction memory defined under data target subtracting from the information contained in the selected memory In modes 3 through 5 a maximum of 7 digits are evaluated the 8th digit from the right is the mathematical operation 1 ee 0010 Decimal Position To 2 or 3 decimal places depending on setting in BOO7 For 3 decimal places For 2 decimal places 1 10 1 10 2 10 2 10 10 3 10 4 100 4 10 5 10 5 102 6 102 6 10 7 109 7 10 8 10 8 10 9 Sign 9 Sign Starting input number for inputted data with the BCD value ee 10 1 11 2 12 ee 3 13 Data target In mode 1 2 Program block
128. Menu 2 Press the number 1 Operation Mode Scaling The Operation Mode allows the user to configure the following amplifier parameters e Analog Outputs e Bipolar Velocity Limit Value e Overload Factor e Analog Output Position Data Scaling e Analog Output Velocity Data Scaling The Indramat Digital Amplifier has two analog outputs AK1 Connector pin 1 referenced to OVm pin 2 and AK2 Connector referenced to Ovm pin 4 These outputs can be configured to output following items e Velocity Command Value e Velocity Feedback Value e Position Feedback Value e Motor Encoder Sine e Motor Encoder Cosine e Current Command Value Press the up or down arrow keys to position the cursor on the proper channel Then press the left or right arrow keys to select the desired output Continue pressing until the desired output is selected Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 6 8 Installation Start Up DLC A and DLC G Bipolar Velocity Limit Value The Bipolar Velocity Limit Value sets the motor s maximum velocity limit in the forward or reverse direction Position the cursor to the right of the Bipolar Velocity Limit Value and type in the desired velocity in revolutions per minute RPM Note The value entered should not exceed the maximum velocity of the motor If an operating velocity of less than maximum is desired enter that value here Overload Factor The Overload Factor is det
129. Mode is not selected another mode is selected or the system has defaulted to the Manual Mode If this signal line is high at the same time the Parameter Mode is selected input high the DLC issues the Invalid Mode Selection diagnostic error message NOTE Task 3 will be running in both Manual and Automatic Mode Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 3 16 Functional Description of DEA 4 I O Connections DLC A and DLC G Emergency Stop Cycle Start Rexroth Indramat DEA 4 Connector X17 pin3 Function Input Commands the servo system to stop immediately 24 Allows the DLC to operate properly 0 servo system is commanded immediately to zero velocity Drive reaches zero speed in the minimum time possible given the inertia and maximum torque available The DLC issues an Emergency Stop diagnostic message WARNING This signal must be used to ensure safety WARNING The E Stop signal should go through the Zks input on the DKS drive X9 pin 1 amp 2 in series with this DLC input Conditions which warrant pressing the E Stop include 1 Any condition posing an immediate danger to personnel 2 A jam in the machinery or any other condition that poses an immediate harm to the system equipment NOTE The Task 3 program will continue to operate during an E Stop condition When the E Stop condition no longer exists and the clear input is issued Task 3 wi
130. NG ert ru radi 5 83 SAC Set Absolute Counter rien 5 84 SIN SING E 5 85 501 Scanning of Inputs and Modifying Position Velocity Special Option 1 5 86 STH Sendto HoSl oreet Een uec EORR pite Er fee 5 89 STO Send Information To Outputs 5 90 vca Velocity Change Absolute 5 92 vcc Velocity Change 5 93 VEO Velocity Override Command et ena ut e eec dae 5 94 WAL Wait Time Delay nt ee ceto du ea 5 96 WRI Write in Absolute Position Teach Command 5 97 Eisen M 5 99 D G40 G43 G44 EE 5 99 jov A E E AN A E T 5 100 Selecting a Correction 5 101 5 101 Activating Tool Correction aate deer dre dae e edad E t die ed da koe e 5 102 Deactivating Tool 5 103 External 5 103 6 lnstallation Start c 6 1 6 1 MOUNTING Cabinet
131. P BITS WORD Fig 7 4 Data Format The word length is set in parameter B003 see Chapter 4 for entry procedures e 7 7 bit word length e 8 8bit word length The parity type is set in parameter B003 see Chapter 4 for entry procedures e 1 n0 parity e 2 even parity e odd parity Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 7 4 Serial Interface Baud Rate Interface Mode DLC A and DLC G The baud rate is set in parameter B003 see Chapter 4 for entry procedures You may choose any baud rate from among the following values Parameter Entry Baud Rate 0030 0300 0060 0600 0120 1200 0240 2400 0320 3200 0480 4800 0640 6400 0960 9600 1920 19200 The interface mode is set in parameter 003 see Chapter 4 for entry procedures You may choose from among the following 0 Standard RS232 Full Duplex 1 IDS decade switch option 2 Same as Mode 0 3 Serial port for SOT Station Operator Terminal RS 232 half duplex one station ONLY 4 Serial bus for SOT RS 485 half duplex station 1 through 32 entered in parameter B004 7 3 DLC Control String Protocol The following sections describe each control character requirements for proper protocol First 1 Control String Character Transmission Type All data transmissions to the DLC must start with one of the following control characters to identify what type of transmission
132. Programming DLC A and DLC G BPT Branch on Position Test Rexroth Indramat E 0060 BPT 0456 12345 678 0456 Target Block 1 Axis 1 12345 678 Absolute Position 2 or 3 decimal places as set B007 This command can be used to check the absolute position of the axis If the axis is in position switching tolerance set in A106 the jump to the target block will take place If not stepping to the next block takes place Note The BPT command only functions after the axis has been homed Prior to this the block is scanned only and no execution takes place DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 31 BZP Branch If the Target Position Exceeds the Position Limit Value E 1550 BZP 0678 12345 678 0678 Target Block 1 Axis 1 12345 678 Position Limit Value to 2 or 3 decimal places as set in 007 You can use this command to check that a commanded positions does exceed the position limit value set by this command At the execution of this block the jump to the target block takes place if the actual position or the target position of the axis is equal to or greater than the programmed position limit value If the actual position or the target position is less than the programmed position limit value the program steps to the next block instead of jumping to the branch block number Note The BZP command only functions after the axi
133. RL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 71 POM Position On Memory Requires IDS Setup E 300 POM 100 1 Axis 1 0 Mode 0 Position incremental 1 Position in absolute dimensions 1 Position direction 0 Positive 1 Negative The POM command is an incremental or absolute positioning command The programmed feed length and velocity are stored in a single memory location by an Indramat IDS decade switch option Note that the axis can be controlled by the POM command but given a single memory location only one value can be stored at one time Stepping to the next block takes place immediately after the POM command is read into the program This allows other functions to be executed while the axis is moving toward the end position The ATS command programmed to monitor the Position Tolerance Output Parameter A106 or the Position pre signal Parameter A107 is useful in controlling when to step to the next block When using the IDS decade switch enable this option in Parameter If the decade switch option is not enabled this block is scanned and no positioning takes place Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 72 Programming DLC A and DLC G PSA Position Absolute With In Position Signal E 0310 PSA 12345 678 999 Rexroth Indramat 1 Axis 1 12345 678 Plus or minus absolute target position in input units to 2 or 3 decimal
134. Street Sha He Kou District Dalian 116 023 P R China Phone 0411 46 78 930 Fax 0411 46 78 932 Korea Rexroth Seki Co Ltd 1500 12 Da Dae Dong Saha Gu Pusan 604 050 Korea Phone 051 264 90 01 Fax 051 264 90 10 China Rexroth China Ltd Shanghai Office Room 206 Shanghai Intern Trade Centre 2200 Yanan Xi Lu Shanghai 200335 P R China Phone 021 627 55 333 Fax 021 627 55 666 Hong Kong Rexroth China Ltd 19 Cheung Shun Street 1st Floor Cheung Sha Wan Kowloon Hong Kong Phone 741 13 51 54 or 741 14 30 Telex 3346 17 GL REX HX Fax 7864019 786 07 33 Seo Chang Corporation Ltd Room 903 Jeail Building 44 35 Yoido Dong Youngdeungpo Ku Seoul Korea Phone 02 780 82 07 9 Fax 02 784 54 08 China Rexroth China Ltd Shanghai Parts amp Service Centre 199 Wu Cao Road Hua Cao Minhang District Shanghai 201 103 P R China Phone 021 622 00 058 Fax 021 622 00 068 India Mannesmann Rexroth India Ltd INDRAMAT Division Plot 96 Phase III Peenya Industrial Area Bangalore 560058 India Phone 80 839 21 01 80 839 73 74 Telex 845 5028 RexB Fax 80 839 43 45 Canada Basic Technologies Corporation Burlington Division 3426 Mainway Drive Burlington Ontario Canada L7M 1A8 Phone 905 335 55 11 Fax 905 335 41 84 Brazil Mannesmann Rexroth Automa o Ltda Divis o INDRAMAT Rua Georg Rexroth 609 Vila Padre Anchieta BR 09 951
135. TS E G EDIT PROGRAM Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 e Indramat B 2 DLC Display Screen Map DLC A and DLC G Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Drawings and Schematics C 1 C Drawings and Schematics CAUTION The drawings in this Appendix are included for illustrative purposes only and are subject to change without notice Check with Indramat to be sure you are working with the latest drawings prior to installing wiring and powering equipment Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat C 2 Drawings and Schematics DLC A and DLC G C 1 DKS DLC A MDD Interconnection Sheets 1 10 REXROTH INDRAMAT b1162 1 wmf Figure C 1 DKS DLC A MDD Interconnection Sheet 1 of 10 Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Drawings and Schematics C 3 JOFFMAN ESTATES REXROTH INDRAMAT b1162 2 wmf Figure C 2 DKS DLC A MDD Interconnection Sheet 2 of 10 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat G DLC A and DLC C 4 Drawings and Schematics 15 1N3Wn20 SE S31V183 NVA3JOH AJVINVHONI
136. The status of the inputs and outputs after processing the M function are defined in the M Function table The table of M functions is specified in parameters only and can be modified by the CTA keyboard or seriallly through the RS 232 RS 485 port Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 80 Parameters DLC A and DLC G M Function Table Set Up To enter M Function data you must be in Parameter Mode After entering Parameter Mode use the up or down arrow keys until your display looks like one of the two shown below The M Function table has the following format for every pre defined M function M Functions M Functions MHmm XXXXXXXX High Byte MLmm XXXXXXXX Low Byte mm Number of the M function 00 63 Sixteen inputs outputs can be set with every M function M Functions MLmm 8xxxxxxl 1 1st output 1st input 8 8th output 8th input M Functions MHmm 16xxxxx9 9 9th output 9th input 16 16th output 16th input The first user output and the first user acknowledgment input are defined in parameter B008 Every position x corresponds to an input output pair and can assume the following significance 0 Turn output OFF with input acknowledgment 1 Turn output ON with input acknowledgment 2 Output unchanged with no acknowledgment Turn output OFF with no input acknowledgment 4 Turn output ON with no input acknowledgment 5 Turn output ON with no acknowledgment set t
137. a 1 output 1 and input 1 Example E 0801 BIO 0400 1 1110000000 Inputs and outputs from 10 to 13 will be compared BIO Data 10 1 112 1 122 13 0 14 0 Outputs 10 1 11 1 12 1 13 0 14 1 Inputs 10 1 11 1 12 0 13 1 1421 Condition met met not met not checked not checked Since the condition is not being met at one point input 12 the jump will not be executed Stepping to the next program block takes place instead Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 27 BMB Branch on Multiple Binary Outputs E 0120 BMB 1234 45 67 8 Outputs Significance Output value 1234 Block Offset 0000 2999 used to calculate Target Block 45 Length of Jump 67 Starting Output Number 01 99 8 Number of Outputs consecutive Being Used This command will cause a jump to be executed which is determined by means of the output assignment as defined in the command Example E 1200 BMB 0100 02 05 8 12 11 10 09 08 07 06 05 128 64 32 16 08 04 02 01 0 0 1 1 0 0 1 1 Output value 51 The target block is calculated as follows Block offset output value x length of jump 0100 51 x 02 Target block 0202 Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 28 Programming DLC A and DLC G BPA Branch on Parallel Acknowledgments Outputs Rexroth Indramat E 0130 BPA 0234 1 1111000022 02
138. activated all MW movements are used if MW deactivated all motor transmitter movements are used 12345 678 Second Position Axis 1 in EGE Status 10 Axis 1 Position Lag 7 X 10_ Cr Lf _10_ 11111 111_ _ 5 AA Cr LE X 10 Status 10 d Direction 11111 111 Position Lag of Axis 1 in input units XXXXX XXX Not Used Status 14 Command Current at Position X coq ow Lr X _ 14e 12345 678t123 45 hh Cr Lf X 14 2 Status 14 e A Axis 1 has been homed Axis 1 has not been homed 12345 678 Position of Axis 1 123 45 Commanded current in amps Status 18 Drive Diagnostics _X __18_Cr Lf X 18 123 6 tt bb C 6t 6 a S BOE E X 18 Status 18 123 Drive diagnostic code t Drive diagnostic text DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Request Format Response Format Request Format Response Format Request Format Response Format Serial Interface 7 17 Status 19 Hardware and Software Version al 9 Cr Lf X 19 HHHHHHHHHHHHHH SSS eS S 5 58 5 55 hhCr Lf X 19 Status 19 H Hardware Version example _ DLC 1 1 A__ S Software Version example 1 1 03 02 Status 46 Length Counter E X 4 6 Cr LE A axis number 1
139. alid data in it The DLC parameters might contain asterisks indicating invalid data has been entered Refer to Chapter 4 for information on how to enter the DLC parameters Error Message Code Program Lost 06 When power to the DLC is turned off and the battery does not have sufficient power to retain its memory or is disconnected this error occurs when power is re applied It signifies that the program that was stored in memory is no longer in memory This error may also occur if the firmware is removed or if different DLC firmware is installed This error will also occur if you change the number of decimal places selected in parameter B007 Rexroth Indramat 8 8 Diagnostics And Troubleshooting Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Rexroth Indramat DLC A and DLC G 1 If this error occurs every time the DLC is powered up replace the backup battery 2 Verify that every DLC program block has valid data in it The DLC program might contain asterisks indicating invalid data has been entered Refer to Chapter 5 for information on how to enter the DLC program 3 If you changed the number of decimal places in B007 pull up the Program Edit screen and press the
140. also move the cursor within and between fields To change from one parameter set to another move the cursor to the A B or C parameter number and press the up or down arrow key You can also press the Blank key below the Block Store key to scroll through the different parameter sets With the cursor on the parameter number type over to enter the parameter number desired The display changes as the new parameter number is entered Pressing the or keys will also cause the parameter display to change to the next higher or lower parameter number within each parameter set Perform the following steps to change or edit the value of a parameter from the CTA keypad see Chapter 7 for procedures to download from a PC or SOT via the serial interface 1 Move the cursor arrow keys over the digit you want to change 2 Enter the desired number on the CTA keypad type over existing entry Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 4 Parameters Displaying of Decimals DLC A and DLC G 3 Verify data changes are correct in the display 4 Press the Store key to save the new parameter values displayed data into memory The display automatically changes to the next parameter 5 Repeat this procedure to change each parameter required by your application Maintain a current list of parameter entries Appendix E provides work sheets which show the organization of each parameter and provide spaces to
141. alues is possible on line through the CTA keyboard Tool Correction register values can be entered in manual and automatic mode External Tool Correction data input is also possible through parallel inputs using the SO1 command see Chapter 5 for a complete description of the SO1 command Tool Correction Dnn 00010 It is possible to use the Tool Correction registers for a variable memory however only one correction value can be selected and calculated per programming command Each correction value memory can accept a seven digit correction value The eighth digit is the sign bit Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 2 10 Controls and Indicators DLC A and DLC G System Auxiliary I O Status Screens System Auxiliary I O Status screens show the status of each system and auxiliary input and output These displays are helpful to verify wiring during start up or troubleshooting They also provide a quick summary of system auxiliary status during normal operation System Inputs System Outputs a PREP 01 16 Outputs 97 99 ME Tias 11 System I O Status Screens The status of each of the input or output signal lines on a screen are represented by a character in the bottom row of the display A Low signal 0 volts is represented by a decimal A High signal 24 volts is indicated by a one 1 The system Inputs and Outputs have a fixed or pre defined function fo
142. amat The DLC Digital AC Servo System typical configuration consists of e DLC 1 1 control card e DEA 4 1 Input Output card e Digital Drive DKS DDS e MDD Digital AC Servo Motor Complete interconnect cable sets are also available from Indramat The components are chosen to best fit the required application Figure 1 2 isa block diagram of a typical DLC Servo System configuration These components are designed into a mechanical system For example it could feed some type of material into another processing station such as a punch press thermoforming station packaging machine etc The machine builder or user enters data into the DLC parameters to specify the mechanical and operating characteristics of the system Based on this data plus the feed length and feed rate entered by the operator the DLC issues positioning commands to the digital drive a DKS Digital Compact Drive or DDS Digital Drive which controls the current driving the MDD AC Servo Motor which drives the mechanical feed mechanism The MDD AC Servo Motor includes a high resolution feedback which provides velocity and position feedback to the digital controller ensuring precise repeatable positioning of the material being fed The final accuracy of the feed system depends on various factors such as type of material gearbox backlash and other machine mechanics System components are modular thus installation and replacement of any component of the system is fast a
143. ameter A124 Free Free 124 00000000 0000000 Not used must be set to 0000000 Parameter A124 Free is currently undefined Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 34 Parameters DLC A and DLC G Parameter A125 Jerk Constant as of software version DA1 04VRS Rexroth Indramat Jerk Constant 125 0000 0 000 0000 Not used 0 000 Time constant for acceleration s Range 0 000 1 024 0 Constant acceleration The Time constant for acceleration displays the time in which the DLC builds up the acceleration DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 35 Parameter A126 Position Window as of software version DA1 04VRS Position Window A126 00 123 456 00 Output 123 456 Position window The DLC stores the last programmed move position If the drive moves from the last programmed move position by the value listed in the position window the programmed output will be turned off Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 36 Parameters DLC A and DLC G Parameter B000 Enable Axis 2 software Enable Axis 2 B000 00000000 0000000 Not used must be set to 0000000 Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 37 Parameter B001 System Inputs DG software System Inputs B001 87654321 8 Clear external 7
144. any feed instructions and should not be located in the main program Select by parameter to start this program by an external input push button switch or automatically when mode is changed from Automatic to Manual The program is aborted if switched out of Manual Mode The manual vector is not accepted while jogging or homing in Manual Mode see last section Jogging or homing is not possible while the manual vector program is running The manual vector program must end with an RTS command An example use of the Manual Vector program is to use the APE command to set the states of auxiliary outputs This command is programmed to set a bank group of ten outputs individually to ON OFF or Don t Care states This allows setting outputs for a shut down mode or as default before starting automatic operation See Chapter 4 for additional information on parameters and Chapter 5 for programming commands Outputs e Manual mode indicator Refer to Section 3 2 Operating Mode Selection Manual Mode Indicator 3 4 Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 3 12 Functional Description of DEA 4 I O Connections DLC A and DLC G Fault Diagnostic Monitoring Rexroth Indramat Inputs e Clear External 3 3 The fault recovery procedure is to first troubleshoot and remedy the problem Then press the Clear key on the CTA control panel or external Clear input on user control panel to clear the DLC fault status and d
145. arameter entry forms which show the required entry positions Always maintain an accurate listing of your parameter entries for reference when troubleshooting or changing parameters for a different application There are two methods to select the different parameters numbers The first method is to press either the left or right arrow key until the cursor is positioned on the parameter number and type in the desired parameter number The second method involves the CR key on the CTA keypad If the cursor is within the data field pressing CR once will cause it to move to the beginning of that field Press it again to move the cursor to the parameter number Type in the desired parameter number To change to different parameter sets press the Blank key located just below the Store key This will allow you to get to A1xx for Axis 1 BOxx for DLC system parameters for DKS Drive Tuning parameters and the C100 screen to reset DKS Drive to Standard Drive parameters Refer to Chapter 4 for specific parameter entry options and requirements Drive Diagnostic DLC Status DLC Hardware Software Version Display Screens Rexroth Indramat When the proper interconnection of the Indramat Digital Drive and DLC DEA cards is completed by turning on to the system power the message Waiting for Retrigger will appear for 2 3 seconds then the drive diagnostic screen will be displayed Drive Diagnostic 102 Drive Enabled Drive D
146. arities in drive conditions such as drive runaway or excess position lag conditions Parameters allow the user to set the magnitude of certain variations as required for the application before an error is considered a fault condition Programming Structure The basic program for standard motions is user programmed The user prepares a program of up to 3000 lines blocks utilizing pre defined commands These commands represented by three letter mnemonic codes specify the function The DLC when used with the optional CTA keypad display guides the user for proper entry of the necessary data for each command function utilized such as desired position desired Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Q Indramat 1 8 General Description DLC A and DLC G velocity etc The DLC can be programmed to run up to three separate task simultaneously multi tasking The DLC can be programmed with several sub routines The user can select a different sub routine from the main program to run different applications The user can customize the operation of the DLC control for any number of particular applications The user can download program blocks to the DLC from a host device computer PLC etc while the control is in operation Therefore the effective program size can be much larger than 3000 lines if needed Programmable Acceleration Rate Programmable I O The acceleration rate set by parameter can be changed reduced by
147. at error received via the port This information cannot be requested Transmission Format X OL Fe DOE Ae ee Lf e Error Number t Error Text Consult Chapter 8 Diagnostics and Troubleshooting for more information on the serial communication error used in the DLC Control Card Status 02 Current Program Block for Task 1 only Request Format i3 I Bee Response Format X 02 NNNN nnnn h h Cr Lf N Current Block Number n Return to Main program Block number if in a sub routine JSR Stack pointer Status 03 Axis Current Position Hexadecimal Format Request Format 2X 03 _ Cr f Response Format 53 7 7 2 2 2 _ ____ hh Cr Lf 22222222 Current position of axis 1 in Hexadecimal format yyyyyyyy Not Used Response is in Hexadecimal Use the following formulas to convert to Input Units to axis 1 current position in decimal format For Linear IU s 27777777 A108 A104 x 4 For Rotary IU s 27777777 A108 360 A105 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 7 14 Serial Interface DLC A and DLC G Status 04 Counter Status Request Format 04 NNNN Cr Le Response Format X 04 NNNN aaaaaa tttttt JD 5 hh Cr Lf NNNN Counter block number aaaaaa
148. at the specified auxiliary input Auxiliary input numbers 8 37 can also be used with optional DEA 5 amp DEA 6 expansion I O card Input 00 does not exist AKN commands containing Input 00 result in an Invalid Program Command diagnostic Note Note Example 0000 JMP 0860 0861 PSI 0862 AEA 0863 JMP 900 AKN 901 AEA 0902 PSI 0903 JMP DOK CONTRL DLC A DLC G AWO3 AE P 12 99 0860 02 1 1 00010 56 500 11 1 0900 02 0 11 0 1 00010 56 999 0860 Jump to block 0860 Scan aux input 02 until status is ON axis 1 incremental feed with acknowledgment of 10 56 IU at 50 of maximum velocity A100 Turn On auxiliary output 11 Unconditional Jump to block 0900 Scan aux input 02 until status is OFF Turn OFF output 1 1 axis 1 incremental feed reverse with acknowledgment of 10 56 IU at 10096 of maximum velocity A100 Jump to block 0860 repeat cycle Rexroth Indramat 5 14 Programming DLC A and DLC G AKP Acknowledge Parallel Input 0044 AKP 2100122011 Rexroth Indramat Bank tens Individual ones Input Number Programmed state 3 Bank number 0 9 group of 10 inputs Bank X Inputs 0 9 i e Bank 2 Inputs 20 29 Bank 3 Inputs 30 39 etc 2100122011 input status each of 10 as listed below 0 the input will be checked for condition Off 1 the input will be checked for condition On 2 the input will not be checked Don t Care
149. ation 1 through 32 entered in parameter B004 Note If you select the IDS option do not enter the other values for this parameter The DLC will configure the interface automatically 1 Parity 1 No parity 2 Even parity 3 Odd parity 8 Word Length 7 7 Bits 8 8 Bits 1 Number of Stop Bits 1 1 Bit 2 2 Bits Example Decade switch query with IDS unit Interface B003 00001000 0000 No meaning 1 Decade switch query 000 No meaning The interface transmission parameter for the decade switch are set as follows 2400 baud 8 bit 1 start bit 1 stop bit no parity check Rexroth Indramat DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 DLC A and DLC G Parameters 4 41 Parameter B004 Serial Interface Serial Interface B004 1108 9 T 00 1 Checksum Hardware Handshake RTS CTS 0 Checksum ON RTS CTS OFF 1 Checksum OFF RTS CTS OFF 2 Checksum ON RTS CTS ON 3 Checksum OFF RTS CTS ON 4 Disables checksum operation 1 Transmission Acknowledgment CR LF 0 Acknowledgment OFF 1 Acknowledgment ON 08 Station Number 01 32 Used with serial bus for SOT communication See Parameter B003 Serial Interface Interface Mode description 9 Error Code Over Serial Interface 0 Function Disabled 1 In case of DLC fault automatically send an error message via the serial interface See Status 53 in chapter 7 for details T Serial Jog Time Out Time T 25msec use T 4 or 6 for best
150. ation with CON was ON it is switched OFF After reading the PBK command the program jumps to the next block This command could be used in another task to control the actions of the axis Note The KDI command could be used for storing the approximate remaining distance otherwise the information is permanently lost Example 0000 CON 1 1 999 00 0001 WAI 02 00 0002 PBK 1 0003 POI 1 000050 00 100 After reading in the PBK command the axis then drives the braking path from V 99 9 to V 0 plus 50 EGE units However a flowing transition from V 99 9 to V 10 actually results V og Speed 100 t Time Figure 5 1 PBK Flowing Transition Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 67 PFA Absolute Position Feed To Positive Stop E 1346 PFA 1 00020 000 999 1 Axis 1 00020 000 Absolute position feed to a positive stop in input units to 2 or 3 decimal places depending on the setting in B007 999 feed rate in 96 00 1 99 9 of the maximum velocity set in parameter A100 The PFA command is used in conjunction with the MOM command The PFA command will absolute position the axis to a positive stop and the MOM command will determine the percentage of maximum torque during the move to the positive stop and the maximum torque at the positive stop When using the PFA command the positive stop must be within the software overtravel limits set in param
151. ay _1234 Counter 123456 456789 Counter Screen M indicates operating mode M Manual Mode selected A Automatic Mode selected 1234 indicates block number of counter 123456 actual number of counts 456789 preset number of counts Use the left or right arrow to move the cursor and enter a program block number which contains a counter command The second line displays the current values of the counter To scroll to the next or previous block with a counter use the and keys To leave the counter display mode use the up or down arrow keys A counter can be programmed see Chapter 5 BAC or COU command to execute X number of parts then stop and turn ON a light etc Count is maintained during shut down so the actual manufacturing process can be over several days Counters can also be used to keep track of production NOTE The actual count will be maintained by battery backup even when power is turned OFF Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 2 14 Controls and Indicators DLC A and DLC G Axis Information Screen The Axis Information Screen displays the current position Pos current following error FE and the current remaining distance Rem for Axis 1 By pressing the right arrow key the Commanded and Actual Speeds will be displayed in RPM Revolutions Per Minute for Axis 1 The values on these screens keep changing as they display the actual current system informatio
