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Power Mate APM for Series 90-30 PLC Follower Mode User`s

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1. CTLO1 CTLOS 845326 Extra Master input for Axis COCA E 1 only on 2 axis Power Mate APM ENABLED A AXIS FOLLOWER CONTROL LOOP DESTE ENABLE IN VEL Axis 1 loop is shown ACT PSN CONTROL hehe eos REGISTER 34 LIMIT Axis 2 loop is identical on 2 axis Power Mate APM esl A MASTER CTS CTS MS SAMPLE VELOCITY SELECTED BY 4 0 O O UMT TIMEBASE ANALOG INPUT i xA INPUT SCALING MASTER y FF VEL ACT PSN REGISTER v Q SELECT TRACKING INT MASTER ERROR RATIO 1 per Power Mate ACCUMULATOR B 9 INTERNAL APM MASTER 5 VELOCITY 7 VEL xB GENERATOR VELOCITY gt MISMATCH GENERATOR 4 09 1 per Power Mate COMPARATOR MISMATCH MOVE APM VEL SIGN PSN ERROR HOME Master Axis functions inside this outline 1 per Power Matel FB COUNTS APM MOTION PROGRAMS t Y d ACT PSN COUNTS SAMPLE PSN INC REGISTER 20 gt v NOTE BOSHION a PSN ERROR IN FOLLOWER MODE ENCODER 1 ERROR FB COUNTS COUNTS MASTER COUNTS x A B AND __g gt IN ERROR LIMIT IN ZONE DETECTION IN ZONE COMMANDED Y VELOCITY x PSN x VEL PSN LOOP FF TINE CONSTANT LOOP GAIN FF GAIN v 10V a D A COMMAND 4 lt Figure 5 1 Axis Follower Control Loop Block Diagram 5 4 Power Mate APM for Series 90 30 PLC Follower Mod
2. Jw o m Fase of I O connection with factory cables and standard terminal blocks 1 1 Versatile 1 0 m 10 volt Velocity Command analog output m 12 bit plus sign analog input m Home and Drive OK switch inputs m User defined control inputs and outputs Encoder Feedback up to 175 kHz per channel Firmware Compatibility Tables Released Firmware Version 1 Axis Power Mate APM PLC Motion Control Loop Power Mate Programmer Programmer Catalog Number Capability APM Version Version Manual 1 00 1 10 ICG93APU301A D GFK 0707A 3 50orlater 1 01lorlater GFK 0664 Motion Programmer Manual 2 02 IC693APU301E H Standard GFK 0840 4 01 or later 1 500rlater GFK 0664A Follower GFK 0781 2 11 IC693APU301 Standard GFK 0840 6 01 orlater 1 50 or later Follower GFK 0781 2 50 IC693APU301K Standard GFK 0840 6 01 orlater 1 50 or later Follower GFK 0781 The I axis Power Mate APM firmware release 2 02 requires PLC Programmer version 4 50 or later to allow Released Firmware Version configuration in Follower mode 2 Axis Power Mate APM PLC Motion Control Loop Power Mate Programmer Programmer Catalog Number Capability APM Version Version Manual GFK 0664A GFK 0664A Motion Programmer Manual IC693APU302A B 0781 3 50orlater 1 50orlater GFK 0664A 2 01 2 02 IC693APU302GG Standard GFK 0840 4 01 or later 1 50 or later GFK 0
3. 4 3 Table 4 3 AI Status Words for the 1 Axis Power Mate APM IC693APU301 4 6 Table 4 4 AI Status Words for the 2 Axis Power Mate APM IC693APU302 4 6 Table 4 5 Q Discrete Commands for the 1 Axis Power Mate APM IC693APU301 4 8 Table 4 6 Q Discrete Commands for the 2 Axis Power Mate APM IC693APU302 4 9 Table 4 7 Axis Dependent Immediate Commands Using the 6 Byte Format 4 12 Table 4 8 Axis Independent Immediate Commands Using the 6 Byte Format 4 13 Table 6 1 Command Input Effect on Position Registers 6 40 Table 6 2 Actions Affecting Program Command 6 41 Table A 1 Status Word Error Codes 2 A 2 Table A 1 Status Word Error Codes Continued A 3 Table A 1 Status Word Error Codes Continued A 4 Table C 1 I O Cable Wire Coding for IC693CBL311 and IC693CBL319 C 7 Table C 2 I O Cable Wire Coding for IC693CBL317 and 693 320 C 8 x Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August 1996 GFK 0781C Chapter Features of the Power Mate APM aE ak GFK 0781C 1 Introduction The Follower option of the 1 and
4. 4 4 9 X e i B3 B3 A3 10 88 5 a X MASTER i 53 23 Z3 ENCODER A2 11 237 x 23 5V 5V 9 8 A1 12 oy X Oy 2 10 Figure 2 4 Functional Diagram for 1 Axis Power Mate APM I O Connector Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C CONNECTOR B 247105 GENERAL PURPOSE ANALOG OUTPUT WITH ENABLE RELAY GENERAL PURPOSE ANALOG INPUT GENERAL PURPOSE 5V INPUTS Power Mate APM FIRMWARES 2 10 TERMINAL M BLOCK CONNECTOR TERMINAL NUMBER NUMBER GENERAL PURPOSE 24V SWITCH INPUTS AG CTLO4 B5 14 CTL07 24VDC AS 5 CTLOB B ie INCOM2 AB 4 VEL a gt B7 m VEL COM x EN2 3 p EN2 XC X B6 16 p HIELD B12 13 S Ko B1 24 Allies 4 A2 11 AIN x X M 13 SHIELD TLO1 7 B11 18 CuM E TLO1 K A12 5 pro CTLO2 B10 19 CTLO2 XC 11 6 V B8 21 a Figure 2 5 Functional Diagram for 1 Axis Power Mate APM I O Connector GFK 0781C Chapter 2 Installing the Power Mate 2 11 Functional Connection Diagrams for the 2 Axis Power Mate APM VO CONNECTOR 245316 S 7 CONNECTOR TE
5. RS 232 LM90 PC Multidrop Multidrop Cable Cable 2 2 3 PLC Power Mate Power Mate CPU APM APM Figure 2 1 Connecting Power Mate APM Modules in a Multidrop Configuration GFK 0781C Chapter 2 Installing the Power Mate 2 3 The multidrop cable should be made according to the following diagram PIN PIN 845251 9 SD A 10 E SC EH 10 Rb A gt Q SD B 11 NY 11 RD gt 12 12 SD A ba 00 RD B 13 XX 13 SD B E 0 CTS A 6 6 RTS EK 0 ICTS 14 ll 14 5 9 0 RTS 15 dg 15 CTS A 00 RTS B 8 1 8 CTS ai E 0 4 e 7 0 Co SHLD 1 uy 1 SHD 1 5 CONNECTOR 1 es esses CONNECTOR 2 15 PIN 0 15 PIN FEMALE MALE NOTES X 1 Cables may be daisy chained PIN for more CPUs or Power Mate APMs amp 5 10 Lm 2 Connector 1 is 15 pin D shell 11 DE female 12 SD A KG 13 SD B KG 3 Connectors 2 and 3 are ue RTS 15 pin D shell male with 15 right angle hood wires coming B CTS out PIN 1 end IE M m 1 SHLD CONNECTOR 3 15 PIN MALE Figure 2 2 Multidrop Cable for the Power Mate APM
6. C 2 Power Mate APM for Sseries 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Encoder Inputs m Input Type 5V differential or single ended Input Impedance 4000 ohms common mode Input Threshold Single ended 1 5 V nominal 0 4V Differential 40 5 V nominal 0 4V Input Common Mode Range 15V Signal Ended Input Voltage 15 V maximum Maximum Input Frequency 175 kHz Channel X4 count rate 700 kHz Input Filtering Noise pulses shorter than 1 Microsecond will be rejected Encoder Power Non isolated current limited 5 V supply is available at the PM APM front panel I O connectors for use by one or more encoders Maximum load must be limited to 500 mA 40 C 300 mA 55 C m Quadrature Tolerance 90 degrees 30 degrees m Quadrature Error Detection Simultaneous transitions on the Channel A and Channel B inputs will be detected as loss of quadrature m Z Channel Marker Operation A positive going edge on the marker channel will be used to latch the present encoder position The minimum pulse width is 4 us m Encoder direction of travel Channel A leading Channel B indicates motion in positive direction 245338 Motion in Positive Direction Motion in Negative Direction Gratis engl ql ub 245272 LINE 2K RCVR 2K ov 0 75V Figure C 3 Encoder Input Circuitry GFK 0781C AppendixC Specifications C 3 Encoder Power m Encoder Power Non
7. T 89 2 EwederChamebAge cot Ps Common or TUS S Eus a iv OR Crp 8 1 3 EmbleReayTG Oupat Frag velocity Command Common trata Outpt WetocyCommand gt 5 22 CR L9 3 memceeme a6 coder Channel BI 8 B ememed E gt mesmwe 7 Fused Output an external source applied to this output could open the fuse 2 6 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C GFK 0781C Table 2 3 Cable Connections to Faceplate 1 0 Connector B 1 Axis Power Mate Power Mate APM Terminal Module Block Description Connector B Terminal Number Pin Number gt Input Fused Output an external source AINE to this output could open the fuse Chapter 2 Installing the Power Mate 2 7 I O Cable Connections for the 2 Axis Power Mate APM IC693APU302 Tables 2 4 and 2 5 define the cable connections for the 2 AxisPower Mate APM Table 2 4 Cable Connections to Faceplate I O Connector A 2 Axis Power Mate APM Power Mate APM Terminal Module Connector A Block Description Pin Number Terminal Number eoru ec i 20 ATO 7 POT 25 connection O Fused Output an external source applied to this output could open the fuse 2 8 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GF