152. ay because once you enable Task 3 in parameter B006 it will begin to run as soon as you leave parameter mode 1 The BCB BCD BMB program commands can result in a jump or branch to a target block greater than 2999 This jump is caused by a combination of an offset jump distance or binary input If any of these commands are used refer to Chapter 5 to determine if the program command is used properly 2 The branch or jump command contains an asterisk in the target block Refer to Chapter 5 to determine if the program command is used properly Error Message Code Invalid Mode 08 This occurs when both the Automatic and Parameter inputs are held high at the same time 1 If you remove the parameter input you must reset the DLC to continue 2 If you remove the Automatic input the DLC will be in Parameter Mode with no error resulting Error Message Code Invalid Prg Command This error occurred because the DLC program encountered an invalid program command If Task 3 is being used enter the program for Task 3 in the appropriate program block location before enabling Task 3 in parameter B006 You must do it this way because once you enable Task 3 in parameter B006 it will begin to run as soon as you leave parameter mode 1 The program command contains asterisks Refer to Chapter 5 to determine if the program command is being used properly 2 The auxiliary input or output
153. blished auxiliary output as set in parameter A112 to prevent reading any Absolute Position commands POA PSA until the home procedure is finished Homing Procedure Refer to Figure 3 4 1 The axis moves towards the home switch at the velocity set in parameter A110 unless the axis is already on the switch 2 After the home switch closes the axis decelerates to a stop on the marker pulse NOTE For any amount of travel that exists in the minus direction of the home switch point the home switch must remain closed The home switch dog must be at least as long as the reverse travel distance from the home switch to the reading of the marker pulse Home Z Switch Home Position Figure 3 4 Axis Homing Routine The zero pulse appears once in each motor revolution The function of the Home Limit switch is to indicate the specific motor revolution in which the zero pulse is used DOK CONTRL DCL A DLC G AWO3 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 9 In the homing procedure regardless of the beginning position the slide must stop on the Home Limit switch closing it The next zero pulse after the closing of the Home Limit switch indicates the reference position In many cases some position other than home such as the center line of the machine is used as the reference position for machining All programmed distances are then specified in reference to this point This is establ
154. block JSR 345 Jump to Subroutine JST 345 Jump and Stop JTK 345 1 Jump in Task task interrupt KDI 200 100 1 Copy Position Difference MOM 1 123 123 12 123 Torque Reduction 12 Select M Function NOP Blank Block no operation PBK _ 1 Position Break PFA 1 12345 678 999 Absolute Position Feed to Positive Stop PFl 1 12345 678 999 Incremental Position Feed to Positive Stop 1 12345 678 999 Position Absolute Feed POI 1 12345 678 999 Position Incremental Feed POM 1 0 Incremental Feed to Decade Switch Position PSA 1 12345 678 999 Absolute Feed with Position Acknowledgment PSI 1 12345 678 999 Incremental Feed with Position Acknowledge PSM 1 0 Feed to Decade Switch Pos w Acknowledge PST 1 01 12345 678 Position Test REF 1 0 999 12 Detect Registration Mark Input REP 345 123456 Registration Search Limit Branch RMI 0 01 Registration Mark Interrupt RSV 1 000 100000 Restart Vector RTS Return from Subroutine 1 0 12345 678 Set Absolute Counter SIN_1__07_12 345_123 Sine Oscillation 501 1 1 07 999 Scanning of Inputs and Modifying Length STH 0 001 Send to Host STO 123 1 2 1234 12 Send Information to Outputs VCA_1_ 12345 678_999 Velocity Change Absolute VCC 1 12345 678 999 Velocity Change VEO
155. broutine level in Task 2 only 4 Setsubroutine stack to this level 0 sets stack to zero See Note below 1 92 change subroutine stack level from one to nine levels The starting block for Task 2 is set up in Parameter B006 Start Task 2 amp 3 Task 1 programming does not need to be set up in parameters The CST command is used to change to different subroutine stack levels It is used in conjunction with JSR and RTS Task 1 and Task 2 have a maximum number of nine stack levels that can be changed in a single CST command The CST command can be used in subroutines to allow for more functions when program space is limited After using a CST command to correct a stack the next RTS command will jump the program beyond undesirable subroutines to a selected level Note If the stack is set to zero an RTS command cannot be used as this becomes the programs main level If an RTS command is used after setting the stack to zero the error RTS Nesting will occur Example The following example shows the program flow and the CST command Subroutine level 3 block E0309 CST 1 1 is used to change the subroutine stack level to level 1 in Task 1 MATH LEVEL SUBROUTINE LEVELS 000 Level 2 Level 1 E110 JSR 200 E307 505 01 1 E025 JSR 100 E240 JSR 300 9 JMP 000 Figure 5 1 Program Flow CST Command Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 e Indramat 5 42 Programming DLC A and
156. c mode of operation The DLC offers a great deal of flexibility in customizing the homing routine to compensate for backlash forward moving only applications homing to a switch or a variety of other needs Registration control maintains each position as close as possible to a registration mark printed on the material This ensures that printed patterns are kept in alignment with the finished product Registration accuracy is limited to 1 millisecond input acknowledgment time RS 232 485 Serial Interface A multi format serial interface allows communication with a programmable logic controller a Indramat IDS or SOT a personal computer or other host device All information normally entered with optional CTA display can be communicated over the RS 232 485 Serial Interface at rates of up to 19200 Baud CTA Remote Keypad Display Rexroth Indramat The CTA is a remote keypad display which is mounted separately from the DLC The DLC Digital AC Servo System is panel mounted inside a DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G General Description 1 9 cabinet with the CTA separately mounted on the cabinet surface When using CTA 01 3 B with backlit display the maximum distance from the DLC card is 30 feet When using 01 3 N with non backlit display the maximum distance from the DLC card is 90 feet Optional IDS Module An optional thumbwheel switch module IDS with two digit seven segment display illust
157. cceleration DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 31 Parameter A123 Follow Axis Measuring Wheel Mode Requires DEF Card Note This parameter s function is changed as of software version DAO1 1 01 2 Followaxis A123 400000 00 4 Mode 0 Normal Feed Axis 2 Follow axis only DEF card 3 Measuring wheel mode Version 1 Control with measuring encoder 4 Measuring wheel mode Version 2 Measuring encoder as feed correction only DEF card 5 Feed axis with external encoder DEF card necessary 6 Feed axis controlled 0 For follow axis only DEF 1 Axis 1 follows external encoder 1 parameters B016 to B019 2 Axis 1 follows external encoder 2 parameters B020 to 023 For measuring wheel mode only DEF card 1 Measuring wheel with external encoder 1 Parameters B016 to B019 2 Measuring wheel with external encoder 2 Parameters B020 to B023 For feed axis with external encoder 1 External encoder 1 Parameters B016 to B019 2 External encoder 2 Parameters B020 to B023 0 Not Used 0 Not Used 00 For measuring wheel mode and feed axis with external encoder Monitoring window in percent 00 to 99 between motor encoder and external encoder 00 Monitoring switched OFF 00 For measuring wheel mode Input Encoder active Input 01 to 37 00 Encoder always active Note The DEF Incremental Encoder Input Card must be installed in
158. cceleration rate NOTE The axis cannot be jogged when this input is low Jog Forward DEA 4 Connector X17 pin 6 for Axis 1 Function Input Jogs the axis in the forward direction 24 In Manual Mode the axis feeds forward at the velocity set in Parameters A101 The axis will feed forward as long as the high signal is present switch held closed 0 In Manual Mode the axis stops feeding forward when a low signal is present switch is released This input is typically wired to a normally open push button switch on the user control panel Jog Forward is not functional when the DLC is in the Parameter or Automatic Mode Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 3 18 Functional Description of DEA 4 I O Connections DLC A and DLC G Jog Reverse Clear External DEA 4 Connector X17 pin 7 for Axis 1 Function Input Jogs the axis in the reverse direction 24 In Manual Mode the axis feeds in the reverse direction at the velocity set in Parameters A101 The axis will feed in reverse as long as the high signal is present switch held closed 0 In Manual Mode the axis stops feeding reverse when a low signal is present switch is released This input is typically wired to a normally open push button switch on the user control panel Jog Reverse is not functional when the DLC is in the Parameter or Automatic Mode DEA 4 Connector X17 pin 8
159. change this rate on the fly it will take effect starting with the next positioning command A change in acceleration can only take affect if the feed comes to a complete stop The change will not take affect if a feed is currently in progress The acceleration rate remains in effect for every positioning command until it is changed via another ACC command If the DLC is taken out of Automatic Mode the acceleration rate resets to the value programmed in the acceleration parameter A102 Note You can use the ACC command or Parameter A117 Knee Point Second Acceleration but not both When using one the other does not function Example 0000 NOP No operation 0001 1 750 Change the acceleration rate to 75 0 of A102 axis 1 0002 PSI 1 00100 000 999 axis 1 incremental feed with acknowledgment of 100 000 at max speed 0003 WAI 00 50 Wait allows for axis motion to completely stop 0004 1 999 Change the acceleration back to max the value set in A102 0005 JST 0001 Jump and stop to block 0001 10 Input Units desired unit of measure for positioning Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 5 12 Programming DLC A and DLC G AEA Auxiliary Output ON OFF E 0020 AEA 07 0 07 Auxiliary output number 01 99 0 Output state 0 turn output Off 1 turn output On The AEA command is used to set the state of any single auxiliary output Stepping to the next block occurs im
160. ck 0000 for task 1 Note that task 2 and task 3 programs start at the block number assigned by the user in parameter BOO6 If block 0000 is not displayed press the CR key until the cursor is positioned on the first digit of the block number Type the number 0000 to display that block number To enter or change a program command for each block first press the right arrow key until the cursor moves to the right of the three digit program command mnemonic i e NOP Press the up or down arrow keys to increment or decrement through the commands alphabetically When the desired command appears on the screen press the right arrow key The cursor moves to the beginning of the second line where the data fields appear specifically for the selected command If this block was not previously programmed with this same command asterisks appear in the digit positions where data must be entered After entering and verifying the program block press the Store key to save the programmed block to memory The next program block number automatically appears waiting to be programmed Continue this process until all lines of user program are done Note that the program can be edited or added to at a later time When changing data from the Edit screen pressing the CR key before pressing the Store key will cancel the change and leave the data as previously stored saved The display remains at the same block number and the cursor moves to the first positi
161. ck sum if enabled in parameter 004 CrLf Carriage Return Line Feed DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Serial Interface 7 9 Parameter Set Code yy Parameter Number xx General parameter BO 00 to 15 Axis 1 parameter A1 00 to 25 Drive Parameter CO 00 to 12 M Function MH or ML 00 to 63 Tool Corrections DO 01 to 19 Note The DLC must be in Parameter Mode before sending parameter information or an error will be issued 7 7 Alphabetical Listing of Commands ACC 1 999 Acceleration Change AEA 07 1 Auxiliary Output ON OFF AKN 07 1 Acknowledge Single Input AKP 0 0001112220 Parallel Acknowledgment Input APE _ 0 0001112220 Parallel Outputs ON OFF APJ 123 4 0001112220 Set Parallel Outputs then Jump ATS 07 1 Output State Monitor 345 1234 12345 Branch And Count BCA_345 07 1 Output Dependent Conditional Branch BCB 345 20 1 Binary Input Conditional Branch BCD 345 20 BCD Dependent Conditional Branch BCE 345 07 1 Input Dependent Conditional Branch 1234 20 15 3 0 Branch Input Output Compare BIO 345 1 0001112220 Branch Input Output Compare 100 10 04 8 Binary Output Dependent Conditional Branch BPA 345 1 0001112220 Branch on Parallel Outputs 345 1 0001112220 Branch on Parallel Inputs BPT 345 2
162. code and message from the DLC serial communications port Connector X31 to the host device The error code and message are transmitted with the status number 01 Refer to the Serial Interface Chapter 7 for information on formats and how status 01 operates The DLC serial communication errors are as follows Error Message Code Block Too Large 01 12 The program block number transmitted to the DLC was too large 1 Verify that the block number is between 0000 and 2999 2 Referto Chapter 7 Section 7 6 1 for the correct format Error Message Code Invalid Mode 01 05 An attempt was made to transmit parameter information without first selecting Parameter mode Verify that Parameter mode is selected before transmitting parameter information to the DLC Error Message Code Invalid P Block 01 11 The parameter format transmitted to the DLC was incorrect 1 Verify that the parameter format is transmitted correctly to the DLC 2 Referto Chapter 7 Section 7 6 2 for the correct format Error Message Code Invalid Prg Command 01 13 The program command being transmitted to the DLC is invalid It is not included in the list of programming commands found in Chapter 5 1 Verify that the program command being transmitted to the DLC is listed in Chapter 5 2 Verify that the command was entered correctly See Chapter 7 Section 7 6 1 for the proper format
163. covery procedure is to first troubleshoot and remedy the problem Then press the Clear key on the DLC control panel or external Clear input on user control panel see section 3 2 6 to clear the DLC fault status and diagnostic message on the display DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 7 Normal Operation Signals Inputs Cycle Start 3 3 Cycle Stop 3 3 The automatic execution of the user program begins when the Cycle Start line goes high momentary with the DLC in Automatic Mode Once the automatic cycle begins it is normally stopped by actuating the Cycle Stop input signal goes low The system will also stop if an error is detected or if the DLC is switched to Manual Mode Outputs Axis Nearing Position Pre Signal A107 Axis In Position A106 An auxiliary output Position Pre signal can be assigned in parameter A107 to turn ON when the axis position is at a specified distance in input units from the target position of the commanded feed Use this pre signal when there is a need to anticipate the end of a feed so another process can be initiated ahead of time An example use would be to turn on a heater for bag sealing or plastic thermal forming operations See Chapter 4 for further information on this parameter function An auxiliary output Axis In Position can be assigned in parameter A106 to turn ON when the axis position is within the po
164. cribed for the REF command and stepping to the next block takes place The target block should be the start of a recovery routine written to restore operation from a missed mark It will need to be customized for each application Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 78 Programming DLC A and DLC G The following command combinations are permitted 1 Reference position travel without driving to an offset dimension and without search distance limiting REF 1 0 050 05 2 Reference position travel driving to an offset dimension without search distance limiting REF 1 0 50 10 PSI 1 000200 00 100 3 Reference position travel is programmed in the REF command Limiting to max 500 mm is programmed in the REP command REF 1 0 100 12 REP 0900 1 000500 4 Reference position travel with search distance limiting and offset dimension REF 1 1 222 11 REP 0900 1 POI 1 000123 00 99 Reference position travel is programmed in the REF command Limiting to max 900 mm is programmed in the REP command An offset dimension of 123 mm is programmed in the POI command The REP command and the feed POI or PSI possible are processed in the same controller cycle as the REF command Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 79 RMI Registration Mark Interrupt E 0300 RMI 0 01 This command can be used to initiate additional processing ind
165. d The status of the inputs and outputs after processing the M function are defined in the M Function table found in Section 4 6 of Chapter 4 The table of M functions is specified in parameters only and can be modified by the CTA keyboard or serially through the RS 232 RS 485 port Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 65 NOP No Operation Blank Block E 0021 NOP This is the command to describe a blank block During processing in the automatic mode this blank block is scanned only processing continues with the next block NOP s can be used to reserve program block space for future program change and expansion Also use NOP s in the program where you may want to add commands on the fly to modify production NOP s may also be used as a program delay for each block Note that the smallest delay programmable in the WAI command is 10 milliseconds The NOP command allows for smaller increments of delay The default delay time for each NOP block is 1 millisecond Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 66 Programming DLC A and DLC G PBK Positioning Interrupt E 0055 PBK 1 1 Axis 1 The PBK command stops the execution of the current motion profile The axis is braked to a controlled stop The axis will decelerate using the current programmed acceleration deceleration rate The remaining distance to be traveled is ignored If continuous oper
166. d the digital drive Write down the current configuration and DLC firmware installed and contact the Indramat Service Department for more information Error Message Code Drive 1 Not Ready 40 The digital drive being used did not allow the main contactor to energize allowing 3 phase power to be applied 1 An error has occurred in the Indramat digital drive See the specific Indramat drive manual to determine the cause for the fault in the drive 2 The digital drive does not have power applied Verify the power to the digital drive is correctly wired and the proper inputs are applied to bring up main power Rexroth Indramat 8 4 Diagnostics And Troubleshooting Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Rexroth Indramat DLC A and DLC G Error Message Code Drive Runaway A1 42 The DLC uses a mathematical model to calculate the normal following error expected This diagnostic will occur when the actual following error exceeds the calculated following error by a percentage greater than that which is programmed in parameter A122 1 The motor physically moved without being commanded to move 2 The Monitoring Window percentage parameter A122 is too small The typical setting is 10 Error Message Code Emergency Stop
167. de push button or PLC output 00 Manual Mode homing not used 01 37 Selected input number to be used to initiate Homing 12 Home Zero Reference Select Marker Pulse or Home Switch 00 Homing to Marker Pulse for Single Turn Absolute Feedback Homing Speed for Homing to Marker Pulse is 3 of Max Velocity 01 37 Selected input number to be used for home switch input Note The standard DLC with the DEA 4 I O card has a maximum of 7 auxiliary inputs that are physically accessible to the user With the optional DEA 5 and 6 I O cards the auxiliary inputs are expanded to 37 00 Unassigned 13 Auxiliary output number to be used for Home Established signal Note The standard DLC with the DEA 4 I O card has a maximum of 11 auxiliary outputs that are physically accessible to the user With the optional DEA 5 and 6 I O cards the auxiliary outputs are expanded to 43 For multi turn absolute feedback operation A112 should be set to 00000000 Note The auxiliary output for Homing complete established can be turned OFF with an AEA command output ON OFF The travel limits will remain in effect still referenced to home Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 20 Parameters DLC A and DLC G Parameter A113 Travel Limit Minimum Value Min Travel A113 01234 567 This parameter specifies the travel limit value in the negative direction in reference to the Home Position The limit is effective o
168. de or a ballscrew driven axis The switches should be wired to the Cycle Stop input of the DLC You must reserve distance beyond the limit switches to allow for the axis to decelerate to a stop DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 11 Manual Mode Operations Inputs e Jog Forward 3 3 e Jog Reverse 3 3 e initiate Manual Vector Program B011 The Jog inputs allow the axis to jog in the forward or reverse direction Parameter A101 specifies the axis jog feed rate for Axis 1 It usually is set to approximately 10 of the maximum feed rate It can never be more than the maximum feed rate In Manual Mode the axis can be jogged forward or reverse The Jog inputs are not functional in Parameter or Automatic Modes A high on the Jog Forward input causes the axis to feed forward at the velocity set in parameter A101 The feed continues as long as the Jog Forward remains high The Jog Reverse operates similarly jogging the axis in the reverse direction In order to make use of the software travel limits when in Manual Mode the axis must be homed first It is recommended to prevent jogging by interlocking with the Home Established output A112 until the axis home position is established An auxiliary input Initiate Manual Vector Program can be assigned in parameter B011 and used to initiate a user program to run in Manual Mode This program must not contain
169. digital controller If all connections are correct the H1 status will be bb If the diagnostic is not bb consult the digital controller manual for information on how to correct the problem The CTA display should also display no errors Consult Chapter 8 Diagnostics And Troubleshooting for more information on how to correct the problem The DLC Digital Servo Systems is ready for drive amp system parameters to be installed 6 12 Digital AC Servo Amplifier Parameter Entry The Indramat Digital AC Servo Amplifier contains an RS232 interface Connector X2 This interface gives you information regarding the status of the drive and allows you to read and adjust all the amplifier s system parameters The RS232 interface provides screens and menus which are accessible via a VT 100 terminal or a PC computer with a VT100 emulator e g Procomm Windows 3 1 etc The communication settings are as follows Baud Rate 9600 Parity None Data Bits 8 Stop Bits 1 Connect the VT 100 terminal or PC with VT 100 terminal emulation software to the Digital AC Servo Amplifier to connector X2 via an IN 391 cable and press the lt Enter gt key This will bring up the Main Menu screen Note Digital drive parameters can also be set with the CTA keypad If using the keypad for drive parameter entry skip this section and refer to Chapter 4 Changing The Display Language Rexroth Indramat In order to change the language displayed on t
170. e C 6 DKS DLC A MDD Interconnection Sheet 6 of 10 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat C 8 Drawings and Schematics DLC A and DLC G NING NUMSE DRAY STATES IL HOFFMAI E rk oz lt x t ua rz b1162 7 wmf Figure C 7 DKS DLC A MDD Interconnection Sheet 7 of 10 Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Drawings and Schematics C 9 AWING NUMBER DR TES REXROTH INDRAMAT b1162 8 wmf Figure C 8 DKS DLC A MDD Interconnection Sheet 8 of 10 Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat C 10 Drawings and Schematics DLC A and DLC G PART NUMBE REXROTH OPTIONA DS PANE OF TH TH b1162 9 wmf Figure C 9 DKS DLC A MDD Interconnection Sheet 9 of 10 Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Drawings and Schematics C 11 IOFFMAN ESTA REXROTH INDRAMAT b1162 10 wmf Figure C 10 DKS DLC A MDD Interconnection Sheet 10 of 10 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat C 12 Drawings and
171. e runs on any DOS based computer ScreenManager is used to create application specific screens for the SOT With ScreenManager the operator can view or edit machine information on the SOT screen in easy to read useful information for each specific application The SOT connects to the serial communications port of the DLC and can be mounted up to 3000 feet away when configured for RS 485 communication An SOT User s Guide is provided with the option Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 1 10 General Description DLC A and DLC G Figure 1 4 SOT Station Operator Terminal MotionManager Option The MotionManager software development tool is an efficient method of creating and editing executable user programs for the DLC control This user friendly software package runs on any DOS based computer It provides several benefits over programming the DLC from the CTA keypad display It also includes enhanced features for creating and editing programs that are not possible from the CTA keypad display Optional CTA 10 User Interface The CTA 10 is an optional user interface that can be used as a front end when a system contains multiple DLC cards The serial port of the DLC must be configured as an RS485 station by using the CTA 4 keypad and an IKS745 cable For more information refer to the CTA 10 DL 1 User Manual IMD RAR
172. e six aux outputs to the desired states The first of six consecutive aux outputs to be changed is entered in the program block The DLC then advances to the next program block Due to the scan time the delay of setting the output states compared to the axis position takes 1 millisecond Therefore the actual position of the axis when the outputs are set can vary with the present velocity of the axis The formula used to calculate the accuracy of the outputs is Speed in EGE sec x 1 msec 1000 If the axis has been homed all test positions are taken in reference to the current absolute position If the axis has not been homed the test position is taken in reference to the last incremental feed Rexroth Indramat DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 37 Set up A116 for Rotary Table A108 for 360 degree feed constant and the system implements an incremental encoder for position feedback 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 CLA APE CON COC COC COC COC COC COC COC JMP 1 0 2000000222 1 001 00 00 221122 01 022222 01 220222 01 222022 01 212222 01 202222 01 122222 0003 365 040 150 180 305 4335 352 Sets actual position counter for axis 1 to zero initializes axis Sets all cam outputs aux outputs 1 through 6 to
173. eak Error 8 11 13 IDS Checksum Error 8 11 14 IDS Format Error 8 12 15 IDS Data Too Long 8 12 16 Axis No False 8 4 18 Software Combination 8 18 1A Configuration 8 6 1B DLC Watch Dog 8 6 1C DPR Error 8 7 20 M Command 8 24 21 M Command 0 1 8 25 22 Malfunction SO1 Command 8 25 23 G01 without F 8 24 24 No G60 8 26 40 Drive 1 Not Ready 8 7 41 Feed Angle Loss 1 8 10 42 Drive Runaway A1 8 8 43 Excess Pos Lag 1 8 9 45 Abs Range 8 3 46 Min Travel Lmt 1 8 15 47 Max Travel Lmt 1 8 15 48 Axis 1 Not Homed 8 4 4B Home Switch Pos 8 10 4 Encoder Fault 8 9 Table 8 2 DLC A Diagnostics Sorted by Code DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Indramat 8 16 Diagnostics And Troubleshooting DLC A and DLC G Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming Notes A 1 Programming Notes This section is periodically updated with hints and examples of use and application of different programming commands Notes included in this section Page Description A 1 Axis Homing for the DLC A 1 Axis Homing for the DLC General Homing of a linear or rotary axis is required if you need to do absolute positioning and are using an incremental position feedback device mounted on the motor or machine The homing process usually a series of back and forth moves to locate a reference point in relation to a mechanical setup can be accomplished through a varie
174. ed by the user for controlling and acknowledging machine functions The expanded configuration for the DLC DEA 4 DEA 5 DEA 6 with DKS Digital Compact Drive illustrated in Figure 1 6 expands the auxiliary inputs to 37 and auxiliary outputs to 43 The functional description of the I O signal connections is described in Chapter 3 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 1 12 General Description DLC A and DLC G DLC Control Card DEA 5 Input Output Card Optional DEA 4 Input Output Card DEA 6 Input Output Card Optional Figure 1 7 Expanded I O Configuration Of DKS With DLC Control Card DEA 4 5 6 I O card Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G General Description 1 13 Standard Configuration Of DKS With DLC Control Card DEA 4 Input Output Card And Optional DEF 1 Incremental Encoder Interface Card The DLC Control Card plugs into the U1 slot and the DEA 4 Input Output Card plugs into the U2 slot of the Indramat Digital Drive The optional DEF 1 incremental encoder interface card
175. ediate stop without error Emergency Stop will cause an immediate stop also but will cause a fault to be displayed De actuate the E stop switch and press the CL clear key on the CTA keypad to clear the fault to allow restarting the operation Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 6 12 Installation Start Up DLC A and DLC G Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Serial Interface 7 1 7 Serial Interface The DLC Control Card includes multi format RS 232 485 port for two way communication of programs parameters and system status between the DLC and a host device The interface protocol is designed to easily transmit and receive data to and from the DLC This chapter describes the protocol and other communication requirements The host device must strictly adhere to the communications format as described in this chapter to achieve proper communication or one of several RS Format Errors will be returned through the port or indicated on the control status display see Figure 2 2 for a map of displays indicating that the information was not properly formatted or understood User programs Block information can be downloaded to the DLC when it is in any mode of operation Auto Manual or Parameter The same is true for system status System parameters can be downloaded to the DLC only when it is in Parameter Mode If attempted in any other mode the host recei
176. election 1 use auxiliary inputs 1 4 4 3 2 1 25 2 2 2 8 4 2 1 Input Bank Selection 2 use auxiliary inputs 5 8 8 7 6 5 25 2 2 2 8 4 2 1 With input bank selection 1 or 2 a total of 15 targets is possible Input Bank Selection 3 use auxiliary inputs 1 8 8 7 6 5 4 3 2 1 27 2 2 24 23 2 2 2 128 64 32 16 8 4 2 1 With input bank selection 3 a total of 256 targets is possible Note There is no Invalid Program Command diagnostic if this command is programmed to exceed block 2999 That is because the destination block is dependent on the value determined from aux inputs relative to the Binary Input Value selected However an Invalid Block diagnostic is issued when the BCB command is executed and the destination block exceeds program block 2999 DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 23 BCD Binary Coded Decimal Conditional Branch Inputs E 0900 BCD 0100 12 Aux Inputs BCD Significance Aux Inputs BCD Input Decimal Equivalent Target Block Aux Inputs BCD Input Decimal Equivalent Target Block 0100 Block Offset 0000 2999 12 Length of jump The BCD command executes a jump which has been defined by means of BCD Binary Coded Decimal inputs at the auxiliary inputs 1 to 8 The target block is calculated as follows Target Block Offset BCD Input Value x Length of Jump The BCD Input Value should be converted to a decimal
177. en feeding at a lower speed the following error will be lower but the maximum deviation from the expected following error will still be 0 16 inches Note the following e f you change the parameters Position Gain or Maximum Velocity you do not need to reprogram the Monitoring Window because it is entered in percentage of maximum position deviation e f the Monitoring Window entry as converted is smaller than the Position Tolerance the DLC is unable to correctly distinguish between Drive Runaway and Excessive Position Lag Therefore the converted Monitoring Window parameter should be greater than the Position Tolerance e f the programmed entry for Monitoring Window is too small even a normal feed will generate a Drive Runaway or Excessive Position Lag e The Monitoring Window value depends on your application You should enter the lowest percentage possible that will not cause nuisance faults Possible causes for Drive Runaway e The axis moved when no command value has been output e The maximum RPM in A121 is smaller than specified RPM check the DSM software module e A122 entry is too small typical setting is 10 Possible causes for Excessive Position Lag e Position command issued but no movement detected e The motor cannot turn because of a mechanical bind e The maximum RPM in A121 is greater than specified RPM check the DSM software module e The acceleration is too great A102 also A117 second a
178. engineering mannesmann Rexroth DLC Single Axis Control Card for Firmware Versions DA and DG User Manual Rexroth DOK CONTRL DLG A DLC G AW03 AE P o Indramat About this Documentation Title Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Rexroth Indramat Record of Revisions Copyright Validity Published by DLC A and DLC G DLC Single Axis Control Card for Firmware Versions DA and DG User Manual DOK CONTRL DLC A DLC G AW03 AE P 12 99 e DLC A DLC G User Manual e 120 0400 B324 03 AE e Part No 286834 This documentation is written for both operating personnel and the machine builder It explains how to interface install set up and operate the Indramat DLC Positioning Control with DA or DG software Description Release Date inta Release 5194 Updated added Parameters 7 95 Rev B Updated Commands Updated added Status Codes Updated rearranged Error Codes Added Alphabetical and Numerical Tables of Error Codes Deleted Appendix C DLC Program Commands Format Deleted Appendix D Parameter Input Sheets Combine DLC A Pub 68000 and 12 99 Rev C DLC G Pub 68006 Manuals Parameter additions and changes 1999 Mannesmann Rexroth Indramat Copying this document giving it to others and the use or communication of the c
179. ependently of the positioning program The additional registration mark processing is inititated after the recognition of an input pulse and after an offset has been traversed The startup signal edge of the pulse is evaluated The positioning program is interrupted for this registration mark processing and subsequently continued 0 Mode 0 Wait for pulse at the registration mark input stepping to the next block takes place after recognition of the pulse and traversing the offset 1 Terminate registration mark processing continue program stepping to the next block takes place immediately 01 Registration mark input 00 No registration mark selected 01 16 Standard auxiliary input recognition in approx 1 msec The registration mark program has to be programmed in Task 2 An offset can be programmed in the form of an incremental position command POI PSI POM or PSM The incremental position command has to follow the RMI command directly Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 5 80 Programming Rexroth Indramat DLC A and DLC G Example of application Perforated sheet metal should be cut according to the location of the perforations which are stamped into the flat sheet metal on the stamping table The material is then fed through the pass rolling mill A hole serves as a reference signal for recognition of the registration mark Since an unknown change of length occurs during profiling the
180. er A123 is programmed with 4100XXXX the Measuring Wheel Version 2 is selected In Automatic Mode the Measuring Wheel Version 2 will close the position loop on the axis The axis position is compared to the measuring wheel encoder position and the difference is compensated for during the axis move When the axis is in the in position tolerance window defined in parameter A106 Position Tolerance no compensation for the difference will occur Compensation for the difference occurs when the axis is commanded out of the position tolerance window This allows a degree of backlash in the mechanical System without effecting the stability of the servo The following formula should be used when using this option to get optimum results Acceleration rate Gain x16 66 When using the Measuring Wheel Version 1 3100XXXX or Version 2 4100XXXX the machine builder can program a percentage of deviation and an auxiliary input to enable the measuring wheel function The percentage of deviation defines how much difference between the measuring wheel encoder position and the axis position will be allowed When the difference becomes greater than this percentage the error Encoder Fault A1 will occur Position Tolerance Note If 00 is specified for the percent deviation there will be no comparison between the measuring wheel position and the motor s position DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 33 Par
181. er Set Parameter Set Continued A101 Jog Velocity B008 M Function DG only A102 Accel Rate B009 M Function Timer DG only A103 Position Gain B010 Free A104 Encoder Resolution B011 Manual Vector A107 Pos Pre signal B014 Restart Vector A108 Feed Constant B015 Cycle Time A110 Homing Setup B017 External Encoder 1 Lines Rev A111 Homing Offset B018 External Encoder 1Feed Constant A112 Homing Ack B019 External Encoder 1 Offset kenn S S ree me fre 771 700 A123 Follow Axis C003 Position Data Scaling A Output A124 C004 Velocity Data Scaling A Output abst Encore Rterence Postion 090 PaamerSeB Table 4 1 Parameter List A126 Position Window C006 Position Velocity Window Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 3 4 3 Entering the Parameters The DLC must be in Parameter Mode to enter or edit parameters on the CTA keypad The E Stop signal must be present 24 Vdc at DEA 4 connector X17 pin 3 The Parameter Mode is normally selected via a keyswitch on the user control panel to prevent unauthorized changes to the parameter values Parameters are entered or changed by writing over any previous data and pressing the Store Key These changes are made through the CTA keypad or via a serial interfaced host device A Lithium backup battery assures this memory is retained when the DLC is powered down or
182. ermined based on the desired intermittent torque and duty cycle of the system Consult the Indramat Digital Amplifier Selection List for the proper Overload Factor Value For the purpose of testing the DLC with the Indramat Amplifier set the Overload Factor to 10096 Position the cursor to the right of the Overload Factor and type 100 then hit enter Position Data Scaling at the Analog Output Degrees 10V When the position values are selected for either of the analog outputs the Position Data Scaling defines a zero to ten volt linear scaling based upon the angle of the motor s rotor position For example if 360 degrees were entered one revolution of the motor would provide one linear voltage ramp from 0 to 10V Position the cursor to the right of the Position Data Scaling and type in the desired degrees Typically 360 degrees is entered Velocity Data Scaling At The Analog Output RPM 10V When the velocity values are selected for either of the analog outputs the Velocity Data Scaling defines a zero to ten volts linear scaling based upon the velocity of the motor in RPM For example if the Bipolar Velocity Limit is 3000 RPM then when the motor is operating at 1500 RPM 5 volts will be the output 1 Position the cursor to the right of the Velocity Data Scaling and type in the desired velocity per 10 Volts Typically the value entered here is the same value entered in the Bipolar Velocity Limit Value 2 Press lt ESC gt to r
183. errupted it cannot be resumed It must be started over Interrupt vector only interrupts Task 1 Task 2 amp 3 continue to run The Interrupt Vector can be called up only in Automatic operation The Cycle Start and Cycle Stop remain effective The sub program stack JSR RTS is cleared each time the Interrupt Vector program is called up A call to the Interrupt Vector while a sub program is running xxOxxxxx is stored in B012 until all sub programs have been processed Only then will the program continue with the Interrupt Vector program Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 51 Parameter B013 Velocity Override as of software version DLC1 1 DA1 04V00 Override B013 5 0 000000 5 Axis Velocity Override 0 Override off 4 Override per Interbus S object axis 1 only 5 Override binary encoded through inputs 01 07 6 Override gray coded inputs 04 07 7 Override binary coded over 15 inputs 8 22 as of software version 04V08 0 Override Axis 2 000000 Unused set to 000000 The Velocity Override parameter allows the machine builder to change the velocity anytime The velocity can be changed by a binary input using auxiliary inputs 1 through 7 or by gray code inputs using auxiliary inputs 4 through 7 Gray Code Override The following input assignments result in the noted speed Note the velocity in the right column enter the respective number on
184. es the connectors on the DLC DEA 4 1 plug in cards Refer to Figure 1 5 in Chapter 1 for an illustration of the DLC DEA 4 1 card and its connector locations in the DKS X17 DEA 4 1 System Auxiliary Input Output Cable Cable 04 0123 X30 CTA Keypad amp Display Female 34 pin shielded ribbon cable connected to the front panel of the DLC The cable is an IKS 745 and its standard length is 2 meters It connects from the DLC to the back of the CTA Refer to the DKS DLC interconnects in Appendix C for the proper orientation of the IKS 745 cable X31 RS 232 485 Communications Port Interface Female DB 9 connector is located on the lower front panel of the DLC It is used for serial communication between the DLC and a host terminal SOT or the IDS option Refer to Chapter 7 for description of this multi functional two way communications port 6 7 Pre Operation Start Up Tests 6 8 Connections The following sections are intended to provide the user with an example of a DLC Digital AC Servo System start up They provide an example of a single axis application that will verify proper function of the system WARNING The information given in the following sections may not be suitable for a specific application If you use this example for testing do not mechanically connect the servomotor to the actual load Note Do not apply power until all connections have been made Refer to the drawings in Appendixes C and D for mounting and co
185. essing the down arrow key from any screen in the Row C changes to the Counter Screen on Row D It show the status of the counter now executing in the selected block number A _0104 Counter 000003 000005 Counter Screen Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Controls and Indicators 2 7 Row E Refer to the Display in Figure 2 2 Pressing the down arrow key from the display in Row D changes to the Axis Information Screen in Row E The Axis Information Screen consists of the axis position axis following error and the remaining distance to be positioned Pressing the right arrow key causes the Speed of Axis 1 to be displayed This screen will display the commanded and actual speed of the axis in revolutions per minute RPM Axis 1 Iner Speed Axis 1 Pos 00001 000 FE 00000 010 Com 0500 RPM Rem 00000 000 Act 0500 RPM Axis 1 Information Motor Speed of Axis 1 Row F Refer to the Display in Figure 2 2 Press the down arrow key from any display in Row E to see the Current Program Status If the DLC is in Manual Mode a M appears on the screen along with the status of Task 1 2 and 3 Use the left right arrow keys to toggle between this screen and the Axis 1 Enabled screen Progr Status Task 1 0091 BCE Task 2 0366 VCC Task 3 0901 BCE e Manual Al Init Manual Mode Task Screen Axis Enabled Screen When the DLC is in Automatic Mode
186. et Count desired is normally 100 At this time the Actual Count is 50 However you desire only 20 more pieces 70 total Program the BAC block as follows The Offset Number data field should be programmed with a 0030 E 0600 BAC 1500 0030 00100 When you press the Store key the Actual Count is set to 80 when viewing the Counter Display screen Therefore the Preset Count is reached after 20 counts resulting in 70 total parts All times after that the counter starts at 000000 resulting in 100 increments The same holds true if a negative number is entered in the Offset Number data field of the BAC program block Using the same example as above if an Offset Number of lt 0030 gt was entered the Actual Count starts at 20 Therefore 80 increments are encountered before the 100 Preset Count is achieved Thereafter the Actual Count begins at 000000 If a negative Offset Number entered is greater than the Actual Count the Actual Count will be set to zero The Actual Count cannot be set to a negative value set to do less than zero increments An example use for this command would be when you need to make up for bad parts Let s say you had a jam reached the end of the roll of material or for some other reason you have five defective parts Now instead of 100 parts you need 105 parts to make your production quota There are two things that can be done to the program block containing the BAC command The Preset Count can be c
187. et to 000 120 00 Volts Amp Minimum 001 00 030 00 Maximum 015 00 300 00 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 72 Parameters DLC A and DLC G Parameter C010 Velocity Loop Proportional Gain as of software version DAO1 1 01 6 Velocity Loop P Gain C010 00000800 000 Not used must be set to 000 00800 mAsec rad 00000 65000 Rexroth Indramat DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Parameters 4 73 Parameter C011 Velocity Loop Integral Reaction Time as of software version DA01 1 01 6 Velocity Loop I_Reaction Time C011 0002500 0 000 Not used must be set to 000 2500 0 msec 0000 1 6500 0 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 74 Parameters DLC A and DLC G Parameter C012 Smoothing Time Constant as of software version DAO1 1 01 6 Smoothing Time Constant C012 00000600 000 Not used must be set to 000 00600 us 00250 65000 Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 75 Parameter C013 External Brake Release External Brake Release C013 00000001 0000000 Not used 1 Enable External Brake Release function in the drive Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 76 Parameters DLC A and DLC G Parameter C100 Set Standard Drive Tuning Parameters Via CTA as of software version DAO1 1 01 6 Rexroth
188. etd aed Ls 3 11 Fault Diagnostico Monitorning ssassn ccs Fee Ce ee ee estu eua Rte Fue ue lob eO 3 12 Feed Monitoring Program 3 13 Sp cial FUNCIONS EDD 3 14 3 3 DEA 4 Input Signal Descriptions 3 15 Parameter Mode 5 3 15 Automatic Mode 5 3 15 Emergency Stop acc eCopt Serrated actos 3 16 Cycle LM E Eti 3 16 1 o 3 17 JOG 3 17 09 3 18 Clear External 2 2 dit aed dint deletes 3 18 Auxiliary Inputs 1 Through 7 eei eem eee een ee 3 18 3 4 DEA 4 Output Signal Descriptions 3 19 System Fault 3 19 Manual Mode lridiGator 2 quoe deed xa 3 19 Automatic Mode cM 3 20 Parameter Mode IndlCatOF u icit tct e tht i gerit tuin Peu di ed a 3 20 Automatic Cycle Running Indicator sese esee enne nnne nennen nnne nnns 3 20 Auxiliary Outputs 1 Through 11 3 20 4 P ramet ip Pc 4 1
189. eters A113 and A114 The absolute position programmed in the PFA command must be greater than or equal to the exact distance to the positive stop otherwise the positive stop cannot be reached The programmed absolute position can be greater than the software overtravel limits Only one PFA command can be active at one time The program flow continues immediately after one or both of the following conditions e f positive stop is not reached the next block in the program is executed The next block is typically a unconditional jump JMP command to a error routine to notify the operator that the positive stop was not reached e f the positive is reached the program flow will jump over the block immediately after the PFA command Refer to the MOM command in Chapter 5 for more information and an example of how the PFA command will operate Notes 1 The axis must be homed prior to the execution of this command 2 f the positive stop is not reached the maximum torque of the axis and the overload factor of the drive are active Warning When the MOM command is used and while positioning to a positive stop or positioned at the positive stop the overload factor in the drive is internally set to 400 percent The MOM command is the only limit for the percentage of maximum torque Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 68 Programming DLC A and DLC G PFI Incremental Position Feed To Positive Stop
190. eturn to the Parameter Menu The Absolute Encoder Parameters are automatically set by the amplifier When power is applied the amplifier reads the type of motor connected and sets the Absolute Encoder Parameters based upon a single or multi turn feedback 3 Press the number 3 error Reaction There are three types of Error Reaction to select The Error Reaction selected determines how the amplifier will react when a shutdown error occurs Typically 0 is selected as the Error Reaction 4 Press lt ESC gt to return to Parameter Menu The Torque Limits are currently not available 5 Press the number 5 Gain Parameters The Gain Parameters allow the user to adjust the velocity current loop gains of the amplifier 6 Tosetthe amplifier motor combination to standard values position the cursor to Reset To Standard Parameters and press the Enter key Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Installation Start Up 6 9 7 The following question will be displayed Are You sure Yes gt Y 8 Press the lt Y gt key on your computer to reset to standard parameters Press any other key to prevent resetting to standard parameters Note You must be in parameter mode RF disabled to reset to standard parameters 9 Press lt ESC gt to return to the Parameter Menu The amplifier s parameters entry has been completed The parameter management section allows the user to save and load the paramete
191. f 10 aux outputs Bank X gt aux outputs X0 X9 i e Bank 2 aux outputs 20 29 Bank 3 aux outputs 30 39 etc 2100122011 aux output status each of 10 as listed below 0 the output will be reset to an Off condition 1 the output will be set to an On condition 2 the output will not be changed This command can be used to simultaneously set the condition 10 auxiliary outputs of the DLC The jump to the target block takes place after all 10 auxiliary outputs meet the programmed condition Notes 1 Output 00 of Bank 0 does not exist Program this aux output with a Don t Change 2 status No error diagnostic occurs if this output is programmed with anything besides a Don t Change condition 2 The standard DLC A or DLC G with the DEA 4 system auxiliary I O card has a maximum of 11 auxiliary outputs that are physically accessible to the user The DLC A or DLC G with the DEA 5 expansion I O card has expanded auxiliary output capability of 27 outputs The DLC A or DLC G with the DEA 5 amp DEA 6 expansion I O cards has expanded auxiliary output capability of 43 outputs Warnings 1 If the Monitoring Window is turned OFF by setting flag 95 to ON the DLC will have no way of detecting if a motor has Drive Runaway or Drive Stalled 2 f motion is interrupted by setting flag 98 to ON it will resume automatically when the output is turned OFF Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and
192. feed rate in parameter A100 will be programmed in inches per second The acceleration parameter would then be in units of inches per second squared The F feedrate command calculates the feed rate for you using the formula Parameter A108 x 60 Therefore all speeds programmed using the F command are always in units per minute upm Note that positioning commands for the application program are to two or three decimal places If you require positioning to 0 001 set the decimal selection in parameter 007 to three places In general when using US System inches measurements set 007 for three decimal places When using Metric millimeters set B007 for two decimal places 4 4 Linear or Rotary Operation The DLC is capable of Linear or Rotary operation for each axis Most applications will utilize the linear method of programming i e Ball Screw Belt Slide Some applications require the special features allowed with rotary programming A116 Rotary Table Linear operation programming allows each axis minimum and maximum software over travel limits effective after the axis has been homed Motions can be programmed in any type of Input Units i e inches mm degrees etc Rotary operation programming allows each axis the capability of 360 degrees of motion The actual position screen L P Screen counts from 0 degrees to the value set in A108 resetting back to zero after each complete revolution 360 degrees Eac
193. following error can usually be minimized by slightly changing A121 RPM 10V typical adjustment is less than 2 If no Special Functions are used enter lt 00000000 gt Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 23 Parameter A116 Rotary Axis Gear Ratio Rotary Table 116 1234 5678 Use this parameter for Rotary applications This parameter sets the gear ratio of the input motor shaft to the output The rotary table option is activated in the last two digits of parameter A110 1234 Input motor shaft turns gear box input encoder 5678 Output turns gear box output table Step down ratio 1234 5678 The result per table revolution is Input units Revolution of table Feed constant x Step down ratio Examples 00010001 a 1 1 ratio 1 turn input 1 turn output 00120001 a 12 1 ratio 12 turns input 1 turn output 02300025 a 9 2 1 ratio 230 turns input 25 turns output Note Gear down only entry must be whole numbers If the ratio is decimal simply enter the number of teeth on the input and output gear shafts Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 24 Parameters DLC A and DLC G Parameter A117 Second Acceleration Rate Knee Point 117 12 00386 0 12 Velocity change point in of Velocity Max A100 Above this 96 the second acceleration turns on Knee point of acceleration change 00 Disables this
194. format of the program command was transmitted incorrectly to the DLC 1 Verify that the program command format is transmitted correctly to the DLC 2 Refer to Chapter 7 Serial Interface for the correct program command format Error Message Code RS Checksum Error 01 04 Information transmitted to the DLC with a checksum must agree with the checksum calculated by the DLC The checksum is used to verify that the information transmitted is correct and complete The checksum may be enabled disabled in the Serial Interface parameter 004 Refer to Chapter 7 Section 7 5 for more information on calculating the checksum Error Message Code RS Format Error 01 02 The information transmitted contains more characters than is allowed or a carriage return line feed is not transmitted at the end of the information 1 Verify that the information transmitted is in the proper format with a carriage return line feed 2 Refer to Chapter 7 Serial Interface for more information on the correct format Error Message Code RS Par No False 01 06 An incorrect parameter number was transmitted to the DLC 1 Verify that the parameter number that was transmitted to the DLC was formatted properly 2 Refer to Chapter 7 Section 7 6 2 for the proper format Error Message Code RS Status False 01 08 An incorrect status number was transmitted to the DLC 1 Veri
195. fy that the status number transmitted to the DLC is in the correct format 2 Referto Chapter 7 for the correct status numbers and format DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Diagnostics And Troubleshooting 8 11 Error Message Code Status Illegal 01 09 Explanation of Diagnostic This error occurs if the status number being transmitted to the DLC is not a valid status number Solution 1 Verify that the proper status number is being transmitted to the DLC 2 Referto Chapter 7 for the correct status numbers and format Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 8 12 Diagnostics And Troubleshooting DLC A and DLC G 8 4 G Code Programming Errors Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Rexroth Indramat Error Message Code G01 without F 23 If a G01 command is called up in the DLC program before a feedrate has been programmed using the F command this error will result When a G01 command is used the desired feedrate must be programmed using the F command Any other feedrate command ie VCC VCA VEO etc will give you this error 1 Program the desired feedrate using the F command 2 Verify that no other velocity change commands are programmed between the F and the G01
196. g 6 3 CHECKSUM Calculations 7 6 CHECKSUM Example Calculation 5 66 5 87 7 7 Command Descriptions 5 10 Command Summary 5 5 5 99 7 9 Auxiliary Functions 5 9 Branch Commands 5 8 Counter Commands 5 9 Jump Commands 5 8 Other Commands 5 9 Position Support Commands 5 7 Positioning Commands 5 6 5 100 5 101 5 102 5 103 Timer Commands 5 9 Connector Wiring DB 25 7 1 Serial Cable Configurations 7 2 Signal Level Requirements 7 2 Controls and Indicators 2 1 CTA Display Screens 2 4 Counter Screen 2 13 Edit Screen 2 16 Mode Tasks Screens 2 15 Axis Enabled Screen Manual Mode 2 15 Task Display Automatic 2 15 Task Screens Manual Mode 2 15 Parameter Mode Display Screens 2 8 Scrolling Through Display Screens 2 4 Servo Status DLC Status DLC Hardware Software Version Display Screens 2 8 System Information Screen 2 14 Actual Speed RPM Display Screen 2 14 Optional Measuring Wheel Encoder Position Screen 2 14 System Auxiliary I O Status Screens 2 9 2 10 CTA Keypad and Display 2 1 CTA10Userlnterface 1 10 D Data Entry Keys 2 2 Data Format 7 3 Baud Rate 7 4 Interface Mode 7 4 Parity Check 7 3 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Index I 1 Word Length 7 3 DEA 4 Input Connections 6 5 DEA 4 Input Signal Descriptions 3 15 DEA 4 Output Connections 6 6 DEA 4 Output Signal Descriptions 3 19 DEA 4 X17 Input Output Connector and Pin Designations 3 1 DEA 5 X32 Output Connector and P
197. h axis can be programmed to make multiple revolutions in either direction direction is relative to the programming of A109 Direction of Operation The software over travel limits are disabled when implementing rotary programming Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 4 6 Parameters DLC A and DLC G 4 5 Parameter Descriptions The following sections describe each parameter as required for the DLC to command motion Each parameter description includes an illustration of the CTA display and the formula required to obtain the parameter value where applicable For easy reference this section describes each parameter in numerical order A100 through A125 then BOOO through B023 then C000 through C012 as shown in Table 4 1 and each new parameter begins on a new page Note When entering the axis parameter data A100 A125 and system parameter data BO00 B023 the Feed Constant parameter A108 needs to be determined before the velocity parameters can be entered correctly The Feed Constant parameter A108 sets the Input Units for positioning the axis Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 7 Parameter A100 Maximum Velocity Max Velocity A100 00050 000 Min 00000010 IU Max 05000000 IU This parameter defines the maximum velocity for the axis entered in Input Units defined in A108 All motion commands are a percentage of this maximu
198. hanged from 100 to 105 parts or lt 0005 gt can be entered as an Offset Value to yield five extra parts by decrementing the Actual Count by five parts If the Preset Count is modified a new Preset Count may need to be entered for proper quantity of parts per quota DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 21 Branch Conditional on Acknowledgment Output Dependent E 0700 BCA 0345 22 0 Target block 0000 2999 Auxiliary output number 01 99 Jump condition 0 jump if aux output is Off 1 jump if aux output is On A jump is executed if the programmed output meets the preselected condition 0 Off or 1 On If the condition is not met at the programmed output the program steps to the next block instead of branching to the target block Example Assume that the following conditions exist absolute positioning by the axis a part requires a constant to 8 125 inches Then the program needs to jump to one of two places depending on the status of output 20 the axis will move to a certain position In this example output 20 is turned ON in another part of the program To run this program the axes must be homed 0000 0053 0054 0055 0056 0100 0101 0200 0202 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 JMP PSA BCA BCA JMP PSA JST PSA JST 0053 148 125 999 0100 20 1 0200 20 0 0054 1 45 25 75 5 0053 1 40 0
199. he position calculated in the model is specified in in parameter A122 Program the maximum permissible deviation in percentage between the actual position and the position calculated by the model in this parameter For the monitoring to function properly program a value in this parameter greater than the percentage of deviation that results under normal operation Otherwise nuisance faults will occur Calculate the maximum positional deviation Max speed IU sec 60 Position Gain KV 1000 RPM as in A121 x VK asin A108 Kv factor as A103 x 1000 Position Deviation in IU Position Deviation in IU Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 30 Parameters Rexroth Indramat DLC A and DLC G Example max RPM A121 2000 RPM IU VK A108 0 39 in Kv A103 1 Monitoring A122 20 Max Position Deviation in IU 0 781 100 1x 1000 20 corresponds to 40 mm If A122 00000020 the DLC will issue an error if the actual following error differs from the expected following error by more than 20 Take 20 of 0 78 in 0 20 x 0 78 0 16 At a positional deviation of 0 16 in the controller interrupts the positioning process and reports a Excessive Position Lag or Drive Runaway A Drive Runaway would occur if the error exceeded 0 78 0 016 0 796 inches Excessive Position Lag would occur if the following error went below 0 78 0 016 0 764 inches Wh