8. 2 Stop Normal Errors Perform an internal abort of any current motion The Drive Enabled and Axis Enabled I bits are turned OFF after the configured Drive Disable Delay 3 Stop Fast Errors Instantly abort all motion by setting the analog output voltage to zero The Drive Enabled and Axis Enabled I bits are turned off after the configured Drive Disable Delay A 1 Table A 1 Status Word Error Codes EA LL Hexadecimal Response Description 2 9 Configuration Parameter Errors Program Errors ue Force D A Errors Status erroris reported command is not executed A 2 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C GFK 0781C Table A 1 Status Word Error Codes Continued Set Position Errors 52 StatusOnly Set Position while not In Zone error OR 352 EN RN End of Travel and Count Limit Errors Drive Disable Errors Software Errors Program and Subroutine Errors P64 Stop Normal Program End command found nSubroutine Program Execution Errors 73 7 EXT 8 Execute Program while Drive Enabled not set sc Sync Block Error during Jump Drive OK Switch error Status erroris reported command is not executed 81 82 83 85 7 Appendix A Error Codes A 3 Table A 1 Status Word Error Codes Continued ErrorNumber Hexadecimal Response Description Hardware Errors BO Status Only Custom Loop TypeMism
9. Motor Dir A configured motor direction of POS Positive defines the positive axis direction as encoder channel A leading channel B encoder feedback or motion away from the feedback transducer head linear feedback A configured motor direction of NEG Negative defines the positive axis direction as encoder channel B leading channel A encoder feedback or motion towards the feedback transducer head linear feedback In practice the motor direction configuration allows the user to reverse the motion caused by all commands without reversing motor or encoder wires GFK 0781C Chapter 3 Configuring the Power MateAPM 3 3 3 4 Serial Communications Port Configuration Data The Power Mate APM can communicate through its Serial Communications Port which supports the SNP protocol on the faceplate of the Power Mate APM The Serial Communications Port must be configured properly to communicate with the Motion Programmer Make sure the configuration parameters for the Motion Program mer and the Serial Communications Port match The configuration parameters for the Serial Port are described in the table below Table 3 2 Serial Communications Port Configuration Data Configuration Description Values Defaults Units Parameter Baud rate of SNP Port 300 600 1200 2400 4800 9600 19200 19200 ODD EVEN NONE ooo Number ofstop bit Nuniberofdatabits 7or8 8 a ModemTT Modemturn around 0 2550 in mu
10. Be Be eR Me Re SEND 70001 _ NOTE SYSID HIGH BYTE COMM REO RACK DESTINATION SYSID LOW BYTE COMM_REQ SLOT DESTINATION HDR_WDS RO196 TASK ALWAYS 0 FOR PM APM COMM REQ CONST SYSID 0007 CONST TASK 00000000 GFK 0781C Appendix B Parameter Download Using COMM REQ B 3 Appendix X Specifications C This appendix provides specifications for the Power Mate APM module and wiring information for the I O connections Module Specifications PowerSupply Voltage 5 Vdc from backplane Power Supply Current 800 mA 1 4 x Encoder Current Drain 95 mA SNP Mini converter Current if used Available Encoder 5V Current Module 500 ma 40C derated to 300 ma 55C Maximumnumberofmodules system Model 311 313 323 PLCs 31C693APU301 in CPU baseplate limited by power supply 21C693APU302 in CPU baseplate limited by AI data Model 331PLC 81C693APUS301 or 4IC693APU302 in CPU expansion and remote base plates limited by AI data Maximum3 per baseplate limited by power supply Model341PLC 141C693A PU301 orIC693APU302 in CPU expansionand remotebaseplates Maximum 2 in CPU baseplate and 3 in each expansion remote baseplate limited by power supply Model351 352 PLC 231C693APU301 or IC693APU302 in CPU expansionand
11. Byte 2 Byte 1 Byte 0 Immediate Command Definition Velocity 30h Internal Master Velocity Vel 1 000 000 1 000 000 counts Position Set Encoder 3 Position Pos 8 388 608 8 388 607 counts 3 Select Return Data Input External Input Enable Follower Input 1 8 CTLO1 CTL08 00 none disabled 4 ConfigurationModes Modes see definition below S x SetConfigurationComplete Parameter Data 50h Load Parameter Immediate Par 0 255 Parameter Data Range depends on parameter usage Null This is the default AQ Immediate command Since the AQ words are auto matically transferred each PLC sweep the Null command should always be used to avoid inadvertent execution of another Immediate command Op Po x 1h oh Make Up Time 42h FollowerRampDistanceMake Up Time Active Range 0 10 32000 ms 5h Position Increment Without Position Update user units This command offsets the axis motion from 128 to 127 user units without updating the Actual or Commanded Position The Power Mate APM will immediately move the axis by the increment comman ded if the servo is enabled Move At Velocity userunits sec This command is executed from the PLC to move the axis at a constant velocity The current Jog Acceleration rate is used for Move at Velocity commands Axis position data will roll over at the configured Hi or Lo Limit when reached during these moves Set Position
12. 1 Use the Logicmaster 90 30 20 Micro software or the Hand Held Programmer to stop the PLC This will prevent the local application program if any from initiating any command that may affect the operation of the module Power down the Series 90 30 PLC system Align the module with the desired base slot and connector Tilt the module upward so that the top rear hook of the module engages the slot on the baseplate Swing the module down until the connectors mate and the lock lever on the bottom of the module snaps into place engaging the baseplate notch Refer to Tables 2 2 through 2 5 and Figures 2 4 through 2 7 for wiring requirements Power up the PLC rack The Status LED of the Power Mate APM 30 will turn ON when the Power Mate APM has passed its power up diagnostics Repeat this procedure for each Power Mate APM Configure the Power Mate APM module s as explained in Chapter 3 GFK 0781C Chapter 2 Installing the Power Mate 2 17 Chapter Configuring the Power Mate APM 3 The Power Mate APM isconfigured using the Logicmaster 90 30 20 Micro Configuration software Configuring the Power Mate APM is a two part procedure consisting of m I ORack Baseplate Configuration Module Configuration I O Rack Baseplate Configuration The Power Mate APM is configured using Logicmaster 90 30 20 Micro software in the same way as other Series 90 30 modules The software is used to define the type and location of all modules p
13. 2 4 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C I O Connectors The Power Mate APM Front Panel contains two 24 pin male high density connectors for servo connections Connector A contains connections for Drive 1 and the Master Encod er Connector B contains connections for Drive 2 and the Analog Input l O Cable and Terminal Block High density connectors are used on the Power Mate APM to permit a large number of I O connections within the physical size limitations of the Power Mate APM To facilitate wiring to the drive and machine each high density connector is typically connected by a short cable IC693CBL311A to a terminal block Refer to Figure 2 3 below and Tables 2 2 through 2 5 g a45113 0 2 2 22 2 22 2222 Sa Power Mate APM MODULE CABLE S TERMINAL BLOCK S Figure 2 3 I O Cable and Terminal Block GFK 0781C Chapter 2 Installing the Power Mate 2 5 I O Cable Connections for the 1 Axis Power Mate APM IC693APU301 Tables 2 2 and 2 3 define the cable connections for the 1 Axis Power Mate APM Table 2 2 Cable Connections to Faceplate 1 0 Connector A 1 Axis Power Mate APM Power Mate APM Terminal Module Block Description Connector A Terminal Number Pin Number x PF cod o8 x