200. he Status Code 53 through an external host device causes the DLC Control card to transmit the error code 00 No error message will be displayed on the CTA panel if used If another MMI device is used it may display a message in response to this information Not Required Error Message Code Abs Range 45 This error occurs if the maximum number of turns of the multi turn absolute feedback has been exceeded Verify that the distance traveled does not exceed the maximum number of turns of the absolute encoder Error Message Code Axis 1 Not Homed 48 This error occurs if the DLC program encounters an absolute position command for the axis but that axis has not yet been homed 1 Refer to Chapter 3 Section 3 2 4 for details on Homing 2 Verify that the axis homing parameters A110 through A114 are correct The axis can be homed in Manual or Automatic mode Refer to Chapter 4 for more information on the Homing parameters 3 Verify that the axis position command in the DLC program is correct Refer to Chapter 5 for more information on positioning commands Error Message Code Axis No False 16 Incorrect axis selected in a feed command Must be axis 1 only Check program block feed command axis designation Error Message Code Battery Is Low 04 This condition occurs when the Lithium battery which retains the DLC memory program parameters counter s
201. he counter must be entered in the status code field 0002 Code for Status options as below 0000 Actual position of each axis 0041 Registration Position REF 0002 Current program block 0043 Measuring Wheel number 0003 Actual position as 0046 Length Counter hexadecimal value 0005 Software version 0047 Actual RPM MW description x006 Current input state 0048 Actual Motor RPM x007 Current output state 0050 System I O Hexadecimal 0008 Current Block Task 1 2 3 0051 Aux Inputs Hexadecimal 0009 Measuring Wheel 0052 Aux Outputs Hexadecimal 0010 Following Error 0053 DLC System Error 0018 Servo Diagnostic 0019 DLC Hardware Software Note x06 and x07 x Input output bank number 0 9 Program controlled data output via the serial interface see Chapter 7 Stepping to the next block takes place immediately after the block has been read in Serial interface must have been activated through parameters B003 B004 Otherwise stepping to the next block takes place without having an output transmitted Examples of STH entry 0 0003 Status 03 actual position of axis 1 and 2 in Hexadecimal is transmitted to Host device via the serial interface 1 1000 Status of counter located in block 1000 The desired and actual number of pieces is transmitted to Host device via the serial interface Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 90 Programming D
202. he screen press the number 3 from the Main Menu German Text Press the number 1 English Text Press the number 2 After the selection the Main Menu screen will be displayed DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Main Menu Installation Start Up 6 7 The Main Menu allows you to view the following information e Drive Status e Parameters e Language Selection e ESC Exit Program In order for the DLC to operate properly the Digital Amplifier s parameters must coincide with the parameters programmed in the DLC To check or adjust the parameter currently in the amplifier press number 2 from the Main Menu screen The Drive Parametrization screen will be displayed Consult the amplifiers manual for a description and the proper parameter values for the amplifier motor combination being used press the letter c to continue The Parameter Menu screen will display the following selection list application parameters drive parameters and parameter management When setting up an Indramat Digital Amplifier with the DLC the application and drive parameters must be set correctly Setting the Amplifier s Parameters to Operate with the DLC Control Card Analog Outputs 1 Press the number 6 Motor amp Drive Data This will display the current amplifier motor combination Look under the Motor Parameters and make a note of the Maximum Velocity of Motor RPM Press lt ESC gt to return to the Parameter
203. iagnostic Screen The DLC Status Screen displays the current operating status of the DLC control card screen In the example below Automatic Mode is selected A and Cycle Start has been pressed to start automatic operation A Start Active DLC Status Screen If a hard or soft fault occurs control function stops and a diagnostic message appears on the display If a fault is present at power ON a DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Controls and Indicators 2 9 diagnostic status message appears first instead of the Drive Diagnostic Display See Chapter 8 for diagnostic messages and troubleshooting procedures EMERGENCY STOP EMERGENCY STOP Example Fault Status Display By pressing the right arrow key the current DLC hardware DA software version installed in the Indramat Digital Drive will be displayed Automatic or Manual Modes DLC 1 1 DG 01 1 XX XX Hardware Software Screen DLC 1 1 indicates hardware type DG 01 1 XX XX indicates software number XX XX revision number Press the left or right arrow keys to scroll through the Servo Status DLC Status and DLC Hardware Software Version screens Tool Correction Data Screen DLC G only The tool length correction consists of a tool correction memory with 20 selectibale Tool Correction registers 000 019 000 is effective upon entering automatic operation and is active once the program is started Inputting of correction v
204. iagnostic message on the display Outputs System Fault Indicator 3 4 The DLC includes extensive diagnostic monitoring circuitry detecting normal operating status operator errors errors in the control itself and machine faults There are several categories of faults as described in Chapter 8 In general once a fault is detected an error message is displayed on the CTA display the System Fault Indicator output turns off and the axis will decelerated to a stop If the system is operating properly the System Fault Indicator output will be on DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 13 Feed Monitoring Program Interruption Inputs e Interrupt Vector Program B012 e Feed Angle Monitoring A120 Feed Interrupt A120 An auxiliary input Interrupt Vector Program can be assigned parameter 012 to interrupt the user program at any time and start an Interrupt Vector sub routine program Automatic Mode Task 1 only When this input goes high the current program sequence will be interrupted immediately or after the current subroutine program is finished option set in parameter The program sequence will then continue at the start program block number assigned in the parameter for the Interrupt Vector program See Chapter 4 for further information on this parameter function An auxiliary input Feed Angle Monitoring can be assigned in parameter A12
205. if counter status is selected and the starting output number The three outputs after the starting output number will be used to output the information The user program must be written to store the absolute position or counter status and then output them in the proper order DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G 0900 0901 0902 0903 0904 0903 0906 0907 0908 0909 0910 0911 0912 0913 0925 0926 0927 STO JSR STO JSR STO JSR STO JSR STO JSR STO JMP AKN AKN RTS Programming 5 91 STO Command Example For this example the absolute position for the axis is equal to 598 00 inches The auxiliary outputs 04 through 07 are used for the BCD value 02 0 02 1 1 1 000000 00 0925 1 1 190000 04 0925 1 1 130000 04 0925 1 1 140000 04 0925 1 1 150000 04 0925 1 1 160000 04 0900 01 0 01 1 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Toggle input 22 to begin the program Store actual position Jump to subroutine at program block 0925 Output the direction of the sign Jump to subroutine at program block 0925 Output third digit XX4321 XX 2 0 XX 1 0 XX 0 8 Jump to subroutine at program block 0925 Output fourth digit XX4321 XX 2 0 XX 1 0 XX 1 9 Jump to subroutine at program block 0925 Output fifth digit XX4320 XX 2 1 XX 0 20 XX 1 5 Jump to subroutine at program block 0925 Output sixth digit XX 3 0 XX 2
206. imer gt 5 Output unchanged with no acknowledgment x 0 1 After calling up the M function it waits until all acknowledgment conditions have been satisfied Then stepping to the next program block and permanent monitoring of the acknowledgments occurs As soon as one of the conditions is not satisfied the program stops in Task 1 and Task 2 axis movements are stopped and the message Stop Active is displayed The program starts running again as soon as all acknowledgment conditions are satisfied 5 After the time defined in parameter B009 has elapsed all bits that have been turned ON will be turned OFF Since there is only one timer a new M function using the time function cannot be set until the timer has run out In this case a timer that has not yet run out has a limiting effect on the processing of any subsequent M Functions X X XxX XxX x x Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G 4 7 Parameter Data Sheets A Parameter Input Sheet POSITION GAIN 203 210 0 0 0 000000 0000000 0 E SIGNAL CONSTANT 000000 ACKNOWLE UM TRAVEL MAXIMUM Parameters 4 81 TRAVE FUNCTION ONITORING MAXIMUM
207. in Designations 3 3 DEA 6 X33 Input Output Connector and Pin Designations 3 4 Description of Parameter Sets 4 1 Diagnostics and Troubleshooting 8 1 Digital AC Servo Amplifier Parameter Entry 6 6 Digital AC Servo Controller Normal Operating Diagnostics 8 1 DKS Positioning Control Module 1 1 DLC Control String Protocol 7 4 First 1 Control String Character Transmission Type 7 4 Other Important Control Characters 7 5 Second 2 Control String Character DLC Unit Identifier 7 5 Third 3 Control String Character Information Type 7 5 DLC System Error Code And System Error Messages 8 2 DLC X6 Connector 7 1 DLC DEA 4 Connectors 6 4 E Electrical Installation 6 3 End of the Program 5 4 Entering the Parameters 4 3 Auxiliary Inputs Outputs 4 4 Displaying of Decimals 4 4 Unit of Measurement 4 5 4 78 4 79 4 80 4 82 4 83 Expanded I O Configuration Of DKS With DLC Control Card DEA 4 5 1 12 F Functional Description Of DEA 4 I O Connections 3 1 G General Description 1 1 General Format 5 5 H Hardware Installation 6 3 Information Characters 7 6 Information Request Requesting a Parameter from the DLC 7 11 Requesting a Program Block from the DLC 7 11 Requesting System Status from the DLC 7 12 Input Signal Descriptions Automatic Mode Select 3 15 Rexroth Indramat l 2 Index Rexroth Indramat Auxiliary Inputs 1 Through 7 3 18 Clear External 3 18 Cycle Start 3 16
208. ine 1 5 41 Tool Correction Memory 5 42 FAK Factor All MOtlOnS iet heeded EE nine 5 43 FON FUNCIONS m 5 44 JL Miri ETEA EAT TE 5 45 GOL Linear a 5 46 MH CTS 5 47 G40 Tool Correction 5 48 G43 Tool Gorrection Added uides tede ed eden redacta older 5 49 G44 Tool Correction Subtracted 5 50 560 Exact 5 51 G61 Velocity Rate Optimization nene 5 52 Gy4 sReference AXIS 5 53 G90 Absolute Dirmiensions ie ee ecetes iine eed ec vente cence 5 54 G91 Incremental Dimensions 5 55 AXIS T RE 5 56 IMP Jump Unconditional zin ett rre em oper px cube x CIPUE 5 57 TSR JUMP to Subroutines ab etn 5 58 JST JUMP and ened 5 59 TK gt A 5 60 KDI Copy Position Difference 5 61 Torque 5 62
209. ined Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 49 Parameter B011 Manual Vector Manual Vector B011 07 1 0 2500 07 Aux input number to initiate Manual Vector program start with rising signal edge 00 Manual Vector Disabled 01 37 Aux Input Number 1 20 Start only with aux input number 1 Start with either aux input number or any time you switch into manual mode 0 Notused set to 0 2500 Start block of Manual Vector program Block 0000 2999 Note You must use the Command RTS Return from Subroutine to terminate the Manual Vector program This function allows you to run a user program in Manual Mode This program must conclude with an RTS the subroutine stack will not be changed This program must not contain any feed instructions The program is aborted if there is a switch over from Manual to Automatic or to Parameter Mode The program is started externally by means of a rising signal edge at one of the aux inputs If 00 is input for the aux input the Manual Vector is disabled When programming Parameter 011 make sure that the start block of the Manual Vector program is not located in the main program Notes The manual vector input is not accepted during jogging or homing in the manual mode While the manual vector program is running jogging or homing is not possible It is not possible to start the manual vector program u
210. ion Pre defined means that the given M function affects fixed assigned outputs that are to be acknowledged by inputs that are also fixed Any inconsistency in the acknowledgments leads to the program stopping in Task 1 and 2 as well as axis movement halting until restoration of the defined acknowledgment Up to 64 predefined M functions can be used Outputs and acknowledgment inputs should always be sequential M functions are monitored during processing of the selected command or if programmed as such they can be permanently monitored Selection occurs in the running program Task 1 or 2 in the GO1 command or by the M word as a separate command E 1000 601 1 000010 00 mm Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 79 Selection of Function E 1000 M mm mm Number 00 63 of the M function to be selected pre coded M function is either set a separate block using M or in combination with G01 command If the M function is programmed in a G01 block it is set after the programmed position has been reached within the limits set by A106 Position Tolerance If G01 is programmed within a G61 contouring mode the M function is set so as to allow optimum speed If the M functions set are time dependent it is important to note that their status will change according to the M function table after the set time in Parameter B009 has expired
211. is reached the percentage of maximum torque at positive stop will be enabled and the program flow will jump over the block immediately after the PFA or PFI command and the program will continue It is also possible to overwrite the torque limit while driving Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Programming 5 63 The default delay time for indexing to the next statement is 1 millisecond When using the MOM command drive errors can occur at low torque limiting Excessive Position Lag Drive Runaway drive error 78 Excessive Position Lag and Drive Runaway can be switched OFF in parameter A122 Rotational speed controller monitoring can be switched OFF using the PC program DDS2PC EXE to prevent drive error 78 Requirements For Recognizing a Positive Stop Condition 1 2 Note Warning millisecond Twenty milliseconds deceleration after reading the PFI command The positive stop is recognized when a b Four times the following error position lag is reached Axis movement is less than 1 1024 of a motor revolution per If the positive stop is not reached the maximum torque of the axis and the overload factor of the drive are active When the MOM command is used and while positioning to a positive stop or positioned at the positive stop the overload factor in the drive is internally set to 400 percent The MOM com
212. ished by entering the distance from home to the new reference location as the Reference Position Homing Offset in parameter A111 When the control is homed this value will be loaded into the position counter and all moves will be made in reference to this position Placement of the Homing Switch As described above the reference position of the AC servo drive is determined after it has moved onto the switch The reference position can be set in steps of one motor revolution each by using the position the switch is in when it is activated By monitoring the switching point of the homing switch and the marker pulse a DLC diagnostic check eliminates the danger that these two are so close to each other that the switching tolerance limits will result in uncertainty about the motor revolution to be evaluated If the switching point of the homing switch is closer than 1 16 of a motor revolution with respect to the marker pulse the control unit will not complete the homing process and will change over to fault indication The display will show Marker Pulse 1 The homing switch should be relocated by 1 3 of the feed constant Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 3 10 Functional Description of DEA 4 I O Connections DLC A and DLC G Rexroth Indramat Activating the Homing Switch Activating the homing switch must be done in such a way that the switch closes upon backing up i e upon the movement away f
213. ision By Zero 8 6 1B DLC Watch Dog 8 6 1C DPR Error 8 7 40 Drive 1 Not Ready 8 7 102 Drive Enabled 8 1 103 Drive Halt 8 1 101 Drive Ready 8 2 42 Drive Runaway A1 8 8 03 EMERGENCY STOP 8 8 4C Encoder Fault 8 9 43 Excess Pos Lag 1 8 9 41 Feed Angle Loss 1 8 10 23 G01 without F 8 24 4B Home Switch Pos 8 10 12 IDS Break Error 8 11 13 IDS Checksum Error 8 11 15 IDS Data Too Long 8 12 14 IDS Format Error 8 12 Invalid Block 8 13 08 Invalid Mode 8 13 01 05 Invalid Mode 8 20 01 11 Invalid P Block 8 20 01 13 Invalid Prg Command 8 20 0A Invalid Prg Command 8 14 02 Is INVALID 8 14 0B JSR Nesting 8 15 01 10 M Wheel P False 8 21 20 M Command 8 24 21 M Command M0 1 8 25 22 Malfunction 501 Command 8 25 47 Max Travel Lmt 1 8 15 46 Min Travel Lmt 1 8 15 24 No G60 8 26 DOK CONTRL DLC A DLC G AW03 AE P 12 99 Rexroth Indramat 8 14 Diagnostics And Troubleshooting Rexroth Indramat DLC A and DLC G CODE Diagnostic Page 100 Operation Ready 8 2 01 07 Param illegal 8 21 01 Parameter Mode 8 16 05 Parameters Lost 8 16 06 Program lost 8 17 01 01 RS Block 4 Wrong 8 21 01 03 RS Block Data Error 8 22 01 04 RS Checksum Error 8 22 01 02 RS Format Error 8 22 01 06 RS Par No False 8 23 01 08 RS Status False 8 23 0C RTS Nesting 8 17 104 Safety Interlock 8 2 18 Software Combination 8 18 01 09 Status Illegal 8 23 11 System Fault IRQOVL Interr
214. izes these signals as necessary to implement the DLC for the application including the design of the system control panel 3 1 Signal Definitions The states of the input and output signals described in this manual are e High 24 e Low 0 Vdc A signal line is described as active high when its associated action is initiated by a high 24 Vdc signal level It is described as active low when its function is initiated by a low signal 0 volts Active low signals are shown this manual when specifically referred to as a signal with a bar line over the signal name as an example Emergency Stop This signal must be high during normal operation If it goes low the DLC initiates the actions required for an emergency stop function 3 2 Interface Descriptions The DLC input and output signals provide handshaking to from the machine builder s equipment Certain I O signals should be considered as functional groups of signals working in concert These functions include Operating Mode Selection Safety Interlocks Normal Operation Signals Axis Homing Manual Operations Fault Diagnostic Circuitry Feed Monitoring Program Interruption Special Functions Figures 3 1 3 2 and 3 3 illustrate the DEA 4 X17 Input Output DEA 5 X32 Input Output and DEA 6 X33 Input Output connectors and each pin designation The following sections describe each group of interface functions first listing the I
215. k the program and if necessary program JSR without RTS Error Message Code Max Travel Lmt 1 47 This maximum travel error occurs in Automatic mode if the value stored in the Maximum Travel Limit parameter is exceeded The axis commanded position has exceeded the maximum software travel limit 1 Verify that the axis maximum travel limit parameter is correct Error Message Code Min Travel Lmt 1 46 This minimum travel error occurs in Automatic mode if the value stored in the Minimum Travel Limit parameter is exceeded The axis commanded position has exceeded the minimum software travel limit Verify that the axis minimum travel limit parameter is correct Error Message Code Parameter Mode 01 When the DLC Control card is put into Parameter mode a host control request for Status 53 causes the DLC Control card to transmit this code Not Required Error Message Code Parameters Lost 05 When power to the DLC is turned off and the battery does not have sufficient power to retain its memory or is disconnected this error occurs when power is re applied It signifies that the parameters that were stored in memory are no longer in memory This error may also occur it the firmware is removed or if a different DLC firmware is installed 1 If this error occurs every time the DLC is powered up replace the backup battery 2 Verify that every DLC parameter has v
216. l on Acknowledgment Output Dependent 5 21 BCB Binary Conditional Branch Inputs 5 22 BCD Binary Coded Decimal Conditional Branch Inputs 5 23 BCE Branch Conditional on Single Input 5 24 BIC Branch Conditional On Binary Inputs cccccccceeeeee cece eeeeee cee eeeeaeeeeaeeseeeeeeeeeseaeessaeeeeneeeeaees 5 25 BIO Branch Input Output 5 26 BMB Branch on Multiple Binary Outputs enne enne 5 27 BPA Branch on Parallel Acknowledgments Outputs sse 5 28 Branch orn Parallel Inputs ott idt ett Ito EEUU 5 29 Branch om Position ed tome reine eee eee 5 30 BZP Branch If the Target Position Exceeds the Position Limit Value 5 31 CID Change Instruction 5 32 CIO Copy Input Output to 5 33 CLA Clear Absolute Position 5 34 CHG Clear 5 35 coc Gam Output Control eva d bu Rd Rene dua 5 36 Continuous ODpeTratioriz 5 38 COU CON 5 39 CPL Clear Position tote ea ede 5 40 CST Change Subrout
217. lect M Functions PST Position test turn output ON OFF based on position STO Send information to outputs Input Output Monitoring Commands AKN Check a single input state continue if state matches 1 to 37 AKP Check a parallel group of inputs continue if all match 10 inputs group 0 9 ATS Check a single output state continue if state matches 1 to 99 M Select M Functions Useful for tracking progress of a process You can use any number of cycle parts batch counters within a program BAC Branch until the item count is met up to 99 999 counts CLC Clears the counter at a block with a counter command in it set to zero COU Turn output ON at end of count up to 999 999 counts The DLC firmware supports the delay of the program in a wait block for a preset time WAI Wait for a set time delay then move to next block 10 ms to 99 99 Sec G04 Dwell Time 1 ms to 9 999 sec The following commands have the indicated function Refer to the next section for a detailed description of every programming command CID Change instruction data NOP No Operation RSV Restart vector STH Send to host Communications Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 10 Programming DLC A and DLC G 5 9 Command Descriptions Rexroth Indramat This section describes each programming command The first line of the illustrated displays are as previously described with E indicating Edit Mode a random
218. ll jump to the first block in Task 3 and then run DEA 4 Connector X17 pin 4 Function Input Starts automatic cycle 24 momentary Starts the execution of the programs Task 1 and 2 when Automatic Mode is selected 0 Has no effect on the system operation Once initiated only a system failure fault or error the presence of the Emergency Stop or Cycle Stop or user defined Feed Interrupt will halt the automatic cycle This input is typically wired to a normally open push button switch on the user control panel NOTE Task 3 will be running in both Manual and Automatic Mode DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 17 Cycle Stop DEA 4 Connector X17 pin 5 Function Input Used to stop the automatic cycle 24 Vdc Continuous Allows Automatic Mode operation 0 Momentary Stops the execution of the program in Task 1 and 2 in Automatic Mode This input is typically wired to a normally closed push button switch on the user control panel When this input goes low during the execution of a program in Task 1 and 2 the program will stop in the block it is currently executing When a cycle start is re applied the program will continue from where it stopped If a position command is executing and a cycle stop is applied the axis will immediately decelerate to a stop The deceleration rate is the same as the a
219. llow Axis Measuring Wheel Mode 4 31 A124 Free 4 33 A125 Jerk Constant 4 34 A126 Position Window 4 35 B000 Enable Axis 4 36 B001 Serial Jog Enable 4 38 DLC A and DLC G B001 System Inputs 4 37 002 User I O 4 39 B003 Serial Interface 4 40 B004 Serial Interface 4 41 005 Memory Display 4 42 B006 Start Task 2 amp 3 4 43 B007 Display Language Decimal Place Keypad Lockout 4 44 008 M Function Inputs and Outputs 4 46 B009 M Function Timer 4 47 B010 Free 4 48 B011 Manual Vector 4 49 B012 Program Interrupt Vector Jump on Event 4 50 B013 Velocity Override 4 51 B014 Restart Vector 4 52 B015 Cycle Time 4 53 B016 External Encoder 1 4 54 B017 External Encoder 1 4 55 B018 External Encoder 1 Feed Constant 4 56 B019 Offset Dimension External Encoder 1 4 57 020 External Encoder 2 Encoder Selection 4 58 B021 External Encoder 2 Pulses Revolution 4 59 B022 External Encoder 2 Feed Constant 4 60 B023 Offset Dimension External Encoder 2 4 61 C000 Analog Output Channel 1 4 62 C001 Analog Output Channel 2 4 63 C002 Overload Factor 4 64 C003 Display Language Decimal Place Keypad Lockout 4 65 C004 Velocity Data Scaling at Analog Outputs AK1 and AK2 4 66 C006 Position Velocity Window 4 68 C007 Absolute Encoder Reference Position 4 69 C008 Error Reaction 4 70 C009 Current Loop Proportional Gain 4 71 C010 Velocit
220. lock of the program executes Task 2 starts running at the block number set in parameter B006 only in automatic mode Task 1 always starts at block 0000 only in automatic mode In manual mode the display shows information for tasks 1 and 2 for the program block that was executing or next to execute during automatic mode cycling or starting block Axis Enabled Screen Manual Mode Manual Al Init Axis Enabled Screen A1 indicated the axis is ready to operate Init indicates axis has been homed Task Display Automatic A Program Status Task 1 0091 BCE Task 2 1366 AEA Task 3 2901 BCE Automatic Mode Task Display This display shows the current block number and related command mnuemonic for each task Task 3 runs when the DLC is in manual or automatic mode Task 2 starts running at the block number set in parameter B006 only in automatic mode Task 1 always starts at block 0000 only in automatic mode During automatic operation after Cycle Start the information keeps changing as each block of program executes If Cycle Stop signal goes low switch is pressed the drive immediately stops and the display shows information for the program block that was executing or just about to execute Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 2 16 Controls and Indicators Edit Screen Rexroth Indramat DLC A and DLC G Use the Program Edit screen to enter the complete executable program Al
221. lt in its current block until a Cycle Start command is issued to restart the program Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 60 Programming JTK Jump in Task Rexroth Indramat DLC A and DLC G E 1345 JTK 1000 1 1000 Target block 1 1 Task 1 2 Task 2 The JTK command is used for initiating an Unconditional Jump within a selected task This command terminates the current program sequence for the selected task and then causes it to jump to the target block If the task is currently executing a move profile the motion is completed before the task can be interrupted If necessary a PBK command can be used before the JTK to terminate the motion thereby providing an immediate interrupt The JTK command permits the use of many specific interrupt routines trapped by numerous events Note If only one input dependent interrupt routine is needed it is recommended to use the interrupt vector parameter B012 In most applications the JTK command will be issued from one of the other tasks typically Task 3 If used correctly the JTK command can provide many of the functions available in B012 Interrupt Vector with the additional flexibility to use any event or series of events position count one or more inputs or outputs to cause an interrupt to Task 1 or 2 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 61 KDI Copy Position Difference E 0500 KDI 2000 1000
222. m Your first source of information should be this manual To report a problem or request assistance call Indramat at 847 645 3600 between 9 00 AM and 5 00 PM Central time Ask for a Service Engineer or call our 24 hour Service Hotline at 1 800 860 1055 You may also write or FAX to the following Rexroth Indramat Attn Service Department 5150 Prairie Stone Parkway Hoffman Estates IL 60192 FAX 847 645 6201 How To Use This Manual Chapier 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 The manual is organized such that Chapters 1 and 2 describe the DLC control and its operation These chapters plus Chapter 8 on diagnostics will be sufficient for most operating personnel Chapters 3 8 provide functional description installation setup parameter entry programming and diagnostic and troubleshooting information required by the machine builder and setup personnel General Description This section describes the DLC control and the features which make it well suited for motion control Describes and illustrates various options Lists specifications Controls amp Indicators This section describes the CTA keypad and displays interfaced with the DLC control card Functional Description This section describes all pre defined plus several user definable input and output signals and the various interfacing and operating modes of the DLC This information is necessary for interfacing the DLC to the machine builder s equipme
223. m handshaking with a parameter specified output or with an output whose state is changed by another task number All auxiliary outputs can be monitored and used in the execution of an ATS command Auxiliary outputs 73 through 99 function differently than other aux outputs See Table 5 1 for more information The following example shows how the ATS command is used to test axis position The program can be held up until the moving axis is in position by monitoring the In Position output programmed in Parameter A106 for each axis Example The In Position output programmed for the axis is number 15 Aux output 15 is Off while the axis is in motion until it is In Position at which time it will come On 0000 JMP 0500 Jump to Block 0500 0500 1 00100 15 39 5 Incremental position command axis 1 100 15 IU at 39 5 of max feed rate 0501 ATS 15 1 Poll status of aux 15 for an On status axis has reached position 0502 AEA 02 1 Turn On aux output 02 0503 JST 0000 Jump and Stop at Block 0000 Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 19 BAC Branch And Count E 0060 BAC 1500 0000 00500 1500 Target Block 0000 2999 0000 Offset Value 00500 Preset Count Each time this block is executed the Actual Count increments by one Program branching to the Target Block occurs until the Actual Count equals the Preset Count Then the Actual Count is set t