14. Actual Velocity is Updated by Internal cmd vel Master cmd vel Commanded Velocity is Updated by Internal cmd vel only 6 40 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August 1996 GFK 0781C s The Program Command Position is synchronized to the Actual Position by the Home command execution or by the Set Position AQ command or if the follower is not enabled by the Execute motion program command This is indicated in Table 6 2 below Subsequent rollovers of the Program Command Position have no affect on the Actual Position or vice versa Table 6 2 Actions Affecting Program Command Position Follower ACTION Enabled Resulting Updates to Follower Position Registers Home Found No Actual Position is set to Home Value Program Command Position is set to Actual Position Position Error Yes Home Command is Not Allowed Status Error is returned AQ Set Position Not Actual Position is set to AQ Value applicable ProgramCommand Position is set to Actual Position PositionError Note Set Position is not allowed if Command Move is ON Execute Program No Actual Position is NOT affected Select Program Command Position is set to Actual Position Position Error Yes Actual Position is NOT affected Program Command Position is set to Reference Position Reference Position is 0 Program moves will execute in a rotary fashion such that incremental programmed commands past the limits will roll over at the lim
15. Drive OK Switch Final Home Velocity 8 6 Find Home Velocity High Count Limit 3 6 Home Mode Home Offset B 6 Home Position In Pos Zone Integrator Mode Integrator Time Constant 3 6 Jog Acceleration Jog Acceleration Mode Jog Velocity Low Count Limit Master Source Negative End Of Travel Negative Velocity Limit 3 6 Position Error Limit Position Loop Time Constant 8 6 Positive End Of Travel Positive Velocity Limit 3 6 Ratio A Value 3 6 Ratio B Value Reversal Compensation User Units Bd Velocity at 10 V 3 6 Velocity FF B 6 Axis Dependent Immediate Commands Using the 6 Byte Format Axis Enabled I Status Bit 14 3 AxisFollower Enabled I Status Bit 4 5 Axis Independent Immediate Commands Using the 6 Byte Format B Baud Rate b 4 Block Numbers and Jumps C Cable Connections for I O Connector A G A Cable Connections for I O Connector A 2 Axis 2 9 Cable Connections for I O Connector B AKSEN Cable Connections for I O Connector B 2 9 CFG LED 2 2 Clamping Velocity Clear Error Q Discrete Command 4 10 Combined Motion 6 38 ForceD Move at Velocity Position Increment 6 4 Command Move l Status Bit Position AI Status Word 4 7 ass Velocity AI Status Word 4 7 Commands Com a Among Firmware Releases 1 2 Conditional Jumps Conditions Which Stop a Motion Program 6 6 Configuratio
16. Normal Stop before JUMP Null AQ Immediate Command O OK LED 2 2 Open Loop Mode B 10 Operation Unidirectional Operator Interfaces Ordering Information E 1 Other Considerations Other Programmed Motion Considerations Out of Sync B 7 Overview of PM APM Follower Operations P Parameter Download Using COMM REQ Parameters for Programmed Moves Parameters in the PM APM Parameters Configuration Parity Pin Definitions of the Serial COMM Connector PLC Configuration Complete I Status Bit 4 4 PLC Control Active I Status Bit 4 5 PM APM Motion Control PM APM Configuration B 1 PM APM Parameters in the 6 28 Position Error AI Status Word l7 Position Error Limit Position Increment AO Immediate Command Position Increment Command Position Loop Time Constant Position Loop Time Constant AQ Immediate Command 4 15 Position Valid I Status Bit Position Valid Encoder 3 1 Status Bit 4 5 Positioning Move PMOVE Positioning References Types 6 7 Positioning Absolute 6 7 Positioning Incremental b 7 Positive End Of Travel 3 6 Positive Velocity Limit Power Mate APM Configuration Prerequisites for Programmed Motion Procedures Startup 5 1 Program Active lI Status Bit 4 3 Program Command Position AI Status Word Programmed Motion 6 5 Prerequisites 6 6 GFK 0781C GFK 0781C Programmed Motion Considerations Other Programmed M
17. This command sets the acceleration value used by Jog Move at Velocity a Home Cycle and Abort All Moves Position Loop Time Constant milliseconds This command allows the servo posi tion loop time constant to be changed from the PLC If this command is not sent then the initial value configured with the Logicmaster 90 configuration software is used Velocity Feedforward This command sets the Velocity Feedforward gain percent It is the percentage of Master Velocity Commanded Velocity that is added to the velocity command output Increasing Velocity Feedforward causes the servo to operate with faster response and reduced position error Optimum Velocity Feedforward values are 80 90 The Vel at 10 V value must be set correctly for proper operation of the Velocity Feedfor ward gain factor Integrator Time Constant milliseconds This command sets the Integrator Time Constant for the position error integrator The value specifies the amount of time in which 63 of the Position Error will be removed The Integrator Time Constant should be 5 to 10 times greater than the Position Loop Time Constant to prevent instability and oscilla tion Follower A B Ratio This command allows the PLC to update the A B ratio used in each follower loop A is a 16 bit signed integer with a minimum value of 32 768 and a maximum of 32 767 B is a 16 bit integer with a minimum value of 1 and a maximum value of 32767 The ratio of A B must be in the ran
18. tion is stored by the PLC Parameters can be assigned in three ways the motion pro gram command LOAD the immediate command Load Parameter Immediate and the COMM REO function block in the PLC The COMM REO function block is described in Appendix B Assigning a value to a parameter overwrites any previous value Parame ter values may be changed during program execution but the change must occur before the Power Mate APM begins executing the block previous to the block that uses the pa rameter 6 28 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Follower Motion When the Enable Follower Q bit is turned ON an axis will immediately begin following the selected Master Source unless an external Enable Trigger input has been selected If an external Enable Trigger input has been selected then the Enable Follower Q bit must be ON and an OFF to ON transition of the trigger input must occur The external trigger input CTLO1 CTL08 can be selected using AQ command 41h refer to AQ Immediate Commands in Chapter 4 There are two ways to provide acceleration control when following a master source 1 External means such as ramping the velocity of the master input be used to limit acceleration 2 Select the Follower Ramp mode with AQ Command 45h to make the Follower axis ramp up at the Jog acceleration rate Master Sources GFK 0781C A Power Mate APM axis can follow one o
19. v a45311 Figure 6 12 Jump Followed by PMOVE SCURVE Jumps Jumps during linear motion and jumps during scurve motion at constant velocities im mediately begin accelerating or decelerating to a new velocity Jumps during an scurve acceleration or deceleration however require different rules in order to maintain an s curve profile What happens when a jump occurs during an scurve move while chang ing velocity depends on whether the jump occurs before or after the midpoint the point where the acceleration magnitude is greatest and whether the velocity at the jump des tination is higher or lower than the current velocity If the jump occurs after the midpoint of the change in velocity the change will continue normally until constant velocity is reached then the velocity will be changed to the new velocity using the acceleration mode of the move at the jump destination 6 22 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Example 12 SCURVE Jumping After the Midpoint of Acceleration or Deceleration In the following example a jump occurs during the final phase of deceleration at the dotted line The deceleration continues until constant velocity is reached and then the acceleration to the higher velocity begins ACCEL 50000 VELOC 100000 BLOCK 1 JUMP CTL01 3 CMOVE 500000 ABS SCURVE BLOCK 2 VELOC 60000 CMOVE 500000 INC SCURVE BLOCK 3 VELOC 85000 ACCEL 10000
20. 8 Follower Motion Velocity Clamping Example 9 JUMP Without Stopping Example 9 Follower Motion Unidirectional Operation 6 35 Execute Motio ogram 1 6 Q Discrete Command External Input Enable Follower Immediate Command External Input for Enabling the Follower 6 36 Faceplate Input Status CTL01 08 I Status Bit kid Features of the PM APM easy to use 1 1 E high performance versatile O Feedback Type Final Home Velocity Find Home Axis 1 2 Q Discrete Command Teo Find Home Encoder 3 Q Discrete Command 4 10 Find Home Mode 5 9 Find Home Velocity Firmware Releases Compatibility Follower A BRatio AQ Immediate Command Follower Axis Acceleration Ramp Control 6 37 Follower Motion 6 29 Follower Motion Combined with Motion Programs Follower Operation Follower Ramp Distance Make up Time AQ Immediate Command Follower System Startup Procedures 5 1 ForceD A Command 5 4 Force D A Output 76AQ Immediate Command Functional Block Diagrams for the 2 Axis PM APM Functional Connection Diagrams 2 10 Functional Connection Diagrams for the 1 AxisPM APM P 10 Functional Connection Diagrams for the 2 AxisPM APM 12 H High Count Limit High Count Limit Actual Position B 8 Home Cycle Home Mode Home Mode Find 9 Home Offset Home Position Home Position Offset 3 9 Home Switch Mode Home Velocity Find B 9 I
21. AI table is POSITIVE If the motor moves in the wrong direction consult the manufacturers instructions for corrective action The Motor Dir parameter in the Configuration Software can also be used to swap the positive and negative axis directions Power Mate APM Firmware 2 10 or later If the motor moves in the POSITIVE direction but the Power Mate APM reports that Actual GFK 0781C 5 1 10 11 12 Velocity is NEGATIVE then the encoder channel A and channel B inputs must be swapped Record the actual motor velocity reported by the Power Mate APM with a 1 0 volt velocity command Multiply this velocity by 10 and update the Vel 10V entry in the Power Mate APM configuration Initially set the Pos Loop TC configuration entry to a high value typically 100 to 1000 ms Turn on the Q Jog Plus bit Confirm that the servo moves in the proper direction and that the Actual Velocity reported by the Power Mate APM in the AI table matches the configured jog velocity With the Drive Enabled Q bit on and no servo motion commanded adjust the servo drive zero offset for zero Position Error The integrator should be OFF during this process Check for proper operation of the Find Home cycle by momentarily turning on the Q Find Home bit the Drive Enabled Q bit must also be maintained on The axis should move towards the Home Switch at the configured Find Home velocity then seek the Encoder Marker at the configured Fnl Home velocity If nece
22. Absolute Encoder is used Actual Position Absolute Encoder Data Absolute Feedback Offset Power Mate APM module Firmware Revisions should be interpreted as two separate words for major minor revision codes At least three PLC sweeps or 20 milliseconds whichever represents more time must elapse before the new Selected Return Data is available in the PLC External Input Enable Follower This command selects the input that will trigger the follower axis to start following the master command When byte 2 00 the external input feature is disabled and the follower is Enabled Disabled in thenormal manner by the ON OFF state of the Enable Follower 96Q command Setting Byte 2 01 08 selects the input CTLO1 CTL08 that is used to trigger the axis to start following when the Enable Follower Q bit is ON When the Enable Follower Q bit is turned OFF the follower is disabled and will not be enabled until the Enable Follower Q bit is turned ON and the selected trigger input turns on Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C GFK 0781C Follower Ramp Distance Make Up Time When the Follower Ramp feature has been selected and the follower is enabled the following axis is ramped up to the Master velocity at the current jog acceleration rate without losing any of the master counts during ramp up if the make up time is set for a non zero value The master counts that cannot be sent during ra
23. Axis Velocity will be ramped up at the Jog acceleration rate When the Enable Follower Q bit is turned off the axis velocity will ramp down at the same rate The Command Move bit indication is turned on while the ramp control is in effect for both the ramp up make up and ramp down The 1 Follower Enabled and I Command Move bits can be monitored by the PLC to determine which part of the follower ramp up ramp down cycle is active The following figure shows the state of Follower Enabled and Command Move during a follower cycle Acceleration Make updistance Follower A Disabled Pd Velocity i M make uptime 0 1 1 1 i Time Follower i Enabled Move Figure 6 28 Follower Ramp Up Ramp Down Cycle GFK 0781C Chapter 6 Power Mate APM Motion Control 6 37 L6 Combined Motion Combined motion consists of Follower motion commanded from a master axis combined with one of these internally commanded motions m Q Jog Command Move at Velocity Command m AQ Move Command Power Mate APM firmware version 2 10 or later m Stored Motion Program Power Mate APM firmware version 2 10 or later Combined motions are additive The slave axis motion is equal to the sum of the motion commanded by the master axis and the internally commanded motion Example 11 Follower Motion Combined with Jog In this example the Enab
24. CMOVE which could not reach the programmed velocity The Power Mate APM accelerates to the point where it must start decelerating to reach the programmed position of C1 at the velocity of the second CMOVE ACCEL 2000 VELOC 8000 CMOVE 7000 INC LINEAR ACCEL 10000 VELOC 2000 CMOVE 4400 INC LINEAR V 45260 t Figure 6 5 Not Enough Distance to Reach Programmed Velocity Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Example 4 Hanging the Power Mate APM When the Distance Runs Out A serious programming error involves hanging the Power Mate APM at a high velocity when the distance runs out In the following example the first CMOVE accelerates to a high velocity The second CMOVE has an identical velocity However the distance spe cified for the second CMOVE is very short Thus the axis is running at a very high veloc ity and must stop in a short distance If the programmed acceleration is not large enough the following profile could occur In order to not pass the final position the Power Mate APM instantly commands a zero velocity This rapid velocity change is un desirable and could cause damage to the controlled machine ACCEL 500 VELOC 3000 CMOVE 9000 ABS LINEAR ACCEL 600 CMOVE 4800 INC LINEAR V a45261 t Figure 6 6 Hanging the Power Mate APM When the Distance Runs Out GFK 0781C Chapter 6 Power Mate APM Motion Control 6 13 L5 Dwell Co