224. m velocity Velocity is specified in Input Units second to two or three decimal places Set the decimal resolution in B007 before entering this parameter Motion commands programmed for 99 9 velocity results in a travel velocity equal to the maximum velocity 100 096 All lesser numbers programmed results in a travel velocity equal to the actual percent of maximum velocity entered The formula for calculating the max velocity is Max RPM A121 x FeedConstant A 108 Max Velocity T Notes Any gear ratio between the motor shaft input shaft and the output shaft should be taken into consideration in the calculation of the Feed Constant A108 Refer to Parameter A116 Rotary Axis Gear Ratio 1 When using rotary table the max velocity is Max Velocity Max RPM A121 x FeedConstant A108 GearRatio A116 Example Linear Maximum Velocity Calculation Max Motor Speed 1500 RPM Feed Constant 2 441 IU s per rev 1500Rev 1 2 4410 1500RPM Min 60Sec IRev 60Sec The entry in A100 would be lt 00061 025 gt for the system maximum IU Max Velocity x 2441IU 61 025 an or a percentage of this number for your preferred maximum velocity Note Always round the result down i e if the result was 33 333 the entry would be 33 332 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 8 Parameters DLC A and DLC G Parameter A101 Jog Velocity Jog Velocity 1
225. mand is the only limit for the percentage of maximum torque Example Material Positive Stop 200 300 Figure 5 2 Positive Stop MOM Command 000 JMP 0100 0100 MOM 1 020 030 Torque Reduction Before Stop 20 At Stop 3096 0101 POA 1 00250 000 300 Position Axis to 250 inches at 30 max vel 0102 1 00200 000 100 Velocity Change to 10 max vel at 200 inches 0103 PFI 1 00310 000 100 Position to positive stop 310 inches at 1096 max 0104 JMP 0200 to block 0200 Positive Stop Error Routine 0105 BCE 0120 02 1 Jump to block 0120 Input 2 is on Return Home 0106 JMP 0105 Jump to block 0105 Wait for Input 2 to turn on 0120 PSA 1 00000 000 999 Position axis to 0 position Home at 99 9 max 0121 JST 0100 Jump and stop at block 0100 wait for cycle start 0200 AEA 07 1 Turn on auxiliary output 7 Positive Stop Error 0201 PSA 1 00000 000 999 Position axis to 0 position Home at 99 9 max 0202 JST 0100 Jump and stop at block 0100 wait for cycle start Rexroth Indramat 5 64 Programming DLC A and DLC G Selection of an function E 1000 mm mm Number 00 63 of the M function to be selected pre coded M function can also be set a separate block using If the M functions set are time dependent it is important to note that their status will change according to the M function table after the set time in Parameter B009 has expire
226. mediately after this program block is read The auxiliary outputs retain their status when the DLC exits Automatic Mode into Manual Mode In a fault condition or the entry to Parameter Mode the auxiliary outputs will automatically be set to the Off 0 state Upon the clearing of the fault or exiting of Parameter Mode the auxiliary outputs remain in the Off state until their status is changed in the user program in Automatic Mode Warning The manipulation of auxiliary outputs 89 through 99 can have unexpected results See Table 5 1 for more information on auxiliary outputs that serve as status markers Example 0000 JMP 0020 Jump to block 0020 0020 AEA 07 O0 Turn auxiliary output 07 Off 0021 POI 1 00000 550 865 axis 1 incremental feed of 0 550 IU at 86 5 of max velocity A100 0022 ATS 15 1 Check auxiliary output 15 until On status axis in position per tolerance set in A106 0023 AEA 07 1 Turn auxiliary output 07 On 0024 WAI 1 00 Wait 1 second 0025 JMP 0020 Jump to 0020 repeat cycle Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 13 AKN Acknowledge Single Input 12 E 0860 AKN 1 Auxiliary input number 01 07 Input status 0 input status Off 1 input status On With the AKN command the DLC scans the status of the programmed auxiliary input for the specified state Stepping to the next block will not take place until the desired status is present
227. meter A115 DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 15 3 3 DEA 4 Input Signal Descriptions This section describes the system auxiliary inputs to the DEA 4 I O card for the DLC control system The Input and Output signal lines of the DEA 4 I O card are optically isolated from the internal bus structure to minimize electrical noise interference If an I O network option card is used for I O see machine builders I O documentation for a complete listing of I O used The connectors and pin numbers of these signals are described in the following sections and shown in Figures 3 1 DEA 4 connector X17 Parameter Mode Select DEA 4 Connector X17 pin 1 Function Input Selects Parameter Mode 24 Vdc Parameter Mode selected 0 Parameter Mode is not selected another mode is selected or the system has defaulted to the Manual Mode The Parameter Mode Select will override any other mode selection input If properly wired selecting Parameter Mode while Automatic Mode is already selected does not cause an error When Parameter Mode is deselected the DLC returns to the previously selected mode Automatic or Manual default when no other modes are selected NOTE Task 3 stops in Parameter Mode Automatic Mode Select DEA 4 Connector X17 2 Function Input Selects Automatic Mode 24 Automatic Mode selected 0 Automatic
228. meters DLC A and DLC G Parameter C000 Analog Output Channel 1 as of software version DAO1 1 01 6 Analog Output 1 C000 00000002 0000000 Not used must be set to 0000000 2 Output type 0 Current command 1 RPM command 2 RPM actual value from feedback 3 Position Actual value from feedback 4 Motor encoder Sinusoidal feedback 5 Motor encoder Cosinusoidal feedback Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 63 Parameter C001 Analog Output Channel 2 as of software version DAO1 1 01 6 Analog Output 2 C001 00000005 0000000 Not used must be set to 0000000 Output type 5 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 0 Current command RPM command RPM actual value from feedback Position Actual value from feedback Motor encoder Sinusoidal feedback Motor encoder Cosinusoidal feedback DLC Output e g Axis 2 Rexroth Indramat 4 64 Parameters DLC A and DLC G Parameter C002 Overload Factor as of software version DAO1 1 01 6 Overload Factor C002 00000400 00000 Not used must be set to 00000 400 Overload factor in percent 000 400 Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 65 Parameter C003 Position Data Scaling at Analog Outputs AK1 and AK2 as of software version DAO1 1 01 6 Position Data Scaling A Output C003 000
229. mize electrical noise interference The connectors and pin numbers of these signals are described in the following sections and shown in Figures 3 1 DEA 4 connector X17 NOTE The current draw on any of these outputs should not exceed 75 milliamps or the entire bank of 8 outputs will shut off DEA 4 Connector X17 pin 16 Function Output Indicates a fault has occurred 24 The system is functioning properly 0 Vdc The DLC has detected fault This output is typically wired to an indicator light ON when no fault is present on the user control panel or the signal is relayed to a buzzer when 0 Vdc occurs NOTE Any Hard or Soft Faults will turn this output OFF See Chapter 8 for a description of faults WARNING This output is a semiconductor that should not be relied upon in the event of an emergency condition If this signal is used it should be in conjunction with the Emergency Stop chain DEA 4 Connector X17 pin 17 Function Output Indicates that Manual Mode is selected 24 Vdc No other modes are selected The DLC defaults to Manual Mode 0 Vdc Another mode is selected or an error has occurred This output signal is typically wired to an indicator light on the user control panel or to a PLC Rexroth Indramat 3 20 Functional Description of DEA 4 I O Connections DLC A and DLC G Automatic Mode Indicator DEA 4 Connector X17 pin 18 Function Output Indicates that Automa
230. n Software Type Code Designation Product Type IDS Software Version Number IDS Software Revision Number Corresponding DLC Software Version Letter Required For The IDS Software To Work E 5 SOT Hardware Type Codes Hardware Type Code Designation SOT XX X X X XX Model Name SOT Station Operator Terminal Hardware Version 0272 16 line display Construction E Station Unit RAM Capacity 2 512 KB Keyboard A Standard R Rollfeed DLC Application CU Standard Programmable with ScreenManager CR Rollfeed E 6 SOT Software Type Codes Rexroth Indramat Software Type Code Designation 5 2 00 XX 02 X X Model Name SOT Station Operator Terminal Control Type DLC Hardware Version Number Revision Number Software Version CU Standard Programmable with ScreenManager CR Rollfeed Software Revision Revision Supported with Documentation Minor Revision Not Supported with Documentation DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Index A About This Manual 1 5 How To Use This Manual 1 5 Support 1 5 Automatic Mode Operation 6 11 Auxiliary Inputs Outputs Inputs Outputs Signal Definition 5 2 Programming Inputs Outputs 5 2 Axis Jogging in Manual Mode 6 10 Block Diagram 1 3 C C005 Velocity Loop Monitoring 4 67 Cable Routin
231. n Very similar to branch commands except they are not conditional i e jumping takes place immediately when the command is read Subroutines are also part of this category They are common program sequences that are used repeatedly throughout a program returning to the calling point when completed APJ Turn parallel outputs ON or OFF then jump CST Change subroutine stack level JMP Unconditional jump to a block JSR Jump to a subroutine JST Unconditional jump to a block then stop the program Immediately cause a jump to a block in a selected task task interrupt RTS Return from subroutine DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Auxiliary Functions Counter Commands Timer Commands Other Commands Programming 5 9 Refers to the monitoring of Inputs and controlling the states of Outputs This ability is vital for a control to be capable of acknowledging and responding to the external environment and to control functions other than motion Note that branch commands and certain position support and jump commands PST APJ are also used for I O interfacing Output Control Commands AEA Turn a single output ON or OFF 1 to 88 APE Turn a parallel group of output ON or OFF 10 outputs group 0 9 APJ Turn a parallel group of outputs ON or OFF then jump 10 outputs CIO Copy a group of inputs or outputs to a set of outputs 10 outputs COC Turn 6 outputs ON or OFF based on Cam position M Se
232. n Each display screen is further described below See following section 2 3 6 2 for changes in displays when the Measuring Wheel option is enabled Axis 1 Incr Pos 00001 000 FE 00000 010 Rem 00000 000 Axis Information Pos indicates axis current position 00001 000 indicates direction of travel and actual position in Input Units The position values displayed can be cleared by pressing the CR key if the axis has not been homed FE indicates the axis current following error or position deviation 00000 010 difference between the commanded position and current actual axis position in Input Units This value is directly proportional to the velocity command output to the amplifier The higher the speed the higher the following error This value is zero only when the drive is in position An excess following error limits set by parameter due to binds in the system etc will cause a fault condition Rem indicates axis remaining distance 00000 000 difference between the commanded feed length and current actual axis position in Input Units The value displayed here is the distance remaining before the axis reaches the commanded target position When move is complete and axis is in position this value will be zero Actual Speed RPM Display Screen Speed Axis 1 Com 0500 RPM Act 0500 RPM Actual Speed Screen Com Commanded speed in RPM Act Actual speed in RPM Optional
233. n ATS command programmed in a subsequent block to monitor the Position Tolerance Output Parameter A106 or the Position pre signal Parameter A107 is useful in controlling when to step to the next block Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 70 Programming DLC A and DLC G POI Position Incremental E 0290 POI 12345 678 999 Rexroth Indramat 1 Axis 1 Incremental position direction or Note If a character other than is entered for this digit the direction will be minus 12345 678 Incremental target position in input units to 2 or 3 decimal places depending on setting in B007 999 Feed rate in 00 1 99 9 of the maximum velocity set in parameter A100 Example 500 would be 50 0 of the maximum velocity Stepping to the next block takes place immediately after the position block has been read in Since this command does not wait for the axis to be in position before jumping to the next block the program command following this command will be executed This allows the other functions to be executed while the axis is moving toward the end position If multiple commands are in sequence the resulting move will be the sum of all incremental position commands The ATS command programmed to monitor the Position Tolerance Output Parameter A106 or the Position pre signal Parameter A107 is useful in controlling when to step to the next block DOK CONT
234. n Sales Region INDRAMAT GmbH B blinger StraBe 25 D 71229 Leonberg Phone 07152 972 6 Fax 07152 972 727 Western Sales Region INDRAMAT GmbH HansastraBe 25 D 40849 Ratingen Phone 02102 4318 0 Fax 02102 41315 INDRAMAT Service Hotline INDRAMAT GmbH Phone 0172 660 040 6 or Phone 0171 333 882 6 Customer Service in Germany DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Denmark BEC Elektronik AS Zinkvej 6 DK 8900 Randers Phone 086 447866 Fax 086 447160 France Rexroth Sigma S A Division INDRAMAT 91 Bd 1 Joliot Curie F 69634 Venissieux Cx Phone 78785256 Fax 78785231 Netherlands Hydraudyne Hydrauliek B V Kruisbroeksestraat 1a P O Box 32 NL 5280 AA Boxtel Phone 04116 51951 Fax 04116 51483 Switzerland Rexroth SA D partement INDRAMAT Chemin de l Ecole 6 CH 1036 Sullens Phone 021 731 43 77 Fax 021 731 46 78 Northern Sales Region INDRAMAT GmbH FahrhausstraBe 11 D 22085 Hamburg Phone 040 227126 16 Fax 040 227126 15 286834 Printed in Germany Rexroth Indramat
235. ncoder function and establish the feed constant and the number impulses of the encoder They also allow assigning an auxiliary input for selecting either the external encoder or motor high resolution feedback During external encoder operation the measurement of lengths is from the external encoder rather than the motor s high resolution feedback The Dual Encoder Option in parameter A123 allows quicker response with external encoder operation When selected the position loop is closed using motor high resolution feedback and the external encoder provides adjustments to the length during feeding When this option is not selected the Position Loop is closed using the external encoder Lack of stiffness in the mechanical components between the motor and the external encoder can require using a lower gain which decreases the response time During manual operation the position feedback always comes from the motor s high resolution feedback During automatic operation there is a choice between continuous external encoder operation and using an auxiliary input signal to select external encoder operation Error messages are a Excess Pos Lag b Drive Runaway c External Enc Error Outputs e Achieved Programmed Velocity The Achieved Programmed Velocity Output is an auxiliary output which can be assigned to turn on when the commanded velocity is equal to the actual velocity This auxiliary output is programmed in the Special Function para
236. nd easy The Indramat Digital Drive Modules and the MDD AC Servo Motor have quick connect cabling The drive and MDD Servo Motor are matched for optimum operation using a plug in DSM module Thus should a failure occur replacement of the digital drive is accomplished quickly without the need for electronic fine tuning This results in a minimum of lost production because of machine downtime The system is designed to ensure operating integrity and safety using various inputs and outputs for handshaking to assure that the feeder and subsequent processing station or device operate in harmony A complete diagnostic system monitors all inputs outputs and operating conditions and stops the system if a fault is detected Diagnostic messages are displayed to aid the operator in troubleshooting problems and quickly getting the system back into production DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G General Description 1 5 1 2 About This Manual This document is written for both operating personnel and the machine builder It explains how to interface install setup and operate the Indramat DLC Positioning Control with DA or DG software Hardware and Software Support This manual describes the DLC 1 1 hardware used with e DA software versions DA 01 1 01 6 up through version DA 01 1 03 xx DG software versions DG 01 1 02 7 through DG 01 1 03 xx Indramat provides assistance for any problems you may encounter with this syste
237. nds on the selection you set in Parameter B007 You must set this parameter before the other ones can be derived Note If the decimal precision is not programmed in B007 Is Invalid Language diagnostic will appear when switched out of Parameter Mode When switched back to Parameter Mode the parameter with incorrect data is displayed Auxiliary Inputs Outputs Rexroth Indramat Certain parameters require the selection of auxiliary outputs or auxiliary inputs Acknowledgments to be used The auxiliary numbers to use must be selected by the machine builder and shown on their interconnect drawings where applicable Each auxiliary output selected should be unique i e A106 and A112 should not use the same auxiliary output number WARNING Auxiliary input and output numbers that have been dedicated by the machine builder for a specific purpose must not be changed Personal injury or damage to the machine drive train could result from such changes DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Unit of Measurement Parameters 4 5 The user specifies most parameter data in terms of input units IU A unit is defined by the user and can be feet inches millimeters degrees radians etc Once the user has chosen the unit of measurement then all position and feed rate data must be in accordance to that unit where it is logically required For example the input unit could be specified as inches The maximum
238. ng e f the DLC is sending data via the TxD channel and receives the X OFF signal Hexadecimal 13 ASCII via the RxD channel the DLC will interrupt the transmission until the X ON signal Hexadecimal 11 ASCII is received again via the RxD channel e If the DLC is receiving data via the RxD channel and an interruption of the data transmission becomes necessary the DLC will send the X OFF signal Hexadecimal 13 ASCII DC3 via the TxD channel When the transmission can be resumed the DLC will send the X ON signal Hexadecimal 11 ASCII DC1 via the TxD channel 7 4 Information Characters All information characters are coded in hexadecimal The following characters are used for exchange of information 0 Hexadecimal 30 through through 9 Hexadecimal 39 A Hexadecimal 41 through through Z Hexadecimal 5A Used as command codes for the DLC depending on programming Z must be uppercase _ space Hexadecimal 20 For creating the desired format the space character is used Note This chapter indicates a space with the underline character Hexadecimal 2B Hexadecimal 2D The operational sign must be transmitted for position command blocks Hexadecimal 2E 5 Hexadecimal 2C Used in data fields depends on Language selected if responds with period or comma The DLC treats both the same 7 5 CHECKSUM Calculations If checksum is enabled in parameter B004 the following example
239. nless the axis is enabled Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 50 Parameters DLC A and DLC G Parameter B012 Program Interrupt Vector Jump on Event Interruptvector B012 08 1 2 1650 For immediate interruption of main program Task 1 only start Interrupt Vector program Can be used as an Emergency Return procedure 08 00 Disables Interrupt Vector 01 37 Aux input number used to initiate Interrupt Vector program on rising edge of signal 1 0 Delays the function while main program is in sub routine JSR waits for sub routine to finish before continuing to the Interrupt Vector program rising edge 1 Means interrupt anytime even if in a subroutine Interrupt Vector always active rising edge 2 Same as 0 except falling edge 3 Same as 1 except falling edge 2 s 0 A started position command will finish before executing the Interrupt Vector program 1 Position command is interrupted drive s braked until stopped and execute the Interrupt Vector program 1650 Start block of Interrupt Vector program Block 0000 2999 The Interrupt Vector permits you to interrupt a user program externally at any time The program sequence will then continue at the start block number specified for the Interrupt Vector program No RTS command is required at the end of the Interrupt Vector Program There is no return jump to the interrupted main program Notes When a main program is int
240. nly after the axis has been Homed In the Manual Mode the corresponding Jog key is disabled when this position has been reached If in the Automatic Mode the commanded position is smaller more negative than this limit value an error message will be displayed The travel limit value is measured from the reference point Home Position and is not added to or subtracted from the offset distance This parameter is specified in input units to two or three decimal places Set the decimal resolution in B007 before entering this parameter For multi turn absolute feedback operation A plus sign will appear for this parameter instead of a minus sign and the value here will be the minimum travel allowed The travel limit value is measured from the zero point of the encoder and is not added to or subtracted from the offset distance Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 21 Parameter A114 Travel Limit Maximum Value Max Travel A114 01234 567 This parameter specifies the travel limit value in the positive direction in reference to the Home Position The limit is effective only after the axis has been Homed In the Manual Mode the corresponding Jog key is disabled when this position has been reached If in the automatic mode the commanded position is greater than this limit value an error message will be displayed The travel limit value is measured from the
241. nnection information 1 Install the TVD DDS Power Supply Digital AC Servo Drive or DKS Digital Compact Drive per their respective support manuals 2 Connect the MDD motor power cable and high resolution feedback cable to the DDS or DKS per interconnect drawings in Appendix C or refer to the DDS or DKS support manuals 3 Connect the optional CTA Keypad Display to the DLC Connector X30 via IKS 745 ribbon cable Refer to the interconnect drawings in Appendix C Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Installation Start Up 6 5 6 9 DEA 4 1 Input Connections The DEA 4 1 input connections used in this example are minimized for the sake of simplicity Refer to the interconnect drawings in Appendix C for any additional details Connect the incoming side of each switch to a external 24 Vdc source 1 Connect 2 position selector switch to provide a 24 Vdc signal to Pin 2 Automatic Mode input The second position is not wired 0 Vdc and is used for Manual Mode default mode Connect a key switch to provide 24 Vdc to Pin 1 Parameter Mode input 2 Connect a Normally Closed pushbutton switch to Pin 3 Emergency Stop of the DEA 4 1 connector X17 3 Connect a Normally Open momentary pushbutton to Pin 4 Cycle Start of DEA 4 1 connector X17 4 Connect a Normally Closed momentary pushbutton to Pin 5 Cycle Stop of DEA 4 1 connector X17 5 Connect a Normally Open momentar
242. not an incremental position command then the position difference is lost permanently 4 The WRI command cannot be processed while using the KDI command 5 The KDI command can only be used in one task at a time Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 62 Programming DLC A and DLC G Torque Reduction E 1345 MOM 1 020 040 01 123 1 Axis 1 020 Percentage Of Maximum Torque Until Positive Stop Is Reached Minimum Percentage 000 Maximum Percentage 400 040 Percentage Of Maximum Torque At Positive Stop Minimum Percentage 000 Maximum Percentage 100 01 Aux Input for Torque Reduction 00 No input needed reduce torque on execution of MOM command 01 07 Reduce torque any time input is high after one execution of MOM command 123 Percentage Of Maximum Torque Minimum Percentage 000 Maximum Percentage 400 Note If the percentage of maximum torque values entered in the MOM command are greater than the maximum percentage allowed the value entered will be interpreted as 100 percent The MOM command is used to limit the torque to the motor when a positive stop is reached or when MOM command is executed The MOM command requires a PFI Incremental Position To Positive Stop or PFA Absolute Position To Positive Stop command to assist in positioning to a positive stop The MOM command will determine the maximum torque allowed while positioning to the positive stop and the maximum t
243. ns Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat D 6 Installation Drawings DLC A and DLC G 0 5 10 Keyboard and Cabinet Cutout Dimensions Barcode Typecode 0 X1 SUPPLY VOLTAGE FUSE olololololo X2 Rs 485 WAWAWAWAWAWAWAWI jaro ajo X3 RS 232 X4 IN OUTPUT IMD ARIAL 125 2 04 6 02 allowable R4 Rexroth Indramat 115 04 10 Part No 262474 Cabinet cutout max allowable thickness 5 mm Fig 8 4 CTA10 Figure D 5 CTA 10 Keyboard and Cabinet Cutout Dimensions DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Installation Drawings D 7 D 6 CTA DLC Interconnection Option Programming and Display Unit X30 Connector CTA Connector 34 Cable Assembly IKS 745 length in m 1 for 04 1 max length 30m for CTA 04 1B max length 10m DDS X3 5 DKS X8 4 CTA 04 1 B Part No 263051 Display illuminated CTA 04 1 N Part No 263052 Display not illuminated Z D c 1 e S o c Uu 3 a LI 2 X31 Connector for IDS
244. ns 3 5 Operating Mode Selection Inputs Parameter Mode Select 3 3 Automatic Mode Select 3 3 Outputs Manual Mode Indicator 3 4 Auto Mode Indicator 3 4 Parameter Mode Indicator 3 4 The DLC will always be in one of three operating modes e Parameter Mode Allows entry verification of the parameters required to adapt the control for the specific requirements of the application e Automatic Mode Runs the user written executable program for automatic cycle operation Task 1 and 2 run after a Cycle Start input e Manual Mode Default mode when neither of the above are selected In this mode the jog inputs are used to position the axis forward or reverse through the system Parameter and Automatic Modes are selected by bringing the appropriate signal line high 24 Vdc A fault is diagnosed and an Invalid Mode Selection error message is issued if Parameter Mode is selected while Automatic Mode is selected The suggested interface design is to wire the Parameter Mode signal to a key switch where a key is required to enter Parameter Mode and or mount the switch inside the cabinet This helps to prevent unauthorized parameter changes Wire the Automatic Mode input signal to a two position selector switch where Manual Mode is selected when the switch is set to an open contact position The DLC has outputs to verify or acknowledge the currently selected mode These are typically wired to indicator lights on the user
245. nstances the user must define a homing sequence that satisfies the application then write a short program routine to home the axes With this method the user can customize the homing routine to compensate for backlash forward moving only applications homing to a switch or a variety of other needs Homing to a Switch The following program sequences demonstrate several methods of homing to a switch The first example is used to home an axis that cannot backup The second example will provide a more accurate homing relative to the home switch because the axis backs up to the switch The third example is used if you must detect whether the axis is already on the home switch and must back off the switch before homing Note that when customized homing routines are used they are only executed in automatic mode and the ability to home in manual mode is lost Note The following examples assume the parameters and I O are set as shown below This can be freely modified to fit the particular application Inputs Outputs 1 Home switch axis 1 A112 21 axis 1 Homed A112 23 axis 1 In Position A106 Example 1 Illustrates the simplicity of creating a routine to home both axes sequence axis 1 first then axis 2 This routine is very useful for an application in which the axis should not back up while homing such as a rotary table conveyor or continuous web The program starts with blocks
246. nt control panel design and troubleshooting Parameters This section describes all user entered parameters required to adapt the DLC to the mechanical and electrical characteristics of each application Programming This section describes all program commands provided in the DLC for the user to create the executable program as desired for the application Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 1 6 General Description Rexroth Indramat Chapter 6 Chapter 7 Chapter 8 Appendix A Appendix B Appendix C Appendix D Appendix E DLC A and DLC G Installation Start up This section describes procedures for installing a DLC control system Provides an example of a DLC start up and testing procedure Serial Interface This section describes the multi format RS 232 485 port and the protocol for two way communication between the DLC and a host device Diagnostics amp Troubleshooting This section describes the DLC s self diagnostic system lists and explains all diagnostic messages and describes troubleshooting procedures Appendices DA and DG Programming Notes This section is periodically updated with hints and examples of use for programming commands Display Map This section shows the DLC display screens which appear on the CTA control panel Interconnect Drawings This section contains interconnect drawings for e DKS DLC e RS232 Data Interface e SOT DLC RS485 e CTA D
247. nt subroutine stack Note Additional program flow control is possible by using the Change Subroutine Stack command CST with the JSR RTS commands for advanced programming Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 84 Programming DLC A and DLC G SAC Set Absolute Counter E 0300 SAC 1 12345 678 1 Axis 1 0 0 Absolute offset offset change 1 Set absolute position with respect to the command position 2 Set absolute position with respect to the actual position 12345 678 Absolute position or offset plus or minus This command is used to set or change the value of the absolute position counter The axis must be homed before this command can be used Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 85 SIN Sine Oscillation E 0380 SIN 1 10 12 345 999 1 Axis 1 10 Auxiliary input which enables SIN function 12 345 Amplitude in Input Units to 2 or 3 decimal places depending on setting in B007 999 Frequency of oscillation in Hertz 0 01 to 9 99 This function will start up with 0 degrees when the enable input is switched On When the enable input is switched Off the function ends at 360 degrees After this stepping to the next block will take place The axis must be homed or an error will occur when this command is read Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 86 Programming DLC A and D
248. number of inputs required multiplied by the length of jump added to the target block Binary mode is the only conversion mode allowed with the BIC command The user selects the starting auxiliary input number and the number of consecutive binary inputs required The target block is calculated as follows Target Block Block Offset Binary Input Value x Length Of Jump Example E 0000 BIC 0300 10 05 4 0 Aux Inputs 8 7 Binary Input 1 0 Decimal Significance 8 4 6 5 0 1 2 1 Decimal Equivalent 9 Target Block 0300 9 x 10 390 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Rexroth Q Indramat 5 26 Programming DLC A and DLC G BIO Branch Input Output Compare E 0801 BIO 0321 2 1111222222 0321 Target Block 0000 2999 2 Bank number 0 9 group of 10 aux inputs outputs Bank X gt aux I O 0 9 i e Bank 2 aux I O 20 29 Bank 3 aux I O 30 39 etc 1111222222 aux inputs outputs states for comparison States are defined below 0 I O compared for OFF condition 1 compared for ON condition 2 I O not compared Don t Care This command is used to check the aux inputs identified with 1 for the level input 1 if the aux outputs of the same number have been set to 1 The jump to the target block takes place when the condition is met The inputs in the BIO data marked with 0 or 2 will not be checked The only comparison that will cause a jump is if each respective BIO dat
249. o zero and stepping to the next program block number takes place See Counter Display screen example below Information about the Offset Value 1234 Add Offset Number of items to Actual Number of items 1234 Subtract Offset Number of items from Actual Number of items 00000 Reset Actual Number of items to zero 0000 Actual Number of items unchanged 0000 Actual Number of items unchanged This is an example of the Counter Display screen See Chapter 2 for procedures to scroll through displays and view the Counter Display screen Program block number of BAC command A 1500 Counter 000056 000500 _ Preset Counter Value Actual Count Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 20 Programming Rexroth Indramat DLC A and DLC G Immediately after this block is stored in memory the Offset Value entered is summed with the Actual Count and becomes the New Actual Count Then the Offset Value in the BAC program block display is set to 0000 This ensures that the Actual Number of items is only affected once for instance if Store is pressed again the actual count will not be changed The jump to the Target Block continues to be executed until the programmed Preset Count has been reached After that the DLC steps to the next block and the Actual Counter is set to zero The Actual Count can also be set to zero by using the program command CLC Example Assume the Pres
250. of the next program block does not begin until the programmed position has been reached within the position window parameter A106 G60 is the default mode and is automatically active after restarting the program Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 52 Programming DLC A and DLC G G61 Velocity Rate Optimization Rexroth Indramat E 1000 G61 This instruction enables processing of a velocity rate optimization profile using G01 and F instructions This profile may be up to a maximum of 20 blocks long and begins with the G61 command and ends with the G60 command This optimization prevents the axis from stopping between G01 positioning commands without Lag finishing even when the feed rate or program distance is changed Within this profile there may not be any programming commands that would prevent program execution from continuing immediately with the next block e g dwell time program jumps branch jumps etc No change in direction of motion is possible within the profile All positioning commands must be programmed only in absolute or only in incremental positioning Any active Tool Correction is observed If a G60 programming command is encountered the Velocity Optimization ends If there is G60 instruction after 20 blocks from the first G01 command the error message No G60 is displayed Program Example N0000 991 Set incremental positioning N0001 G61 Velocity rate
251. oftware version operation status messages faults status of each input and output counters etc The Edit screen allows programming or editing the program data The following section describes procedures for scrolling through each of these display screens Each following section describes the function of each screen procedures to edit the screens data etc Scrolling Through Display Screens Refer to the Display Map in Figure 2 2 for a full illustration of the display access procedure For convenience the same illustration is included in Appendix C This section describes the basic procedures for reading this map and scrolling through the different displays Each display screen is fully described in the following sections To allow easier description each row of the map is labeled A B C etc In general use the up or down arrow keys to scroll through the different display screens Use the left or right arrow keys to scroll through the displays on each row All rows allow wrapping from the last screen on the row back to the first screen and vice versa by continuing to press the right or left arrow key Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G SYSTEM INPUTS x E F Controls and Indicators 2 5 DRIVE DIAGNOSTIC TOOL CORRECTION REGISTERS amp VALUES POSITION INFORMATION I HARDWARE VERSION DECSTATUS SOFTWARE VERSION DLC G software only INPUTS
252. ommand will subtract 1 to the programmed destination which means it will add 1 to the programmed destination DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 103 Deactivating Tool Correction There are two ways to deactivate a tool correction value e Select Tool Correction memory 00 with 0 00 command e Disable the Tool Correction function with the G40 command G40 Tool Correction Deactivated E 1000 G40 This command disables Tool Correction within the process path in the programmed feed command G40 is effective upon entering automatic operation The register selected remains selected even after deactivating the Tool Correction with G40 If a G43 or G44 command is issued after a G40 is issued the last selected Tool Correction register prior to the G40 command will be used as the selected value External Tool Correction Tool Correction registers can also be specified on line using the SO1 command The SO1 command is used to read in information via decade switches or from a programmable controller Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 104 Programming DLC A and DLC G Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Installation Start Up 6 1 6 Installation Start Up This Chapter covers the installation and initial start up testing procedures for the DLC control system The typical DLC Control system consists of the following componen
253. on of the previous field Changing to another block number display screen etc without first pressing the Store key also causes loss of a change to a block s data Chapter 5 provides the information on commands required for creating the user executable program DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connections 3 1 3 Functional Description of DEA 4 I O Connections The DLC motion control system is designed to function harmoniously within the machine builder s equipment design The DEA 4 Input Output card which plugs into the U2 slot of Indramat s Digital Drives The DEA 4 provides several input output signals to handshake between the DLC control and the machine builder s equipment This chapter describes the functional operation of the interfacing inputs and outputs of the DEA 4 with DLC control card The first sections of this chapter describe the various interface functions in terms of the inputs outputs involved with each This includes the pre defined I O connections of the DLC DEA 4 as well as certain functions which the user can select through parameter or programming using auxiliary I O connections Certain auxiliary output functions are set in firmware as described in Chapter 5 for user programming This first section is followed by an individual description of each pre defined I O signal including name pin assignments and functional description The designer util
254. ons no change can be carried out If the target block includes no valid command stepping to the next block will take place without any changes in the target block For CON and FOL designation of the information type has no significance NOTES 1 It is only possible to process CID KDI or WRI command at given time The commands waiting in other tasks will be delayed until completion of the first instruction 2 At present the use of the CID command is limited to the CON FOL POI PSI POA and PSA commands All others commands will be bypassed with no change Info Position CON speed in Speed in FOL Follow factor Follow factor POI PSI POA PSA Length Speed in PST JMP VCA WAI The information is transmitted to the target statement in right justified format In each case the following command is called once CID 1234 1 0 0000212 DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 33 Copy Input Output to Output 0160 CIO 03 7b 9 1 0 Copy source Auxiliary Inputs 1 Copy source Auxiliary Outputs 2 Copy source System Inputs 3 Copy source System Outputs 03 First Input Output Number looked at Copy Source 01 to 99 75 First Output Number to Copy to Copy Target Destination 01 to 99 9 Quantity of I O to be Copied 1 9 This command can be used to copy the status of several inputs or outputs to other outputs Warning The manipulation of aux o
255. ontents thereof without express authority are forbidden Offenders are liable for the payment of damages All rights are reserved in the event of the grant of a patent or the registration of a utility model or design DIN 34 1 All rights are reserved with respect to the content of this documentation and the availability of the product Mannesmann Rexroth Indramat GmbH Hoffman Estates 5150 Prairie Stone Parkway Hoffman Estates IL 60192 USA Phone 847 645 3600 Fax 847 645 6201 http www rexroth com indramat Dept ESV DOK CONTRL DLO A DLC G AW03 AE P 12 99 DLC A and DLC G Table of Contents Table of Contents 1 1 1 2 2 1 2 2 2 3 General Description 1 1 DLG 1 4 About This Manual tnc 1 5 Hardware and Software 1 5 How To Use This e 1 5 System FOQLUNCS ives 1 7 Superior Performan E ce enlist ed 1 7 Easy to 1 7 Parameter Adaptable to Multiple Machines seen een ener ener 1 7 Fully Selt DiaQmOstics PEE 1 7 Programming Structure 1 7 Programmable Acceleration Rate
256. operating velocity has been reached The axis position commands should not be used while continuous operation is on This command will not be executed for an axis with an absolute value encoder The following example could be used on a web application to run speeds to keep a loop storage accumulator filled 0000 JMP 0100 Jumps to block 0100 0100 CON 1 1 750 00 Feed at initial Fill Speed 75 0101 BCE 0110 02 1 Branch to 0110 if first loop light input 02 is covered input high normal running 0102 BCE 0120 03 1 Branch to 0120 if second loop light input 03 is covered input high loop full 0103 JMP 0101 Scan inputs 02 and 03 again continue fill speed 0110 CON 1 1 500 02 Change speed to 50 turn ON loop normal output 0111 BCE 0100 02 0 Branch if accumulator storage is low 0112 BCE 0120 03 1 Branch if accumulator is full 0113 JMP 0111 Scan again for low full conditions inputs 02 and 03 0120 CON 1 0 000 00 Stop feeding accumulator is full 0121 AEA 03 1 Turn ON storage full output 0122 AKN 030 Wait for additional material to be removed to uncover loop full sensor 0123 AEA 030 Turn OFF storage full output 0124 JMP 0110 Resume at normal running speed block 0110 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G cou Count Programming 5 39 E 2000 COU 12345 12 123456 412345 Offset number of items 12 Signal aux output number 01 88 123456 Preset n
257. optimization turned on 0002 F 010000 00 5 F 10 m min N0003 G01 1 000200 00 01 Move 200 mm and set 0004 F 005000 00 Change F 5 m min N0005 G01 14000100 00 99 Move 100 mm No M Function N0006 F 002000 00 Change F 2 m min N0007 AEA 011 Set output 01 high N0008 G01 1 000050 00 02 Move 50 mm and set M02 N0009 G60 Velocity rate optimization turned off N0010 G04 01 00 1 second dwell time N0011 JMP 0000 Repeat cycle DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 53 G74 Reference Axis E 1000 G74 a Axis always 1 This command corresponds to the HOM command All criteria and limits that apply to the HOM command also apply to the G74 command For further information see the description for the HOM command Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 54 Programming DLC A and DLC G G90 Absolute Dimensions E 1000 G90 This command causes all subsequent process commands having a G code to be interpreted as absolute process commands G90 is the default and is effective upon entering automatic operation and after a program restart Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 55 G91 Incremental Dimensions E 1000 G91 This command causes all subsequent process commands having a G code to be interpreted as incremental process commands Once selected G91 is effective fo
258. orque allowed when the positive stop is reached When the positive stop is reached the programmed torque is applied until another position command POI POA etc is executed Stepping to the next block takes place immediately after the MOM command is read in the program The percentage of maximum torques are valid for all PFA or PFI commands until a new MOM command redefines the percentages The MOM command can be executed from another task When executing the MOM command from another task the new percentages are valid immediately even during the execution the PFA or PFI command in a separate task A typical application consists of programming the MOM command for the percentages of torque required and then commanding the axis to position by using the PFI or PFA command The commanded position must be greater than or equal to the positive stop position The axis will travel to the programmed position at percentage of maximum torque until positive stop is reached The program flow will remain on the PFA or PFI program block until the positive stop is reached or the until the programmed distance in the PFA or PFI command is completed If the programmed distance in the PFA or PFI command is completed before the positive stop is reached the next program block will be executed The next program block can be a jump JMP command to an error routine to tell the machine operator that the positive stop was not reached When the positive stop
259. output is on high 0 Auxiliary output is off low The DEA 4 auxiliary outputs 1 through 11 are defined by the machine builder in the DLC parameters and or program Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 1 4 Parameters This chapter describes the user entered parameters required for the DLC to perform the motion control operation The user adapts the DLC to his machine and the mechanical characteristics of the application by entering values for various parameters These parameters permit a standard control system to conform to different but similar applications It also assures that all application parameters are written with a uniform data format The user must enter parameter values into the DLC memory prior to the operation and programming of the DLC control Note All values for parameters must be known before an application program can be written If a function is programmed or attempted which would exceed the bounds established by the parameters the control will halt and a diagnostic error will be displayed 4 1 Description of Parameter Sets The DLC includes the following sets of parameters Parameter Set A Axis Parameters This axis parameter set A100 through A125 includes the axis operating values for Automatic and Manual Mode operation These parameters allow the user to configure the DLC for the motor and drive package that the DLC is controlling They al
260. p Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 44 Parameters LCA and DLO G Parameter 007 Display Language Decimal Place Keypad Lockout Language 07 01 03 0 0 45 Use this parameter to specify in which language text will display on the CTA display and to set the number of decimal places used in positioning commands and certain parameters It also allows disabling any program entry changes from the CTA keypad 01 Language 00 German 01 English 02 French 03 Spanish 04 Italian 05 Portuguese 03 Number of decimal places used in positioning commands and certain parameters 02 Metric e g millimeters XXX YY 03 US System e g inches XX YYY The number entered for decimal places specifies how many digits are to the right of the decimal point for positioning commands and many parameters Make your selection depending on the resolution required See Appendix E parameter input sheets showing the decimal location for each parameter with resolution set at 2 or 3 in BOO7 Parameter affected A102 A107 A117 A100 A101 A106 A111 A113 A114 A108 B018 Command affected 4 digit of B007 2 POI PSI POA PSA PSM POM PST VCC 2 3 VCA BPT BZP PFA PFI REP SAC Figure 4 1 Decimal place settings 0 Unassigned set to 0 0 Enable fault code via outputs 0 No fault code via outputs 1 Fault code via outputs 01 to 08 2 Fault code
261. p line or use the left right arrow keys Then use the and keys to scroll up or down through the block numbers You can also type the block number desired directly over the existing number ABC 3 letter mnemonic of command programmed in displayed block To scroll through the commands position the cursor to the right of the displayed command three letter mnemonic Use the up or down arrow keys to scroll alphabetically through commands When the desired command is on the display press the right arrow key to select the command and move the cursor into the data field that appears for the specific command on the second line Data Most command requires entry of data specific for that command as described in the following sections 5 8 Command Summary The various commands can be classified into categories by their function as described in the following sections These sections describe the general use and differences between all the programming commands For future reference you can use these sections to select the specific command desired for the general function Then refer to that command description in section 5 9 for further details on how it works and requirements for its entry Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 6 Programming DLC A and DLC G Positioning Commands Rexroth Indramat There are two major types of positioning commands Incremental movement from one point to the ne
262. pad Display l O Interface System Inputs Auxiliary Inputs with DEA card System Outputs with DEA card Auxiliary Outputs Rexroth Indramat Convection 41 to 113 F 5 to 45 C 22 to 185 F 30 to 85 C 3 280 ft 1000 meters higher altitudes permitted with proper cooling High Resolution With Single turn or Multi turn Absolute Resolver Incremental Encoder requires DEF incremental encoder interface card Absolute encoder GDM only requires a DFF interface card 0 001 inches 0 01 mm Normal 0 1 99 9 of Maximum Velocity DG Feed Rate values can be in upm Operator Selectable Jog 0 1 99 9 of Maximum Velocity Parameter Selectable Note Maximum Feed Rate will vary depending on the mechanical design of the equipment Forward Reverse Manual Mode only 0 01 99 99 seconds in 0 01 steps Limited only by number of program lines LCD Optional Backlit Version Available Four 4 line 16 Characters Line 20 membrane switch keys 8 24 Vdc 10 mA pre defined function 7 Standard 37 Expanded user defined and programmable 5 24 Vdc up to 100 mA Sourcing pre defined function 11 Standard 43 Expanded User defined and programmable CAUTION Inputs will have a 10 mA current draw at 24 Vdc Outputs are thermally protected by a current limiter circuit which eliminates requirement for added fuses If the load on the output causes a current draw in excess of 100 m
263. places depending on the setting in 007 999 Feed rate as 00 1 99 9 of the maximum velocity set in parameter A100 Note The axis must be homed prior to execution of this command Otherwise an error message will be issued Stepping to the next block takes place only after the positioning has been completed Parameter A106 Position Tolerance is used to set the position tolerance for stepping to the next block DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 73 PSI Position Incremental With In Position Signal E 1420 PSI 12345 678 999 1 Axis 1 Incremental position direction plus or minus Note If a character other than is entered for this position the direction will be negative 12345 678 Incremental target position in input units to 2 or 3 decimal places depending on setting B007 999 feed rate as 00 1 99 9 of the maximum velocity set in parameter A100 Stepping to the next block takes place only after the positioning has been completed Parameter A106 Position Tolerance is used to set the position tolerance for stepping to the next block Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 74 Programming DLC A and DLC G PSM Position On Memory with In Position Signal Requires IDS Setup E 330 PSM Jr 1 Axis 1 0 Mode 0 Position incremental 1 Position in absolute dimensions 1 Position direction
264. position To physically position the axis to an offset position after the homing routine is completed use a position command See Chapter 5 This parameter is specified to two or three decimal places Set the decimal resolution in B007 before entering this parameter For single turn absolute feedback operation 0 Offset direction 0 Forward 1 Reverse 0000 000 Offset distance in input units to 2 or 3 decimal places For multi turn absolute feedback operation 0 No significance 0000 000 Offset calculated from encoder reference point in input units to 2 or 3 decimal places For rotary applications the zero offset may not exceed the value of input units revolution of table Otherwise the error message input error will appear For instance if degrees have been selected as input units 360 table revolution and 10 has been programmed as the zero offset the zero point is set at 10 Refer to section 3 2 5 for additional information on the Homing function Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 19 Parameter A112 Homing Acknowledgements Homing Ack 112 09 12 00 13 This parameter is used to identify the various I O assigned to the Homing Process In Manual Mode homing can take place by means of the assigned auxiliary input number or in Automatic Mode by use of the command HOM 09 Auxiliary input number used to initiate Homing in Manual Mo
265. processed must be shorter Error Message Code Home Switch Pos 4B This error occurs if the marker pulse of the axis feedback is closer than 1 16 revolution to the homing cam switch 1 Refer to Chapter 3 Section 3 2 4 for details 2 Move the axis home limit switch a distance equal to or greater than 1 3 of the axis feed constant parameter A108 Error Message Code IDS Brake Error 12 This error will occur if the optional IDS board is enabled but the DLC does not detect the connection of the IDS board The IDS board is enabled in parameter B003 Serial Interface 1 The cable between the IDS board and the DLC connector X31 is installed properly 2 The DLC serial communication port is defective 3 The IDS board is defective Error Message Code IDS Checksum Error 13 This error will occur if the optional IDS board is enabled but the DLC does not detect the connection of the IDS board The IDS board is enabled in parameter B003 Serial Interface 1 The cable between the IDS board and the DLC connector X31 is not installed properly 2 f the IDS board is connected then the wiring and its layout to the decade switch should be checked Maximum cable length is 15m Error Message Code IDS Data Too Long 15 This error will occur if the optional IDS board is enabled but the DLC does not detect the connection
266. programmed in the DLC program is 0 zero 3 The REP command was encountered before the REF command was executed in the DLC user program Error Message Code Is INVALID 02 This message appears when the value stored in a DLC parameter exceeds the minimum or maximum limits This message appears on the first line of the display The second line displays the number of the affected parameter The fourth line will display the parameter name The parameter containing the invalid data can be displayed by switching back into parameter mode and pressing the CL key on the CTA keypad or by bringing the External Clear input DEA card X17 pin 8 high 24Vdc Consult Chapter 4 of this manual to determine the minimum and maximum values for the parameter in which the error occurred DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Diagnostics And Troubleshooting 8 7 Error Message Code JSR Nesting 0B This nesting error occurs if the nesting depth of the programmed subroutines is greater than 127 1 Change the DLC program so that the number of nested subroutines does not exceed 127 2 Chec
267. programming command The rate can be changed to different levels for subsequent moves on the fly in automatic mode This is useful for establishing proper rates for new materials or setting required rates for different materials without changing parameter settings The Standard DLC requires a DEA 4 card which includes a set of 7 auxiliary inputs and 11 auxiliary outputs which can be defined by the user for electrically controlling and acknowledging machine functions Optional I O cards can increases the auxiliary I O to 37 inputs and 43 outputs Additional outputs can be programmed as flags The Standard DLC Control is illustrated in Figure 1 5 The Extended version with additional I O connections is illustrated in Figure 1 6 Control Machine System I O Interconnection Homing Registration The DLC has 8 input and 5 output connections which are pre defined They include connections to the machine and its control panel for mode selection cycle start and stop emergency stop mode selection acknowledgment etc These connections are typically made to keep handshake between the control and machine For example on a slide the control will not position if the ram is too close to the material and or the external operation will not start until the positioning is complete The axis will not position if an external operation is pending Homing allows absolute referencing for the axis The user can initiate homing in the manual mode or automati
268. r 42 CrLf Carriage Return Line Feed Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 7 8 Serial Interface DLC A and DLC G Note All transmitted data fields must be comprised of 16 characters Send trailing spaces to fill the data block The following provides example of command strings for program blocks with different size data fields Note the information as it appears on the DLC display then the format required to send the information filling all 16 characters positions of the data field Display Screens E 0100 AEA 07 0 E 0101 PSI 1 02345 678 999 Serial Data To Transmit same information that can be entered from the CTA keypad on the Edit display screens above 4 NO100 07 O S5BCRLF Data Field KKKKKKKKKKKKKKKK _NO101_PSI_ 1_ 12345 678_999 _S53CRLF Refer to Chapter 5 for description of each command and its data field requirements Table 7 1 illustrates the serial data string arrangement for each command and its data field Sending Parameters to the DLC Rexroth Indramat Parameters sent to the DLC must follow this format K_yyxx_dddddddd_ hhCR LF The following describes each part of the command string IK Send parameter to DLC yy Parameter Set Xx Parameter Number dd gt dd Data 8 characters in the proper format for a given parameter End of block check sum may follow hh Che
269. r B014 Restart Vector as of software version DA1 1 03 03 DG01 1 03 03 4 52 Parameter B015 Cycle Time as of software version DA01 1 03V05 DG01 1 03V05 4 53 Parameter B016 External Encoder 1 Encoder Selection as of software version DAO1 1 01 2 4 54 Parameter B017 External Encoder 1 Pulses Revolution as of software version DAO1 1 01 2 4 55 Parameter B018 External Encoder 1 Feed Constant as of software version DAO1 1 01 2 4 56 Parameter B019 Offset Dimension External Encoder 1 4 57 Parameter B020 External Encoder 2 Encoder Selection as of software version DAO1 1 01 2 4 58 Parameter B021 External Encoder 2 Pulses Revolution as of software version DAO1 1 01 2 4 59 Parameter B022 External Encoder 2 Feed Constant as of software version DAO1 1 01 2 4 60 Parameter B023 Offset Dimension External Encoder 2 4 61 Parameter C000 Analog Output Channel 1 as of software version DAO1 1 01 6 4 62 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat IV Table of Contents DLC A and DLC G Parameter C001 Analog Output Channel 2 as of software version DAO1 1 01 6 4 63 Parameter C002 Overload Factor as of software version 01 1 01 6 4 64 Parameter Position Data Scaling at Analog Outpu
270. r all subsequent blocks until it is unselected by a G90 command or until the program is restarted Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 56 Programming HOM Home Axis 1 DLC A and DLC G E 0230 HOM 1 1 Axis 1 Homing proceeds according to how parameters A110 A114 have been programmed Stepping to the next block takes place immediately after the block has been read in Programming measures must be taken ATS AKN to prevent absolute positioning commands POA PSA etc from being encountered before the homing sequence is completed or an error message will be issued An ATS command programmed to monitor the Home Established output Parameter A112 will prevent stepping to the next block until the homing sequence is finished If the HOM command is used for the axis with an absolute value encoder it will result in an error message Note There are alternatives to Homing an axis other than using this predefined routine They are described in Appendix A Programming Notes Rexroth Indramat DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 57 JMP Jump Unconditional E 2500 JMP 1234 1234 Target block When this command is encountered in a given task the program will immediately jump to the specified target block There are several other commands that also provide an unconditional jump but provide added features in the same block They can be useful