25. ENCODER SLAVE AXIS 1 Figure 2 8 2 Axis Cascade Master Source Encoder 3 Internal Master The diagram below illustrates the two axes of the Power Mate APM connected in parallel with encoder 3 or the internal master as the master source for both axis 1 and axis 2 MASTER a45321 ENCODER FEED FORWARD Duc e 9o o RATIO POSITION u A B LOOP ENABLE 5 E FOLLOWER INTERNAL 2 MOTION JOG MASTER PROGRAM MOVE AT VELOCITY 2 ENCODER SLAVE AXIS 2 v FEED FORWARD SLAVE RATIO POSITION Lpo o Moos ENABLE A FOLLOWER MOTION JOG PROGRAM MOVE AT VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 2 9 2 Axis Parallel Master Source Encoder 3 Internal Master 2 14 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C GFK 0781C The following diagram illustrates the two axes of the Power Mate APM connected in cas cade with the analog input as the master source for axis 2 and encoder 2 the master source for axis 1 ANALOG INPUT FEED FORWARD 245322 SLAVE RATIO ES MOTOR 2 ENABLE a 4 n FOLLOWER 2 MOTION JOG PROGRAM MOVE AT VELOCITY 2 ENCODER SLAVE AXIS 2 N FEED FORWARD SLAVE RATIO POSITION Lo o gt ioo gt MOTOR ENABLE a 4 n FOLLOWER 1 MOTION J
26. General Purpose Input Circuitry 1 1 eh C 5 Figure C 6 Analog Input Circuitry C 5 Figure C 7 I O Connector Cable Specifications 1 21 1 C 6 Figure D 1 55 90 Digital 100 Digital 200 Wiring D 1 GFK 0781C Table of Contents ix Contents Table 2 1 Pin Definitions of the Serial COMM Connector 2 3 Table 2 2 Cable Connections to Faceplate I O Connector A 1 AxisPower Mate APM 2 6 Table 2 3 Cable Connections to Faceplate I O Connector B 1 AxisPower Mate 2 7 Table 2 4 Cable Connections to Faceplate I O Connector A 2 AxisPower Mate APM 2 8 Table 2 5 Cable Connections to Faceplate I O Connector B 2 AxisPower Mate 2 9 Table 3 1 Module Configuration 3 2 Table 3 2 Serial Communications Port Configuration Data 3 4 Table 3 3 Master Source Configuration Data 3 5 Table 3 4 Axis Configuration Data 2 2 2 2 3 6 Table 4 1 I Status Bits for the 1 Axis Power Mate APM 1 693 0301 4 2 Table 4 2 I Status Bits for the 2 Axis Power Mate APM IC693APU302
27. Integrator Time Constant ms This is the time constant for the position error integrator in milliseconds This value indicates the length of time in which 63 of the position error will be removed For example if the Integrator Time Constant is 1000 or 1 second the Position Error would be reduced to 37 of its initial value after 1 second A value of zero turns off the integrator The Integrator Time Constant should be 5 to 10 times greater than the Position Loop Time Constant to prevent instability and oscillation Default 0 Intgr Mode Operating Mode for position error integrator OFF means the integrator is not used CONTINUOUS means the integrator runs continuously even during servo motion IN ZONE means the integrator only runs when the Ir Zone status bit is set Default OFF Rev Comp Reversal Compensation is set to 0 and cannot be changed DisDly ms Servo Drive Disable Delay milliseconds The time delay from zero velocity command to the drive enable output switching off Disable Delay is effective when the En able Drive Q bit is turned off or certain error conditions occur Disable Delay should be longer than the deceleration time of the servo from maximum speed Default 100 Jog Vel Jog Velocity User Units second The velocity at which the servo moves during a Jog operation Default 1000 Jog Acc Jog Acceleration Rate User Units second second The acceleration rate used during Jog Find Home Move at Velocity and Ab
28. Mate APM Axis 2 Master Source Encoder 3 Internal Master Axis 1 Master Source Analog Input The diagram below illustrates the two axes of the Power Mate APM connected with the analog input the master source for axis 2 and encoder 3 or the internal master as the master source for axis 1 FEED FORWARD 45325 ANALOG RATIO POSITION SLAVE INPUT POO ag Loop gt MOTOR ENABLE FOLLOWER 2 MOTION JOG PROGRAM MOVE AT VELOCITY 2 ENCODER MASTER SLAVE AXIS 2 ENCODER FEED FORWARD Q SLAVE 7 RATIO POSITION O gt MOTOR LOOP ENABLE a D FOLLOWER 1 MOTION JOG MASTEN PROGRAM MOVE AT VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 2 13 2 Axis Power Mate APM Axis 2 Master Source Analog Input Axis 1 Master Source Encoder 3 Internal Master 2 16 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Section 2 Installing the Power Mate APM The Power Mate APM can operate in any Series 90 30 CPU or expansion baseplate Series 90 30 release 3 or later For limitations on the maximum number of Power Mate APM modules you can install per baseplate and system refer to the section Module Specifica tions The configuration files created by Logicmaster 90 30 20 Micro configuration software must match the physical configuration of the modules To install the Power Mate APM in the rack follow these steps
29. O Cableand Terminal Block I O Cable Connections for the 1 Axis PM APM IC693APU301 P e I O Cable Connections for the 2 Axis PM APM IC693APU302 8 I O Connectors I O Rack Baseplate Configuration I OSpecifications 2 Idle Time Important Configuration Considerations 3 10 In Error Limit I Status Bit GFK 0781C GFK 0781C In Pos Zone B 6 In Position Zone 8 In Position Zone Immediate Command In Velocity Limit I Status Bit In Zone l Status Bit Incremental Positioning 6 7 Information for Ordering E 1 Installing the 2 17 Installing the Power Mate 2 1 Integrator Mode Integrator Time Constant 6 6 3 8 3 10 Integrator Time Constant AO Immediate Command Interfaces Operator 1 4 Internal Master Velocity AQ Immediate Command Internal Master Velocity Generator J Jog Acceleration Jog Acceleration AQ Immediate Command Jog Acceleration Mode Jog Minus Q Discrete Command 4 10 Jog Plus Q Discrete Command 4 9 Jog Velocity Jog Velocity AQ Immediate Command 29 Jogging with the PM APM 6 3 Jump Stop 6 20 Jump Testing Jump Normal Stop before 6 18 Jumping Without Stopping Jumps and Block Numbers 6 15 Jumps Conditional 6 16 Jumps SCURVE 6 22 Jumps Unconditional 6 15 Index L LED Indicators 2 2 Linear Acceleration Load Parameter Immediate Immediate Command Loop Mode 3 10 Low Coun
30. active AFTER a Conditional JUMP command Jump testing occurs one more time Motion Program Example Begin Program 1 CMOVE 1 20000 ABS LINEAR JUMP CTLO1 3 2 PMOVE 1 40000 ABS LINEAR CTLO1 tested only once 3 DWELL 1 100 End Program Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August 1996 GFK 0781C GFK 0781C s In the example above The CTLO1 bit will only be tested once because the PMOVE following the JUMP contains a new Block Number 2 Changing the location of Block Number 2 will cause the CTL bit to be tested throughout the PMOVE following the JUMP Begin Program 1 CMOVE 1 20000 ABS LINEAR 2 JUMP CTLO1 3 PMOVE 1 40000 ABS LINEAR CTLO1 tested throughout PMOVE 3 DWELL 1 100 End Program The Power Mate APM can perform a Conditional JUMP from an active CMOVE to a program block containing a CMOVE or PMOVE without stopping For the axis to jump without stopping the distance represented by the CMOVE or PMOVE in the Jump block must be greater than the servo stopping distance The servo stopping distance is computed using the present commanded velocity and the acceleration parameters that would be in effect when the jump block became active The axis will STOP before jumping if a Conditional Jump trigger occurs under any of the following conditions m When a PMOVE is active m When a CMOVE is active and the Jump destination block contains a CMOVE or PMOWVE representing motion in the
31. bit is cleared Fast Inputs CTLO1 or CTLO2 are recommended for this use if a high speed response is required When the Enable Follower trigger occurs the Commanded Position at that point is captured in a parameter register so that it can be used in a Programmed Move command The position is captured in parameter 253 for axis 1 or parameter 252 for axis 2 The Follower Enable status is returned in l bit offset 28 axis 1 or lI bit offset 29 axis 2 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Follower Axis Acceleration Ramp Control For applications where the Follower is enabled when the Master command is already up to speed the Follower Ramp feature can be used to apply a controlled acceleration rate to bring the follower axis up to speed This may be done without losing any Master command counts from the point at which the Follower was enabled To prevent any master counts from being lost configure the appropriate time milliseconds for making up the counts in the Ramp Distance Make up Time parameter If lost counts during ramp up are of no concern set the Distance Make up Time 0 for simply ramping up to the Master Commanded Velocity To select Ramp Control use AQ Command 45h Set the Follower Ramp distance make up time to the desired time with AQ Command 42h Refer to the description of this command for more information about this parameter feature The Follower
32. connector is available in two lengths Catalog number IC693CBL311 is 10 feet 3 meters in length and IC693CBL319 is 3 feet 1 meter in length The cable wire code list for these cables is provided in Table C 1 An LO cable assembly similar to IC693CBL311 but with the drain shield wire disconnected from pin B12 and brought outside of the cable housing through an 8 pigtail is also available in two lengths Catalog number IC693CBL317 is 10 feet 3 meters in length and IC693CBL320 is 3 feet 1 meter in length This cable improves the PM APM s noise immunity The cable wire code list for these cables is provided in Table C 2 Table 1 I O Cable Wire Coding for IC693CBL311 and IC693CBL319 PinNumber TerminalNumber Mw 8 s Sc gt 29 7 ria gig 6 Same as Terminal Block Terminal Number GFK 0781C AppendixCSpecifications C 7 Table C 2 I O Cable Wire Coding for IC693CBL317 and IC693CBL320 PinNumber Terminal Number Mw 8 16 s m 29 NS 1 Same as Terminal Block Terminal Number 2 16gaugewire greenw yellowtracer 8 length from back of connector terminates with a 10 ring terminal The 24 pin I O connector itself which mates with the I O Connector on the faceplate of the PM APM is available as three types and can be ordered as an accesso
33. following table are offsets to this starting address Table 4 3 Status Words for the 1 Axis Power Mate APM IC693APU301 Word Description Offset x9 musco Reserved Command BlockNumber 1 002 003 Commanded Position Axis1 Position Error Axis1 i The word numbers represent an offset to the starting address for AI references This may be configured to display Commanded Position Program Command Position or other data types See AQ command ConfigurationModes and Select Return Data fModuleConfiguration parameter AI Pos Erris DISABLED Actual Velocity for Encoder 3 will be reported instead of Axis 1 Position Error Table 4 4 Status Words for the 2 Axis Power Mate APM IC693APU302 Word Description Offset Commanded Position Axis1 Position Error Axis1 Position Error Axis2 7 The word numbers represent an offset to the starting address for AI references This may be configured to display Commanded Position Program Command Position or other data types See AQ command ConfigurationModes and Select Return Data 4 6 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Status Code Status Code indicates the current operating status of the module When the Error flag is set it contains the error code number For a list of Power Mate APM error codes refer to Appendix A Error Codes Commanded Position Commanded Position represents t
34. generated when the Analog Input is OV and the negative of the maximum velocity is generated at 10V Example 3 Following the Analog Input In the graph below the Power Mate APM is configured with Master Source ANALOG The A B ratio is 1 1 The dotted lines indicate when the Enable Follower Q bit was turned ON and OFE 245329 Figure 6 20 Following the Analog Input GFK 0781C Chapter 6 Power Mate APM Motion Control 6 31 A B Ratio Encoder Axis 2 Master 2 axis Power Mate APM can be configured so that axis 1 will follow axis 2 With ENC2 as the Master Source for axis 1 axis 1 will follow axis 2 at the axis 2 velocity multi plied by the A B ratio configured for axis 1 Example 4 Following Encoder Axis 2 Axis1 of a 2 axis Power Mate APM is configured with Master Source ENC2 With the ratio 1 2 axis 2 is commanded to Move at Velocity 12000 and then 0 Axis 1 follows axis 2 at half of the axis 2 velocity and acceleration and moves only half the distance that axis 2 moves V V 245330 Axis 2 Master t Axis 1 Follower t Figure 6 21 Following Encoder Axis 2 An Power Mate APM axis following a master input can do so at a wide range of mas ter slave A B ratios The A value can be any number from 32768 to 32767 The B val ue can be anywhere between 1 and 32767 The ratio A B can be from 1 32 to 32 1 Thus very precise ratios such as 12 356 12 354 or 32 000 1024 can be used The Foll
35. internal master input will not set Command Move In Zone The In Zone status bit is set if Command Move is OFF and the follower axis posi tion error is less than the configured In Zone value Therefore In Zone may always be set in a follower system which uses velocity feedforward to achieve zero following error In Power Mate APM firmware release 2 10 In Zone is unconditionally set whenever the Follower is enabled and Command Move is off Chapter 4 Automatic Data Transfers 4 3 4 4 In Velocity Limit The In Velocity Limit status bit is set if the velocity requested by the external or internal master input exceeds the configured Velocity Limits Therefore In Velocity Limit is an indication that the follower axis is no longer locked to its master input A Status Error code is reported when In Velocity Limit is set An exception exists when one of the Velocity Limits is set to 0 A zero Velocity Limit indi cates unidirectional following motion so no error is generated For example if the Ve locity Limit 0 and Counts are input the In Velocity Limit Status bit is set but no Sta tus Error code is reported If one of the Follower Control Loop Velocity Limits is set to zero the position error integrator is inhibited from generating motion in the direction of the Velocity Limit This feature allows unidirectional systems to operate properly with the position error integrator enabled In Error Limit The In Error Limit status bit is
36. motion at the configured Final Home Velocity until a marker pulse is sensed The marker establishes the Home reference position 7 The axis decelerates and is stopped 8 The axis is moved at the current Jog Velocity the number of user units specified by the Home Offset value from the Home reference position 9 The axis decelerates and is stopped 10 Aninternal Set Position sets the Commanded and Actual Positions to the configured Home Position value Finally the Power Mate APM sets the Position Valid l bit to in dicate the Home Cycle is complete Move and Move Modes If Find Home Mode is configured as Move or Move the first marker pulse encoun tered when moving in the appropriate direction positive for Move negative for Move is used to establish the exact location An OFF to ON transition of the Find Home Q bit will perform the following operation 1 The axis is accelerated at the Jog Acceleration rate and moved at the configured Final Home Velocity positive direction for Move negative direction for Move until a marker pulse is sensed This marker pulse establishes the Home reference position 2 The axis is stopped at the configured Jog Acceleration rate and with the configured Jog Acceleration Mode 3 The axis is moved at the configured Jog Velocity and with the configured Jog Acceleration rate and Jog Acceleration Mode the number of user units specified by the Home Offset value from the Home reference pos