271. r the DLC The first fifteen lines inputs of the DEA 4 connector X17 are for system and auxiliary inputs The first eight are system inputs The next seven are user programmable auxiliary inputs Two additional cards DEA 5 and DEA 6 can be installed to expand the DLC auxiliary inputs up to 37 Chapter 3 provides a functional description for each of these I O connections Table 2 1 following this section provides a legend of the Input signal function for each Input screen and the corresponding connector for hardware I O connections The next sixteen lines outputs of DEA 4 connector X17 are for system and auxiliary outputs The first five are system outputs The next eleven are user programmable auxiliary outputs Two additional cards DEA 5 and DEA 6 can be installed to expand the DLC auxiliary outputs up to 43 With either the Standard or Expanded DLC these output points above the auxiliary connections hardware can be programmed as software flags Certain output flags are set in firmware and can be queried by the user program Chapter 5 defines the restrictions and use of these auxiliary outputs as software flags Table 2 2 following this section provides a legend of the Output signal function for each Output screen and the corresponding connector for hardware I O connections Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Controls and Indicators 2 11 CTA Display Position Signal Description
272. rameter A100 x 60 If Fmax is exceeded this command leads to the error message F Command The F instruction is valid for all feed commands including PSA POM PSI When an F feedrate is programmed the of Vmax feedrate active in the program blocks up to that point is then ignored This F feedrate remains effective in memory until it is overwritten by a new F value or until it is canceled by the command F 000000 00 After processing a command having the contents 000000 00 the previous feedrate in of Vmax is reactivated and becomes valid for all subsequent programming blocks Once this occurs it is no longer possible to use the G01 command Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 46 Programming GO1 Linear Feed Rexroth Indramat DLC A and DLC G E 1000 G01 1 000010 00 mm 1 Axis always 1 000010 00 Process path absolute or incremental mm Number of the M function 00 63 that is to be called up after reaching the target position If no M function is used 99 must be entered as the M function to be output If 99 gt mm gt 63 the error message ERROR Command be displayed This command causes a linear position feed at the previously specified feedrate If the feedrate has not been previously defined with the F command when G01 is called up the error message G01 without F results
273. rated in Figure 1 3 are available for the DLC The IDS connects to the RS 232 connector X31 of the DLC This unit is remotely mounted up to a maximum of 60 feet away from the DLC The operator selects the required feed length and a feed rate on different sets of thumb wheel switches The decimal place resolution for the feed length is set by parameter The feed rate is selected as a percentage of the maximum feed rate set by parameter All status and diagnostic message codes appear on the two digit LED alphanumeric display Figure 1 3 Optional IDS Optional Station Operator Terminal SOT and Screen Manager The Indramat SOT is a remote mounted operator control device for the DLC see Figure 1 4 It allows for the same input functions and displays the same information as the CTA keypad display but provides several additional features The SOT includes a backlit liquid crystal display with 16 lines of 40 characters each It can display much more information at a time than the standard display on the CTA keypad display The SOT keypad includes click contact keys for entering or changing data The SOT also has 8 outputs which can be defined by the machine builder with ScreenManager software ScreenManager software is a development tool for the SOT This command line editor software packag
274. rd Length Parity Check Serial Interface 7 3 The DLC requires only three lines of the standard 9 pin connector for RS 232 communication Pin 3 is for Transmitted Data pin 2 for Received Data and pin 5 is the Data Signal Ground Typically pin 1 connects the cable shield to ground on one end only The transmit data connection from one device connects to the receive data of the other device and vice versa Signal ground connection must be common on both devices Pins 7 and 8 are jumped on the DLC side only Consult the manufacturers information for the serial card in your computer for its specific pin configuration Indramat can supply a standard serial cable cable 05 0046 to connect from 9 pin PC to 9 pin DLC card You may prefer to buy the required connectors and wire the cable in house Note that most serial cards do not provide a signal strong enough to go through a cable longer than about 50 feet When possible use a shielded cable no more than 25 50 feet long Only connect the pins shown in this figure Wires connected on any pins other than the ones shown may cause communications errors To achieve proper communications configure the communication parameters B003 and B004 to match between your computer and the DLC Figure 7 4 illustrates the data format Following sections describe each parameter for data communication Section 7 5 further describes the Checksum options of parameter B004 START BIT DATA BITS PARITY BIT STO
275. reference point Home Position and is not added to or subtracted from the offset distance This parameter is specified in input units to two or three decimal places Set the decimal resolution in B007 before entering this parameter For multi turn absolute feedback operation The travel limit value is measured from the zero point of the encoder and is not added to or subtracted from the offset distance Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 22 Parameters DLC A and DLC G Parameter A115 Special Functions Disable Following Error Velocity Achieved Master Encoder Averaging Velocity Feed Forward Special Function 115 12 34 56 7 8 12 Aux Input to disable following error 01 37 34 Aux Output to acknowledge following error is disabled 56 Aux Output to indicate when the programmed velocity has been achieved 7 Not used Enter 0 8 Averaging of Master Encoder input pulse train for Master Slave Mode See FOL command 0 No Averaging No Velocity Feed Forward 1 9 Velocity Feed Forward Mode Average over 1 read Average over 2 reads Average over 4 reads Average over 8 reads Average over 16 reads Average over 32 reads Average over 64 reads Average over 128 reads OMAN OA A OO N gt ll Average over 256 reads Note 1 Read 1 millisecond Feed forward automatically adjusts for following error between the axes when averaging is selected Any remaining
276. rently undefined Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 27 Parameter A120 Feed Angle Monitoring Feed Interrupt Feed Angle Mon A120 01 02 03 00 01 Aux input number for Feed Angle Monitoring with error display 01 37 00 Feed Angle Monitoring not used 02 Aux input number for Feed Interrupt Feed Hold 01 37 00 Feed Interrupt not used 03 Aux output message for Axis Stopped 01 99 00 Stop Axis not used 00 Not Used Note There are no diagnostics for Feed Angle input missing before a feed or when a Feed Interrupt is executed 1 Feed Angle Monitoring Active High This parameter specifies if the feed or positioning is to be monitored or not If 00 is input here then the axis is not monitored If an auxiliary input number has been specified and if there is no signal at the specified input no positioning will take place The DLC processes all blocks not containing any position commands As soon as the program processing comes to a block containing a position command the DLC will stop in this block until there is a signal at the input If the specified auxiliary input signal shuts off during a positioning the axis will be stopped and the error message Feed Angle Loss 1 will be displayed 2 Feed Interrupt or Feed Hold Active Low This parameter specifies whether an interruption of the programmed feed or position command currently being proce
277. rogram for Task 1 2 or 3 If the command stored at the selected target block is not a position command the WRI command will write the absolute position command over the existing command stored in the block The absolute position command selected by the WRI command must have a distance to feed This distance is taken from the Actual Position Display The velocity automatically inserted for doing the positioning is always the maximum 99 996 A preceding VEO selection 4 or subsequent VCC zero feed length can be used to reduce the written velocity to a lower percentage Using the WRI command in Manual Mode This is an example of how to write in absolute positions in the main program Task 3 is selected as the location for the WRI command The Task 3 program must be loaded into the DLC before enabling parameter BOO6 Task 3 is always running even before Cycle Start is pressed Start Task 2 amp 3 Parameter B006 00000150 Note Axis must be homed Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 5 98 Programming Rexroth Indramat DLC A and DLC G Example Program for the WRI command Block 0150 02 1 Aux input 2 writes 1st position 0151 BCA 0150 150 Check axis is homed 0152 WRI 0015 001 Writes in Abs Position at Block 0015 0153 AKN 02 0 Write in complete 0154 AKN 02 1 Aux Input 2 writes in 2nd position 0155 WRI 0019 001 Writes in Abs Position at Block 0019 0156 AKN 02
278. rom the work piece The dog cam for activating the homing switch must be long enough so that the activation is not canceled by a continuing reverse movement up to the minus travel limit of the axis This is required to indicate to the control unit in which direction the slide must be moved in order to approach the reference position Since the interrelationship between the direction of rotation of a servo motor and the movement away from and toward the work piece depends on the particular design of the machine the homing direction must be also set correctly in the parameters If there is no marker pulse within one revolution of the motor s feedback homing sequence is halted and a fault is displayed The display will show No Marker Pulse 1 Interruption of the Homing Routine If while in manual operation there is a stop an interruption feed angle monitoring or a switch of operating modes the homing cycle is interrupted and must be restarted After an interruption or stop occurs while in automatic operation the homing cycle is restarted immediately by activating the Cycle Start input and initiating a HOM or G74 command in the program After a fault or a change of operating modes during the homing cycle the DLC must be re initiated switch to Auto Mode press Cycle Start Over Travel Switches It is recommended that you install forward and reverse over travel switches on applications that have limited axis travel such as a sli
279. rque should be applied to the MDD servomotor If problems exist consult the digital drive manual or Chapter 8 of this manual to correct the problems To verify proper motor hook up and control of the motor jog the axis in Manual Mode Turn the selector switches to the OFF position so that neither the Automatic nor the Parameter Mode inputs are high defaults to Manual Mode 1 Press the Forward Jog pushbutton connected to X17 Pin 6 The axis should jog in the forward direction until the button is released 2 Press the Reverse Jog pushbutton connected to X17 Pin 7 The axis should jog in the reverse direction until the button is released 3 Should either the forward or reverse motor movement fail to react check all cable connections and verify the DLC is in Manual Mode Note If the CTA displays any errors refer to Chapter 8 Diagnostics DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Installation Start Up 6 11 6 16 Automatic Mode Operation To run the sample program and check Automatic Mode operation 1 Turn the selector switch to Automatic Mode wired to connector X17 Pin 2 2 Press the Cycle Start pushbutton connected to X17 Pin 4 Note The DLC will execute the sample program and stop after one cycle Change block 0004 to JMP 0000 to run the cycle continuously 3 Press the Cycle Stop pushbutton to stop operation Press Cycle Start to restart the program Note Cycle Stop will cause an imm
280. rror will occur if a BCD command is encountered the DLC program and the auxiliary inputs are not in BCD format 1 The BCD program command is programmed incorrectly Refer to Chapter 5 for information on the use of the BCD command 2 Verify that auxiliary inputs 1 through 8 are in a BCD format Error Message Code Configuration 1A This error will occur when the DLC Control card and the digital drive are incorrectly configured The firmware installed in the DLC Control card does not have the capability to operate with the present configuration Write down the current configuration and DLC firmware installed and contact the Indramat Service Department for more information Error Message Code Division By Zero 07 This is an internal DLC error 1 Check for a possible acceleration setting of zero or an acceleration change ACC program command to zero 2 Contact the Indramat Service Department This error occurs when there is an initialization conflict between the DLC Control card and the digital drive Write down the current configuration and DLC firmware installed and contact the Indramat Service Department for more information Error Message Code DPR Error 1C This error occurs when there is an initialization conflict between the DLC Control card and the digital drive This is an error in passing information over the dual port RAM between the DLC Control card an
281. rs to and from diskette Consult the Indramat Digital Amplifier Manual for more information The next step is to configure the DLC Control Card to operate with the parameters entered in the digital amplifier 6 13 Parameter Entry The parameters given here are the minimum required to operate the digital drive with the DLC control card For this example the following descriptions assume an input unit IU 2 1 inch Turn the keyswitch to Parameter Mode to enable parameter entry Enter the following parameters refer to Chapter 4 for parameter entry procedures or for further description of each parameter if necessary B007 Language 01030000 English display resolution to 3 places A100 Max Velocity See example entries on the following page or refer to Chapter 4 Parameters for more information A101 Jog Velocity 00005 000 5 0 in sec A102 Acceleration 0000025 0 25 0 in sec A103 Position Gain 0000 01 00 1 0 in min mil of Following Error A106 Position Tolerance 01 000 050 Output 01 position tol 0 050 in A108 Feed Constant 001 00000 1 0 in motor rev A109 Direction 0 0 000000 Direction of operation is unchanged A110 Homing Setup 00020000 Required for MDD High Resolution Multi turn Feedback A121 Maximum Motor Speed Enter maximum motor RPM here A122 Monitor Window 00000010 1096 window Following are three examples for A100 and A121 input Refer to Parameter A100 description to calculate the Max Velocit
282. rvo Motor to drive a ballscrew or some other positioning device This is a closed loop feedback system which provides precise control of speed and position at all times The DLC Digital AC Servo System is used for a variety of positioning applications The DLC DEA 4 installed in the Indramat DKS Digital Compact Drive is illustrated in Figure 1 1 Typical applications include e Rotary tables e Packaging machines e Thermoforming machines e Gantry robots e Handling equipment e Wood working machines lo Figure 1 1 DKS Positioning Control Module Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 1 2 General Description Rexroth Indramat DLC A and DLC G The extensive program command set permits the DLC to perform even complex processing tasks It can do multi tasking operating one motion program and two background programs simultaneously The DLC can be programmed both on line and off line The DLC can be used in remote operation where it is controlled by the customer s line control usually a computer or a programmable controller which controls operation of the whole machine
283. s DEF card 000 Not Used 05000 Encoder line count pulses per encoder revolution 100 to 10000 Enter 00000000 for DFF card Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 56 Parameters DLC A and DLC G Parameter B018 External Encoder 1 Feed Constant as of software version DAO1 1 01 2 Note Requires DEF or DFF card Ext E 1 Constant B018 020 00000 Feed constant of external encoder 1 in input units The distance per encoder revolution Rexroth Indramat DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Parameters 4 57 Parameter B019 Offset Dimension External Encoder 1 Note Requires DEF card Ext E 1 Offset B019 00000000 00000000 Not used must be set to 00000000 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 58 Parameters DLC A and DLC G Parameter 020 External Encoder 2 Encoder Selection as of software version DAO1 1 01 2 Note Requires DEF card External Encod 2 B020 100 00000 1 System selection of hardware 1 DEF1 1 card 2 DEF2 1 card Not Used Operating direction of the encoder o 1 0 Encoder shaft and motor shaft have same rotational direction 1 Encoder and motor shaft have opposing rotational direction 00000 Not Used set to 00000 Note The measuring wheel encoder can also be used for the functions Follow Axis Measuring Wheel and Positioning with External
284. s control panel or to a PLC Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 3 6 Functional Description of DEA 4 I O Connections DLC A and DLC G Safety Interlocks Rexroth Indramat Inputs e Emergency Stop 3 3 Emergency Stop The Emergency Stop input must remain high for the DLC to operate The system incorporates an Emergency Stop E Stop chain This is a circuit connected in series to both the DLC and the user s machine Should any sensor in the E stop chain open all operations immediately stop Note that the time taken to stop depends on the wiring method used and inertia of the load connected to the servo motor on the machine Note that task 3 of the user program continues to run during an Emergency Stop fault condition When Emergency Stop is reset and a CLEAR signal is issued task 3 starts at the beginning block and continues to run Elements connected in the E stop chain commonly include the Emergency Stop switch on the user s control panel E stop switch es on the machine switches on lubrication or coolant pumps and various safety interlock switches on guards and doors Outputs e System Fault Indicator 3 4 There are several categories of faults as described in Chapter 8 In general once a fault is detected an error message is displayed on the CTA display the System Fault Indicator output turns OFF and all axes are immediately decelerated to a stop The fault re
285. s has been homed Prior to this the block is scanned only and no execution takes place Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 32 Programming DLC A and DLC G CID Change Instruction Data Rexroth Indramat E 0034 CID 1234 1 0 0000001 1234 Target block in which the information is to be changed 0000 2999 1 Info position 1 The first modifiable variable value in the target block is processed e g the length in POI command 2 The second modifiable variable value in the target block is processed e g the velocity command 0 Operation value added or subtracted 0 Add or subtract operation value depending on sign of change value 1 Same as 0 but the result of the operation must be positive otherwise the operation will not be carried out 2 Same as 0 but the result of the operation must be negative otherwise the operation will not be carried out 3 Overwrite information with the prefix in the target block the change value is added to target value the change value is subtracted from the target value 0000001 The information in the target block specified by the entry for of information is changed by this amount The position of the decimal is not considered This command changes the data in another block Stepping to the next block takes place when the data changes in the target block have been completed or when due to restricti
286. sition threshold specified in this parameter This position threshold does not affect the accuracy of the feed It tells the program when to read the next program block see PSI PSA in Chapter 5 This output can be used to turn ON a light or buzzer on the user s control panel or as a flag in the program to start a sub routine program operation etc See Chapter 4 for further information on this parameter function Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 3 8 Functional Description of DEA 4 I O Connections DLC A and DLC G Axis Homing Rexroth Indramat Inputs Initiate Homing in Manual Mode A112 Home Switch A112 Outputs Home Established Indicator A112 For absolute referencing for the axis it is necessary to establish a correct measurement reference with the help of a homing routine To initiate homing during manual operation use auxiliary input signal as defined in parameter A112 during automatic operation by use of the HOM or G74 command Auxiliary inputs Initiate Homing can be assigned for axis 1 in parameter A112 to initiate the homing process in Manual Mode by a push button switch or from a PLC output Home position is set by a Home Switch Assign an auxiliary input for the home switch in parameter A112 Homing in Automatic Mode is accomplished through use of the HOM or G74 command After reading in this command the next command should be an ATS command to monitor the Home Esta
287. so allow the user to set the various factors of the motion profile as required for the material and application These include the resolution of the feed acceleration rate feed rate in different modes etc Parameter Set B System Parameters This system parameter set establishes the operating arrangement of the DLC It allows the user to configure the DLC for various options such as the language that shows on the display English German Spanish French Italian or Portuguese selecting control interface options such as the IDS or SOT selecting and configuring other optional features like synchronization measuring wheel operation multi tasking etc Parameter Set C Drive Parameters This parameter set allows drive tuning through the DLC Drive parameters can be tuned using the CTA keypad or RS232 serial interface Default drive parameters can be set only by using the CTA keypad Processing must not occur simultaneously over the CTA keypad and RS232 serial drive interface Drive parameters are viewed and edited in the same manner as for A and B parameters C parameters are administered in the drive With each new power up the C parameters are sent from the drive to the DLC Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 2 Parameters DLC A and DLC G 4 2 Parameter List Table 4 1 lists all of the parameters for the DLC 01 1 A and the DLC 01 1 G with software versions DAO1 1 XX X or DG01 1 XX X Paramet
288. so use this screen to edit or review an existing program E _0096 BCE 0200 02 1 Edit Screen E indicates edit screen 0096 block number 0000 2999 is user selectable for edit and review automatically increments to next higher number during programming BCE command mneumonic 0200 02 1 data for the block command When first scrolling to this screen a flashing cursor appears in the home position first digit of the block number As with other display screens which include a cursor press the left or right arrow keys to move the cursor within the screen Also press the CR key to move the cursor to the home position Press CR again to position the cursor to the first position of the previous field Continue pressing the CR key until the cursor is in home position or over the left digit of the block number before using the up down arrow keys to scroll to different display screens To select different program blocks of information to display for review or edit press the right left arrow keys to position the cursor over the first digit of the block number and type over the existing block number Command and data for this selected block will then appear To scroll through the block numbers press the CR key to locate the cursor in the top line then use the or key to scroll through the blocks The block number will increase or decrease accordingly and display the respective data for each block To enter program start at blo
289. ss is possible not If 00 is input here there will be no monitoring for axis interruption If an input number is assigned and an interrupt is present the axis positioning command will not be processed The DLC will continue to process all blocks not containing any position commands regardless of how A120 is set As soon as the program processing comes to a block containing a position command the DLC will stop in this block until there is a signal at the input If a position command is currently being processed and the interrupt is present the axis will decelerate to a stop WARNING The continuation of the axis positioning will occur immediately as the auxiliary input Feed Interrupt returns high Also if the feed angle monitoring has been specified for the axis the Feed Interrupt input number must be different the two functions cannot use the same input number 3 Axis Stop This output becomes 1 as soon as the following two conditions are met Command Position Value 0 Actual Value Per Minute 6 UpM For functions that directly affect the position control circuit e g following axis SIN command this output does not apply Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 4 28 Parameters DLC A and DLC G Parameter A121 Maximum Motor Speed Max Speed RPM 121 2000 0000 2000 Maximum motor RPM 0000 Unassigned set to 0000 This parameter defines the maximum RPM of the motor Example
290. sted from the DLC 00 Axis 1 Current Position Decimal 01 Transmission Error And Text 02 Current Program Block Operating Task 1 Only 03 Axis 1 Current Position Hexidecimal 04 Counter status 05 Software version 06 Input status 07 Output status 08 Current Program Block And Subroutine Operating All Tasks 09 Current Axis 1 amp Measuring Wheel Encoder Position 10 Axis 1 Position Lag 14 Commanded Current at Position 18 Drive Diagnostics 19 Hardware and Software Version 46 Length Counter 47 Actual RPM Measuring Wheel 48 Axis 1 Current Motor RPM 50 System inputs and outputs Hex 51 User inputs 1 88 Hex 52 User outputs 1 96 Hex 53 System Faults Each Status Request and DLC Response is described on the following pages DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Serial Interface 7 13 Status 00 Axis 1 Current Position Decimal Request Format te Response Format X 00 11111 111 5 Lf e _ if axis has not been Homed A if axis has been Homed d Direction 4 11111 111 Current position of axis 1 in decimal format in input units XXXXX XXX Not Used Status 01 RS Transmission Error and Text This information is sent automatically by the DLC when there is a RS communication form
291. t is applied This input is on the Indramat Digital Drive connector X3 pins 8 amp 9 When the AS input is applied the digital drive will immediately command the motor to zero velocity and then disable the power section of the digital drive This message is a direct response to an external signal applied to the digital drive Check machine wiring to determine why the AS input is being applied Consult the manual for the specific digital drive for more information on the use of the AS inputs Rexroth Indramat 8 2 Diagnostics And Troubleshooting DLC A and DLC G 8 2 DLC System Error Code And System Error Messages Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Rexroth Indramat When the DLC detects an error all outputs are turned off and the error message appears on the CTA display After the error has been corrected the message must be cleared by pressing the CL key on the CTA keypad or by providing a 24 volt input to the external Clear input connector X17 pin 8 Typically the word ERROR appears on the top line of the display The second line displays one of the following messages Error Message Code No diagnostic message is displayed 00 When the DLC Control card is operating properly with no system errors present requesting t
292. t the position is only tested once during the execution of the PST block A program loop must be created to test for a position repeatedly Note PST only functions after the axis has been homed Prior to this the block is scanned only and no execution takes place Rexroth DOK CONTRL DLC A4DLC G AWO3 AE P 12 99 Indramat 5 76 Programming DLC A and DLC G REF Referencing Detect Registration Mark Input E 0350 REF 1 0 123 01 1 Axis 1 0 Direction 0 forward 1 reverse 123 Search speed 00 1 99 9 of the maximum velocity set in parameter A100 01 Registration auxiliary input number Recognition in approx 1 msec It is possible at any time to search for a registration reference mark The axis direction search speed velocity and registration input number can be freely selected After the start of the block the axis moves at the specified search speed until a positive edge occurs at the specified aux input Stepping to the next block takes place only after the reference marker has been found unless the next block is a REP command see page on REP command When the registration mark is found the axis decelerates and travels in reverse to the position the registration mark was detected at If it is desired that the axis does not back up in this manner the REF or REF REP can be followed by a PSI command The PSI position command would be set to the distance it takes to decelerate the axis from
293. tamp 1 stamping with stamp 2 wait for registration mark and traversing of offset distance offset distance from position of registration mark cutter on waiting time cutter off waiting time Rexroth Indramat 5 82 Programming DLC A and DLC G RSV Restart Vector E 0700 RSV 1 000 10000 1 Restore status as before interrupt except outputs 000 Not used set to 000 1 Outputs status Restore status of outputs as before interrupt 1 Do not restore outputs 0000 Not used set to 0000 The Restart Vector is used to recover from a power loss System Error or change in mode from Auto to Manual When any of these events occur the status at the time velocity absolute target position outputs etc are temporarily stored and can be recovered with this command Use this command only if the system has an absolute encoder Note The temporarily stored absolute target position will only be resumed if the axis is equipped with an absolute encoder Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 83 RTS Return from Subroutine E 0370 RTS The RTS command is used to return from a subroutine which has been called by using the JSR command The program is continued at the point where the subroutine had been called which is the next block after the JSR command If in multiple subroutines the RTS command will take the program back only to the level of the curre
294. tance specified starting from the current position Thus if a slide is at 2 inches from home an incremental command to move 3 inches will result in the slide being positioned 5 inches from home Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 2 Programming DLC A and DLC G 5 2 Auxiliary Inputs Outputs The DLC has a set of I O points with a predefined use It also includes a set of I O points which can be defined by the user for controlling machine functions They will be referred to as auxiliary inputs and auxiliary outputs or aux inputs and aux outputs Auxiliary inputs are also known as acknowledgments Certain commands are provided for use to address these inputs and outputs The I O Commands are described in section 5 8 5 Warning Auxiliary input and output numbers that have been dedicated by the machine builder for a specific purpose must not be changed Personal injury or damage to the machine drive train could result from such changes Programming Inputs Outputs Certain outputs are predefined in the DLC internal program and cannot be changed by the user program When the DLC is powered ON it sets certain outputs per the internal program to default position Likewise when a fault occurs it sets many outputs OFF Outputs are re established either through hardware or software i e the Automatic Mode Indicator turns ON after that mode is selected by input assuming all other conditions are met a
295. tatus tool correction values M Function set up etc during power OFF is below minimum voltage level A battery test is made at DLC power up If the battery is low the error message is displayed This message will also re appear every ten minutes as a reminder During Normal operation in any of the three operating modes manual automatic or parameter a battery test is made every four hours If the battery is still low this diagnostic will re appear but no fault will be issued DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Diagnostics And Troubleshooting 8 3 1 If displayed on initial power up reset the DLC by pressing the CL key on the CTA panel or by bringing the External Reset input high 2 Replace the battery within two weeks of the first appearance of this diagnostic To replace the battery turn off the power to the DLC it gets its power from the digital drive remove the DLC card from the U2 slot in the drive and replace the lithium battery Contact the Indramat Service Department at 800 860 1055 if you have any questions Error Message Code BCD Input 00 This e
296. tch first closed 0801 ATS 23 1 Waits for axis 1 to be in position 0802 CLA 1 Initializes axis 1 position buffer to zero 0803 NOP 0804 JMP 0000 Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Example 3 Programming Notes A 3 Illustrates a routine that is very useful for applications in which the axis should not back up past the home switch The program starts with blocks 0000 used to detect if either axis has been previously homed If not the homing routines at blocks 0800 will be executed as required The homing program starts by branching to a BCE command that will branch to block 805 core homing program if the switch is not closed If the home switch was closed the program will drop down to the next three steps comprised of a CON command which will cause the axis to move off the switch at a set velocity an AKN command which causes the program to wait until the home switch input is opened and the PBK which causes the axis to ramp to a stop The REF command starts the core homing program used to locate the home switch The axis moves toward the home switch at a set velocity until the switch is closed After this the axis ramps to a stop and then moves in the reverse direction stopping at the point where the switch was first closed The ATS command waits for the axis to be fully stopped in position before the CLA command is executed The CLA command set the axis position buffer to
297. te is matched 0003 AEA 010 Turn OFF output number 1 0004 JST 0001 Jump to block 0001 and stop If auxiliary inputs are not physically accessible with the current configuration of the auxiliary inputs and anything besides a Don t Care 2 condition is programmed the program would hang up because these inputs would not be satisfied DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Programming 5 15 APE Activate Parallel Outputs 0044 APE 2100122011 Bank Individual Aux Output Number Programmed State 1 Bank number 0 9 group of 10 aux outputs Bank X gt aux outputs X0 X9 i e Bank 2 aux outputs 20 29 Bank 3 aux outputs 30 39 etc 2100122011 aux output status each of 10 as defined below 0 the aux output will be reset to an OFF condition 1 the aux output will be set to an ON condition 2 the aux output will not be changed The APE command sets the state of any programmed bank or group of ten aux outputs The desired bank of aux outputs to be manipulated is first selected The next ten digits set the status of each individual aux output in the bank Stepping to the next block takes place immediately after the APE command is read The standard DLC has aux output numbers 1 11 You can use aux outputs number 12 through 88 as flags bit memory Warning The manipulation of aux outputs 89 through 99 can have unexpected results Refer to Table 5 1 for more information
298. tective diodes Fig 9 3 DEA 5 Figure 3 2 DEA 5 X32 Input Output Connector and Pin Designations Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 3 4 Functional Description of DEA 4 I O Connections DLC A and DLC G X33 Connector Green Black Grey Pink Green Red Yellow Black Green Blue Red Blue Yellow Brown Grey Brown White Red White Pink White Black Pink Brown White Yellow White Green White Blue B IN Outputs A28 A29 A30 A31 A32 A33 A34 A35 A36 A37 A38 A39 A40 A41 A42 A43 Grey Green White Grey White Violet Yellow Pink Blue 5 c 1 E T il t a Yellow Grey ink Green Yellow Pink Brown Black Brown Green Yellow Black Yellow Red Brown Red Brown Black Brown RL 22405 Black Green 0 5mm Red 0VDC Supply voltage of the isolated Green 0 5mm 2AVDC In Outputs Shield Cable Type IKS 711 All Relays must be equipped with protective diodes Fig 9 4 DEA 6 Figure 3 3 DEA 6 X33 Input Output Connector and Pin Designations Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Functional Description of DEA 4 I O Connectio
299. the Off state Sets axis 1 into continuous motion at 0 196 of max velocity Waits until the 5 degree or 365 degree position has been reached and then turns On cam outputs aux outputs 3 and 4 Waits until the 40 degree position has been reached and then turns output 1 Off Waits until the 150 degree position has been reached and then turns output 3 Off Waits until the 180 degree position has been reached and then turns output 4 Off Waits until the 305 degree position has been reached and then turns output 2 On Waits until the 335 degree position has been reached and then turns output 2 Off Waits until the 352 degree position has been reached and then turns output 1 On Jump to block 0003 Rexroth Indramat 5 38 Programming DLC A and DLC G CON Continuous Operation E 1900 CON 1 1 345 01 Rexroth Indramat 1 Axis 1 1 Start stop continuous operation O stop 1 start 345 Speedin to 1 decimal place direction relative to Direction of Operation Parameter A109 01 Output auxiliary function to turn ON when CON velocity is achieved 00 no output Warning Subsequent commands relating to the axis programmed here may be affected by the continuous operation If the axis has limited travel i e ballscrew safeguards should be taken to assure the axis will be stopped before travel limit is exceeded An output can be programmed which is set to 1 once the continuous
300. the search speed Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 77 REP Conditional Jump if Search Distance is Exceeded Referenced to REF Command E 0030 REP 1000 1 123456 78 1000 Target block number 0000 2999 if search path exceeded 1 Axis 1 123456 78 Maximum search path for REF command to 2 or decimal places depending on setting in B007 The REP command is a supplement to the REF command It is used to limit the maximum search distance while looking for the registration input If the maximum search distance entered here is exceeded without finding a registration input a jump is executed to the target block At the same time the drive is braked to a stop The REP command must follow immediately after the REF command A REP command that stands alone leads to the error report Illegal Command during program execution At the start of the REF REP commands the axis moves at the search speed until either the registration mark is detected or the search length has passed If the registration mark is not detected the axis will decelerate to a stop after the search length occurs The actual length traveled will be the search length plus the distance it takes to decelerate the axis to a stop A jump is executed to the target block at the end of the search length as the axis starts decelerating If the registration mark is detected the axis is decelerated as des
301. tic Mode is selected 24 Automatic Mode is selected 0 Another mode is currently selected or normal conditions that allow Automatic Mode operation are not satisfactory or a fault is preventing entry into Automatic Mode This output signal is typically wired to an indicator light on the user control panel or to a PLC Parameter Mode Indicator DEA 4 Connector X17 pin 19 Function Output Indicates that Parameter Mode is selected 24 Parameter Mode is selected This overrides any other mode selection 0 Parameter Mode is not selected This output signal is typically wired to an indicator light on the user control panel or to a PLC Automatic Cycle Running Indicator DEA 4 Connector X17 pin 20 Function Output Indicates that Automatic Mode is selected and cycle start has been pressed 24 Automatic Mode is selected the cycle start has been pressed to start the user program in Task 1 and 2 0 Automatic Mode is not selected Automatic Mode is selected and cycle start has not been pressed An error has occurred preventing the operation of the automatic cycle This output signal is typically wired to an indicator light on the user control panel or to a PLC Auxiliary Outputs 1 Through 11 DEA 4 Connector X17 pins 21 through 31 Function Output Defined by the machine builder in the DLC parameters and program 24 Auxiliary
302. ts e DLC Control Module Card e DEA 4 1 System Auxiliary I O card e CTA Keypad amp Display with remote mounting kit Optional and IKS745 cable e Power Supply e Digital AC Servo Drive e MDD Digital AC Servo Motor The instructions in this chapter primarily describe the installation of the DLC Control Module Card The installation particulars of the other components such as a TVD TVM or KDV power supply the DDS Digital AC Servo Drive or DKS self contained power supply and digital drive module are explained in detail in their respective manuals Tools required e Asmall 1 8 blade standard screwdriver e multimeter VOM e appropriate wrench for 1 4 machine type bolts used for mounting module s to the cabinet e VT 100 terminal or PC with VT 100 terminal emulation software e IN 391 Cable PC to Indramat Digital AC Servo Drive 6 1 Mounting Cabinet It is recommended the Amplifier and Power Supply be mounted in a cabinet side by side see Figure 6 1 The enclosure should be sufficient to protect the equipment from contaminants such as water oil etc Indramat recommends a NEMA 4 or 12 enclosure or equivalent Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 6 2 Installation Start Up
303. ts AK1 and AK2 as of software version DAOT 1 01 6 dne ce einen eria deena 4 65 Parameter C004 Velocity Data Scaling at Analog Outputs AK1 and AK2 as of software version DAOL eaves 4 66 Parameter C005 Velocity Loop Monitoring as of software version DAO1 1 01 6 4 67 Parameter C006 Position Velocity Window as of software version DAO1 1 01 6 4 68 Parameter C007 Absolute Encoder Reference Position as of software version DAO1 1 01 6 4 69 Parameter C008 Error Reaction as of software version DAO1 1 01 6 4 70 Parameter C009 Current Loop Proportional Gain as of software version DAO1 1 01 6 4 71 Parameter C010 Velocity Loop Proportional Gain as of software version DAO1 1 01 6 4 72 Parameter C011 Velocity Loop Integral Reaction Time as of software version DAO1 1 01 6 4 73 Parameter C012 Smoothing Time Constant as of software version DAO1 1 01 6 4 74 Parameter C013 External Brake 4 75 Parameter C100 Set Standard Drive Tuning Parameters Via CTA as of software version BAN Oa LA 4 76 Parameter C101 Set Absolute Position as of software version DA1 04 DG1 04V04 4 77 46
304. ty of methods when using the DLC control This Programming Note describes several different homing methods in detail Note In some applications for mechanical or safety reasons the axis cannot be homed after the process has started For these applications a multi turn absolute encoder is required Because an absolute device is capable of providing a known position relative to the machine s mechanical limits at all times homing is not required Normal Homing The DLC includes a homing routine suitable for most applications This is described in detail in section 3 2 4 of the DLC manual This routine in conjunction with parameters and a home switch provides a fast and easy way for the user to implement a homing sequence This routine is activated by an input in manual mode or through a short series of commands in automatic mode This home sequence in either mode starts with the selected axis performing the following steps 1 The axis moves towards the home switch at the velocity set in parameter A110 unless the axis is already on the switch 2 After the home switch closes the axis decelerates to a stop on the marker pulse Home 1 Switch Fig A 1 Normal Homing Example Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat A 2 Programming Notes DLC A and DLC G Homing Without Using the Homing Routine In certain applications it is not possible or desirable to use the standard homing sequence For those i
305. ue 99999 99 for 2 decimal place systems or 9999 999 for systems set up with 3 decimal places 1 Verify that the value being entered into the Tool Correction register using the SO1 command is valid 2 See Chapter 5 Section 5 10 for a complete description of Tool Correction register use and programming 3 See Chapter 5 Section 5 9 for a complete description of the 501 command and its use Refer to Chapter 4 Section 4 6 for a complete description of M Functions and how they can be used DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Explanation of Diagnostic Solution Diagnostics And Troubleshooting 8 13 Error Message Code No G60 24 There was no G60 command instruction after more than 20 blocks in a G61 Velocity Rate Optimization profile A G61 Velocity Rate Optimization profile can cover a maximum of 20 blocks After 20 blocks 260 command must be programmed 1 Insert a G60 block within 20 blocks of the G61 command 2 Refer to Chapter 5 for a full description of the use of G60 and G61 commands CODE Diagnostic Page 00 No diagnostic message is displayed 8 3 45 Abs Range 8 3 48 Axis 1 Not Homed 8 4 16 Axis No False 8 4 04 Battery Is Low 8 5 00 BCD Input 8 5 01 12 Block Too Large 8 19 1A Configuration 8 6 07 Div
306. umber of counts Once this block has been read the actual item number is increased by 1 Once the preset number of counts has been reached the programmed output is switched on The actual value is subsequently cleared The item counter can be also set to zero by using the command CLC Any number of item counters can be programmed For an example of how to offset the actual count refer to the example for the BAC command This is an example of the Counter Display screen See section 2 3 5 for information how to view the Counter Display screen Program Block Number of COU command A 2000 Counter 000056 000500 Preset Counter Value Actual Count Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 40 Programming DLC A and DLC G CPL Clear Position Lag This command is used to clear the following error after a move to a positive stop routine has been completed E 0201 CST 1 The lag error of the selected axis is zeroed once The program moves the next block immediately following this command CAUTION This command directly affects the position control loop Any lag error that is build up will be deleted Rexroth Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Programming 5 41 cst Change Subroutine Stack E 0201 CST 1 4 1 Changes subroutine level 0 2 0 changes subroutine level in Task 1 and Task 2 12 changes subroutine level in Task 1 only 2 changes su
307. upt 8 18 10 System Fault Stack Overflow 8 18 TC Memory Lost OF WRITE Command 8 19 Table 8 1 DLC A Diagnostics Sorted In Alphabetical Order CODE Diagnostic Page 00 No diagnostic message is displayed 8 3 01 Parameter Mode 8 16 01 01 RS Block Wrong 8 21 01 02 RS Format Error 8 22 01 03 RS Block Data Error 8 22 01 04 RS Checksum Error 8 22 01 05 Invalid Mode 8 20 01 06 RS Par No False 8 23 01 07 Param illegal 8 21 01 08 RS Status False 8 23 01 09 Status Illegal 8 23 01 10 M Wheel P False 8 21 01 11 Invalid P Block 8 20 01 12 Block Too Large 8 19 01 13 Invalid Prg Command 8 20 02 Is INVALID 8 14 03 EMERGENCY STOP 8 8 04 Battery Is Low 8 5 05 Parameters Lost 8 16 06 Program lost 8 17 07 Division By Zero 8 6 08 Invalid Mode 8 13 0A Invalid Prg Command 8 14 0B JSR Nesting 8 15 0C RTS Nesting 8 17 BCD Input 8 5 Invalid Block 8 13 OF WRITE Command 8 19 10 System Fault Stack Overflow 8 18 100 Operation Ready 8 2 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Diagnostics And Troubleshooting 8 15 CODE Diagnostic Page 101 Drive Ready 8 2 102 Drive Enabled 8 1 103 Drive Halt 8 1 104 Safety Interlock 8 2 11 System Fault IRQOVL Interrupt 8 18 12 IDS Br
308. utputs 89 through 99 can have unexpected results Refer to Table 5 1 for more information Example Five inputs are copied to five outputs E 0160 CIO 0 01 23 5 Results of this command can be monitored using the input output status display Status of the inputs are displayed as DLC Inputs 1 7 11 1 Status of inputs 1 5 is 1 1 1 10101 Status of the outputs before the command is executed DLC Outputs12 27 1 11 111 311 pases Status of outputs 23 27 is 01110 Status of the outputs after the command is executed DLC Outputs12 27 1 11 1 1 1 1 1 E Status of outputs 23 27 is now 10101 Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 5 34 Programming DLC A and DLC G CLA Clear Absolute Position E 1700 CLA 1 1 Axis 1 The record of absolute position is cleared for the selected axis using this command Multi turn absolute encoders e Parameter A110 xxx2xxxx The instantaneous position is reset to zero with the CLA command An off set dimension from parameter A111 is not considered This results in the current evaluated position becoming zero Incremental encoder systems e Parameter 1 10 xxxx The instantaneous position is reset to zero using the CLA command An off set dimension from parameter A111 is considered This results in the current evaluated position thereby becoming offset from parameter A11 e f parameter A1102xxxOxxxx the fault
309. value to calculate the target block Example If a parallel input is not sensed in the BCD format this will result in BCD Input Error diagnostic 8 7 6 5 4 3 2 1 80 40 20 10 8 4 2 1 8 7 6 5 4 3 2 1 0 1 0 1 0 0 1 1 50 3 0100 53 x 12 736 In the example above a jump to block 736 takes place 8 7 6 5 4 3 2 1 0 0 0 1 0 0 0 1 10 1 0100 11 x 12 232 If BCD input decimal equivalent 00 jump to block 0100 01 jump to block 0112 offset of 100 1 x 12 66 jump to block 0892 offset of 100 66 x 12 Note There is no Invalid Program Command diagnostic if this command is programmed to exceed block 2999 That is because the destination block is dependent on the value determined from aux inputs relative to the BCD value selected However an Invalid Block diagnostic is issued when the BCD command is executed and the destination block exceeds program block 2999 Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 5 24 Programming DLC A and DLC G BCE Branch Conditional on Single Input E 0100 BCE 0234 01 0 0234 Target block 0000 2999 01 Auxiliary input number 01 07 Note Auxiliary input numbers 08 37 can also be used with optional DEA 5 amp DEA 6 expansion I O card 0 Condition 0 jump if input is OFF low 1 jump if input is ON high A conditional jump to the target block will be executed if the auxiliary input meets the preselected condition 0 or 1 If
310. ves a Invalid Mode error message through the port Parameters can be read from the DLC in any mode The optional Indramat program assembler software MotionManager allows you to write and edit user programs and parameter list on any DOS based computer You can download these into the DLC control through the serial interface You can also upload the information from the DLC and make a print out of your program and parameter files The optional Indramat SOT Station Operator Terminal is a remote mounted operator control device for the DLC It is used to communicate program and parameter information between the DLC and SOT The software in the SOT includes Help screens to assist the operator in using the SOT and for entering information correctly The Indramat command line editor Screen Manager is used to write information and prompt lines for the operator that will appear on the SOT display 16 lines 40 characters each Contact Indramat for additional information on these options 7 1 Connector Wiring DB 9 The serial interface connector standard DB 9 is the X31 connector located on the front of the DLC Control Card Refer to Figure 7 1 for a pin out diagram of the multi function port X31 connector It shows the pin numbers and definitions of signal connections for each type of communication RS 232 CDONFIGURATION SHIELD RECEIVE TRANSMIT GROUND RTS CTS GROUND Bx Ta FIS48S 1 0 RS2321 HxD CRS2321 SHIELD
311. ware version DAO1 1 03V05 DG01 1 03V05 Cycle Time B015 0 00000 00 0 Number of program blocks per cycle time for Task 3 Default for 1st block cycle 00000 Not used 00 DLC Position Control Cycle Time 00 default 1021ms 20 2ms Note For all other values above the DLC automatically sets the cycle time to the following default values 1 axis programmed 1 ms 2 axes programmed 2 ms Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat 4 54 Parameters DLC A and DLC G Parameter B016 External Encoder 1 Encoder Selection as of software version DAO1 1 01 2 Note Requires DEF card External Encod 1 B016 10 1 00000 1 System selection of hardware 1 DEF 1 1 card 2 DEF 2 1 card 3 DFF card as of software version DAO1 1 01 8 0 Not Used 1 Operating direction of the encoder 0 Encoder shaft and motor shaft have same rotational direction 1 Encoder and motor shaft have opposing rotational direction 00000 Not Used set to 00000 Note The DEF card can also be used for the functions Follow Axis and Measuring Wheel Mode These functions are activated in parameter A123 Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Parameters 4 55 Parameter B017 External Encoder 1 Pulses Revolution as of software version DAO1 1 01 2 Note Requires DEF card Ext E 1 Impulse B017 000 05000 Note For incremental encoder only Require
312. wering up the DLC and drive controller without errors To shut down drives in case of an Emergency Stop see documentation for the drive controller or power supply module for modular drive controllers Fig 9 7 Tim Figure C 13 Timing Diagram for DLC with DKS DDS or DDC Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Installation Drawings D 1 D Installation Drawings CAUTION The drawings in this Appendix are included for illustrative purposes only and are subject to change without notice Check with Indramat to be sure you are working with the latest drawings prior to installing wiring and powering equipment Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 Indramat D 2 Installation Drawings DLC A and DLC G D 1 DKS 1 1 Dimensions NUMBER REPANTS PROHIBITED THIS DOCUMENT FOR CUSTOMER USE ONLY NOT COPIED OR RELEASED REFERENCE COPYRIGHT LAW HOFFMAN ESTATES REXROTH INDRAMAT dks1 out wmf Figure D 1 DKS 1 1 Dimensions Rexroth o Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Installation Drawings D 3 D 2 CTA Keyboard and Cabinet Cutout Dimensions REXROTH INDRAMAT ARE SHOWN IN mm INCH FOR REFERENCE ONLY
313. wing error is greater than the calculated following error by a percentage greater than that which is programmed in parameter A122 1 The axis is commanded to a position but the axis servo system has an excessive position lag 2 The digital drive does not have power applied Verify the power to the drive is correctly wired and the proper inputs are applied to bring up main power See machine drawings for power u sequence requirements 3 The Accel Rate parameters A102 or A117 values may be too large The motor may be unable to accelerate at the rate specified 4 The motor may not be able to turn due to a mechanical bind DOK CONTRL DLC A DLC G AW03 AE P 12 99 DLC A and DLC G Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Solution Explanation of Diagnostic Diagnostics And Troubleshooting 8 5 Error Message Code Feed Angle Loss 41 This error occurs if the Feed Angle auxiliary input designated parameter A120 goes low while the axis is moving Refer to Chapter 4 for more information on the Feed Angle auxiliary input 1 Verify that the Feed Angle auxiliary input is properly connected 2 If the Feed Angle is attached to a press that operates continuously either the press speed must be slowed down or the part length being
314. xt point or Absolute movement in relationship to a known home point These can be further broken into two different functional types of positional commands 1 Commands that require the axis to be at the final programmed position as determined by the In Position Signal before stepping to the next block These are identified by the letter 5 in the mnemonic Stop 2 Commands that after being read into the position buffer immediately go to the next block for further program execution These are identified by the letter O in the mnemonic Onward The following is a list of the position commands 601 Linear Feed with Functions G60 Position with Exact Stop G61 Begin Velocity Rate Optimization profile POI Incremental position command PSI Incremental position command with In Position Acknowledged POA Absolute position command PSA Absolute position command with In Position Acknowledged POM Incremental or Absolute positioning to IDS thumbwheel switch setting PSM Incremental or Absolute positioning to IDS with In Position Acknowledged PFA Absolute position to a positive stop PFI Incremental position to a positive stop Position commands have the following characteristics e Position commands must include three components axis Position or Distance and Velocity e Positions are programmed directly in units of your choice inches metric degrees etc e You can select either two or three decimal points of accuracy
315. y Maximum Motor A121 Entry A100 Entry Speed 1500 rpm 1500 0000 00025 000 25 in sec 2000 rpm 2000 0000 00033 333 33 333 in sec 3000 rpm 3000 0000 00050 000 50 in sec Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 6 10 Installation Start Up 6 14 Program Entry Block 0000 Block 0001 Block 0002 Block 0003 Block 0004 Block 0000 Block 0001 Block 0002 Block 0003 Block 0004 DLC A and DLC G This is a sample program for operating the DLC in an automatic mode Enter the program as shown E 0000 PSI 00100 000 200 0001 WAI 01 00 0002 PSI 00100 000 200 E 0003 WAI 01 00 E 0004 JST 0000 will command the axis to rotate in the plus direction 100 input units at 20 of the maximum velocity Since the feed constant equals 1 the motor should turn 100 revolutions will cause a 1 second delay once the axis has reached position will cause the axis to rotate in the minus direction 100 input units at 20 of the maximum velocity will cause a 1 second delay once the axis has reached position will jump back to block 0000 and stop See the following sections for testing procedures 6 15 Axis Jogging in Manual Mode Rexroth Indramat With bb displayed on the digital drive and no errors displayed on the CTA press the Drive On pushbutton The H1 status should display AF and to
316. y Interbus S board DBS 2 2 DLI software only a The system outputs for the DEA 4 can be set only via the DLC b The output map inside the DLC can differ from the actual status of the DEA 4 DEA 6 display Note If this parameter is redefined it takes effect only after exiting and reentering Parameter Mode or after restarting the DLC1 Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat 4 40 Parameters DLC A and DLC G Parameter B003 Serial Interface Serial Interface B003 0960 0181 The serial interface of the DLC can exchange data with peripherals in various ways Define the transmission method in this parameter Chapter 7 describes the interface in more detail If the two parameters B003 and B004 are stored in memory correctly then the serial interface is ready for operation immediately Incorrect entries in the parameters block the serial interface 0960 Baud Rate Min 300 Baud Max 19200 Baud 0000 Interface not operating to host computer Baud Rate input examples using common rates 1920 19200 Baud 0960 9600 Baud 0480 4800 Baud 0240 2400 Baud 0000 Interface deactivated 0 Interface Operating Mode 0 Standard RS232 full duplex 1 Decade switch IDS 2400 Baud 8 data bits 1 stop bit no parity 2 Same as Mode 0 3 Interface to SOT Station Operator Terminal RS232 or RS485 half duplex one station only 4 Serial bus link for SOT RS485 half duplex st
317. y Loop Proportional Gain 4 72 C011 Velocity Loop Integral Reaction Time 4 73 C012 Smoothing Time Constant 4 74 C013 External Brake Release 4 75 C100 Set Standard Drive Tuning Parameters Via CTA 4 76 C101 Set Absolute Position 4 77 Parameter Entry 6 9 Parameter List 4 2 Parameters 4 1 Positioning 5 1 Power 6 3 Power up 6 6 Pre Operation Start Up Tests 6 4 Programming 5 1 Programming Mode 5 4 Programming Notes 9 1 R RS 232 Serial Cable Configurations 7 2 DOK CONTRL DLC A DLC G AWO3 AE P 12 99 DLC A and DLC G Index I 3 5 Sending Information to the DLC 7 7 Sending Parameters to the DLC 7 8 Sending Program Blocks to the DLC 7 7 Serial Communication Errors 8 9 8 12 Serial Interface 7 1 Signal Definitions 3 1 Signal Level Requirements 7 2 SOT Station Operator Terminal 1 10 Specifications 1 14 Control Specifications 1 14 Options 1 15 Physical 1 14 Standard Configuration Of DKS With DLC Control Card DEA 4 I O ca 1 11 1 13 Standard Configuration Of DKS With DLC Control Card DEA 4 Input 1 11 Standard Configuration Of DKS With DLC Control Card DEA 4 Input Output Card Standard Configuration Of DKS With DLC Control Card DEA 4 Input 1 13 System Features 1 7 Transformer Heat Dissipation 6 3 Rexroth DOK CONTRL DLC A DLC G AWO3 AE P 12 99 Indramat l 4 Index DLC A and DLC G Rexroth Q Indramat DOK CONTRL DLC A DLC G AW03 AE P 12 99
318. y pushbutton to Pin 6 Jog Forward of DEA 4 1 connector X17 6 Connect a Normally Open momentary pushbutton to Pin 7 Jog Reverse of DEA 4 1 connector X17 7 Connect a Normally Open momentary pushbutton to Pin 8 Clear of DEA 4 1 connector X17 8 Connect the 24Vdc external power supply to pins 34 35 0 and pins 36 and 37 24Vdc of the DEA 4 1 connector X17 PARAMETER KEYED CONNECTOR X17 PARAMETER MODE SELECT MANUAL AUTOMATIC MODE SELECT 3 EMERGENCY STOP CYCLE START CYCLE STOP JOG FORWARD JOG REVERSE CLEAR 24VDC 24VDC 4 0VDC 5 0VDC Fig 6 2 Example Input Diagram Rexroth DOK CONTRL DLC A DLC G AW03 AE P 12 99 9 Indramat 6 6 Installation Start Up DLC A and DLC G 6 10 DEA 4 1 Output Connections 6 11 Power Up For the purpose of a sample start up the connections for the DEA 4 1 outputs are not necessary The ends of the unused wires in cable 04 0123 should be wrapped in electrical tape to prevent any damage to the outputs Refer to the interconnect drawings in Appendix C for properly interfacing the DEA 4 1 system auxiliary outputs with the machine The system can now be powered up All voltages should be checked by a qualified electrician to ensure proper signals and connections The digital drive being used has two 7 segment LEDs which displays the current operating status of the

DLC Single Axis Control Card for Firmware

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