37. s Manual August1996 GFK 0781C s Example 5 Sample A B Ratios Allof the following samples are following the master source input at various A B ratios V 245331 Master Source Following Ratio 1 2 Following Following Ratio 2 1 Ratio 1 3 Following Ratio 4 3 Following Ratio 5 6 Following Following Ratio 1 1 Ratio 2 3 Figure 6 22 Sample A B Ratios GFK 0781C Chapter 6 Power Mate APM Motion Control 6 33 Example 6 Changing the A B Ratio One example of variable A B ratios is to use one ratio while moving positive and anoth er when moving negative Note that determination of positive and negative velocity and transmission of the A B ratio must be done in the PLC In profile below the follow ing axis uses a 2 1 ratio when moving positive and a 1 2 ratio when moving negative 245332 Master Source Following Axis Figure 6 23 Changing the A B Ratio Example 7 Ratio Stepping Another example of variable A B ratios is step up the ratio as a type of acceleration con trol Initially setting a ratio 0 32 and incrementing the numerator after a delay would step the following axis from 0 32 to 1 32 to 2 32 and so forth all the way to 32 32 which is 1 1 In this example the PLC increments the A B ratio by 1 16th every second until it reaches 1 1 The dotted lines represent ratio changes the dashed line indicates when the Follower Enable Q bit is turned OFE a45333 Following Axis
38. sample again plotting velocity versus time is shown below The curved lines on the graph indicate that the acceleration was not constant When the move begins the acceleration starts slowly and builds until it reaches the programmed acceleration This should be the midpoint of the acceleration Then the acceleration be gins decreasing until it is zero at which time the programmed velocity has been reached Ans curve move requires twice the time and distance to accelerate and decelerate that a linear move needs if the acceleration is the same The area under the velocity vs time graph is also the distance moved ACCEL 2000 VELOC 2000 PMOVE 8000 INC SCURVE V 245257 t Figure 6 2 Sample S curve Motion Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Types of Programmed Move Commands Positioning Move PMOVE A PMOVE uses the most recently programmed velocity and acceleration If a VELOC command has not been encountered in the motion program the Jog Velocity is used as a default If an ACCEL command has not been encountered in the motion program the Jog Acceleration is used as a default A PMOVE will always stop when it is completed to allow the IN ZONE I bit to turn ON Continuous Move CMOVE A CMOVE uses the most recently programmed velocity and acceleration If a VELOC command has not been encountered in the motion program the Jog Velocity is used as a default If an ACCEL co
39. set if the position error required to run the follower servo is greater than the configured Error Limit value Whenever In Error Limit is set all internally or externally generated motion commands will be ignored until Posi tion Error becomes less than Error Limit Therefore In Error Limit is an indication that the follower axis is no longer locked to its master input A Status Error code will be reported when In Error Limit is set and the Enable Follower Q bit is set Faceplate Input Status CTL01 08 These inputs always indicate the state of the external input devices connected to the Power Mate APM faceplate terminals CTL01 08 These in puts as well as CTLO9 CTL12 from the PLC Q table may be tested by the Power Mate APM during execution of Wait and Conditional Jump commands CTL01 08 can also be se lected as a follower enable trigger Several inputs can serve alternate purposes as shown in the following table 01 Axis2 Encoder Marker Channel 2 axis Power Mate only CTL02 Encoder3 Marker Channel 2 axis Power Mate APM only CTL03 Axis 1 HomeSwitch input CTL04 Axis 2 Home Switch Input CTLO05 Axis 1 Drive OK Input CTL06 Encoder 3 Home Switch Input CTL07 Axis2 Drive OK Input CTL08 CTLO1 and CTL02 are assigned to different faceplate inputs on the 1 axis Power Mate APM and 2 axis Power Mate APM Refer to the faceplate connection and wiring diagrams in Chapter 2 Configurati
40. t Figure 6 24 Ratio Stepping Velocity Clamping Velocity clamping is available using the Velocity Limits set in the Configuration software When the master velocity exceeds the configured limit the following axis will continue to move at the limit velocity multiplied by the A B ratio The In Velocity Limit 1 bit is set and a status error is generated to indicate that the slave axis is no longer following the master input positioning The slave axis has essentially fallen behind the master input The Velocity Limit units are counts per millisecond Thus a limit of 400 cts ms will limit velocity to 400 000 cts sec Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Example 8 Velocity Clamping The Velocity Limits are set to 100 and 100 in this example Thus the master input veloc ity is clamped at 100 000 cts sec in either direction When the master axis peaks greater than the limits the following axis stays at the limit After the master slows to under the limit the following axis continues tracking the master axis velocity Counts generated in excess of the Velocity Limits are lost to the follower The horizontal dashed lines indicate the velocity limits The shaded area indicates the times when the In Velocity Limit bit is ON and the following axis is falling behind the master V V 245334 Following Axis Master Axis Figure 6 25 Velocity Clamping Unidir
41. that is transferred between the PLC CPU and the Power Mate APM each sweep Follower System Startup Procedures This chapter explains the proce dures for properly starting up a follower system Power Mate APM Motion Control This chapter provides practical in formation on Power Mate APM control with a number of examples Error Codes Parameter Download Using COMM Specifications Wiring to SS 90 Drives Ordering Information Series 90 PLC Axis Positioning Module Programmer s Manual Power Mate APM for Series 90 30 Standard Mode User s Manual At GE Fanuc Automation we strive to produce quality technical documentation After you have used this manual please take a few moments to complete and return the Reader s Comment Card located on the next page iii Contents Chapter 2 IitrodtclOD ossa coxa o ARR beet aoe deme 1 1 Features of the Power Mate 1 1 Firmware Compatibility Tables 1 2 Overview of Power Mate APM Follower Operations 1 3 Chapter 3 Installing the Power Mate 2 1 Section 1 Description of the Power Mate APM 2 2 LED Indicators 42x ere EIE teda e ene aa a eee tas 2 2 Serial COMM Connector 22 Multidrop Connection 2 3 I7 OGonnectofs vu RR e ea
42. the 1 and 2 axis models of the Power Mate Power Mate APM and how to install the modules on the Series 90 30 PLC baseplate The chapter is divided into the following section m Section 1 Description of the 1 and 2 Axis Power Mate APM m Section 2 Installing the Power Mate APM 2 1 Section 1 Description of the Power Mate APM This section describes the user interfaces of the 1 and 2 axis Power Mate APM in follower mode LED Indicators There are five LEDs which provide status indication for the Power Mate APM These LEDs are described below Status Normally ON FLASHES to provide an indication of operational errors Flashes slow four times second forStatus Only errors Flashes fast eight times second for er rors which cause the servo to stop OK The Power Mate APM OK LED indicates the current status of the Power Mate APM ON When the LED is steady ON the Power Mate APM is functioning properly Normally this LED should always be ON OFF When the LED is OFE the Power Mate APM is not functioning This is the result of a hardware or software malfunction CFG This LED is ON when a valid module configuration has been received from the PLC EN1 When this LED is ON the servo drive for Axis 1 is enabled EN2 When this LED is ON the servo drive for Axis 2 is enabled On a 1 axis Power Mate APM this LED is ON only when a Force D A Immediate command is used for the analog output on Connector B Serial COMM Co
43. the position commanded by the stored program Absolute move commands from the stored program will be referenced to the Program Reference Position Position ranges in counts for the Actual and Program Command Position registers are indicated in the figure below Program Command Position Range Fixed Lo Limit max Hi limit max Fixed 2 8M 8M 2B 0 Actual Position Range from Feedback With sustained commanded motion in the same direction the Program Command Position will roll over at 2 147 483 647 or 2 147 483 648 counts The Actual Position however will be confined by the configured high and low limits with maximum values of 8 388 607 and 8 388 608 counts GFK 0781C Chapter 6 Power Mate APM Motion Control 6 39 Table 6 1 below indicates which source commands affect these position registers and the actual and commanded velocities Program Command Position is updated only by internally generated move commands program commands Jog Home and Move at Velocity The Commanded Velocity returned in 6AI data also only indicates velocity commanded by these internally generated move commands Actual Position and Actual Velocity AI return data reflect the combination of the master input and the move commands In other words counts coming from the master source affect only the Actual Position and Actual Velocity and if there are no internally generated move commands the Commanded Velocity will be 0 and the Program C
44. 0 CMOVE 250000 INC SCURVE V 45265 t Figure 6 13 Jumping After the Midpoint of Acceleration or Deceleration If a jump takes place before the midpoint of acceleration or deceleration the result de pends on whether the velocity at the jump destination is higher or lower than the veloc ity before the jump took place In the first case when accelerating but the new velocity is lower or decelerating and the new velocity is greater the Power Mate APM will im mediately begins reducing the acceleration or deceleration to zero once zero the Power Mate APM will use the jump destination acceleration and velocity and change to the new velocity GFK 0781C Chapter 6 Power Mate APM Motion Control 6 23 Example 13 SCURVE Jumping Before the Midpoint of Acceleration or Deceleration In the following example during the acceleration of the first CMOVE a jump takes place at the first dotted line Because the velocity at the jump destination is lower than the velocity of the first CMOVE the Power Mate APM slows the acceleration to zero Constant velocity zero acceleration occurs at the second dotted line There the Power Mate APM begins decelerating to the new velocity using the acceleration at the jump destination Finally the second CMOVE finishes ACCEL 1000 VELOC 50000 BLOCK 1 JUMP CTL01 3 CMOVE 50000 INC SCURVE BLOCK 3 VELOC 5000 ACCEL 10000 CMOVE 15000 INC SCURVE V 45266 t Figure 6 14 Jumping before the Midpoint
45. 1 Combining PMOVEs and CMOVEs Example 1 Follower Motion Following Encoder 3 Master Input Example 10 Jump Stop 6 21 Example 10 Follower Motion Encoder 3 and Internal Master Synchronization 6 36 Example 11 Jump Followed by PMOVE 692 Example 11 Combined Motion Follower Motion Combined with Jog Example 12 Jumping After the Midpoint of Acceleration or Deceleration 6 23 Example 12 Combined Motion Follower Motion Combined with Motion Program Example 13 Jumping Before the Midpoint of Acceleration or Deceleration Example 14 Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating 6 25 Biss 15 Maximum Acceleration Time 6 26 Example 16 Multi AxisProgramming 627 Example 2 Changing the Acceleration Mode During a Profile 6 11 Example 2 Follower Motion Following the Internal Master Example3 Not Enough Distance to Reach Programmed Velocity Example 3 Follower Motion Following the Analog Input 6 31 Example 4 Hanging the PM APM When the Distance Runs Out Example 4 Follower Motion Following Encoder Axis 2 Example 5 Dwell 6 14 Example 5 Follower Motion Sample A B Ratios Index 3 Index Index 4 Example 6 Unconditional Jump Example 6 Follower Motion Changing the A B Ratio Example 7 Jump Testing Example 7 Follower Motion Ratio Stepping Example 8 Normal Stop before JUMP lis Example
46. 195 RO200 NO USE1 NOT USED ZEROED BY BLKMV RO201 NO USE2 NOT USED ZEROED BY BLKMV RO202 CMDTYP COMMAND TYPE E501 FOR APM RO203 BYTECNT BYTE COUNT OF DATA RO204 MEMTYP MEMORY TYPE OF DATA 8 REG RO205 DATAST START OF DATA BLOCK 1 205 R0206 RO206 PAR NO STARTING PARAM NUMBER RO207 NO VALS NUMBER OF PARAMETERS TO SEND R0208 R0239 PAR DAT Data for 16 Parameters 32 words GFK 0781C B 1 OE E OK CK OE AAA AAA X OK X OE OK OE OK OE KR OR KR OK X E OK OE OK GE OK OE OK OE CK OK CK ORE X OE OK GE AKIRA EK GER E E EK EK EK ER CLEAR THE REGISTER BLOCK THEN LOAD THE COMM REO HEADER DATA 2 Ep ERE SEND 8 001 qc a Bie tS SS BLKMV CLR INT WORD CMREQST CONST Q R0195 RO195 IN 00000 LEN 100045 CONST IN2 00004 CONST IN3 00000 CONST IN4 00008 CONST IN5 00194 CONST IN6 00000 CONST IN7 00000 RRR RR KARR RR KR KK KR KR KR KAKA RR KR SRK kckckckck ck kckckckckck ckck kck KAKA AK AKA RK Y PUT THE COMMAND TYPE E501 IN THE FIRST DATA WORD R202 PUT THE BYTE COUNT OF THE DATA IN THE NEXT WORD R203 PUT THE x MEMORY TYPE OF THE DATA 8 REG IN THE NEXT WORD R204 PUT THE STARTING LOCATION OF THE DATA BLOCK 1 IN THE NEXT WORD R205 3
47. 2 axis Power Mate APM motion control modules pro vides a high performance easy to use master slave controller which is highly integrated with the logic solving and communications functions of the Series 90 30 PLC The Power Mate APM operates in two primary control loop configurations m Standard Mode m Follower Mode This manual describes the Power Mate APM in the Follower control loop mode For in formation on the operation of the Power Mate APM in Standard control loop mode refer to GFK 0840 Power Mate APM for Series 90 30 Standard Mode User s Manual The Power Mate APM Follower option is selected by setting the Module Configuration Parameter Control Loop Type to FOLLOWER The Control Loop Type parameter is ac cessed when performing Module Configuration using the Logicmaster 90 30 Configura tion package 1 STAT CFG High Performance Power Mate APM ONE AXIS m Fast Servo Loop Update 1 millisecond for APU301 2 milliseconds for APU302 m Velocity Feedforward and Position Error Integrator to enhance tracking accuracy 00000000 00 Accurate electronic gearing m Follower motion with superimposed motion program 721 19 9 Easy to Use m Simple and powerful Motion Program instruction set Configured with Logicmaster 90 software m Automatic Data Transfer between PLC tables and Power Mate APM without user programming
48. 5 PUT THE STARTING PARAMETER NUMBER 1 IN THE LOWER BYTE OF R206 AND THEN THE NUMBER OF PARAMETERS TO BE SENT 16 IN THE LOWER 22 BYTE OF R207 e ME Er CE CT i E E c EI x TEE E I ET x T E E T E E T E D SEND 4 MOVE Sea MOVE_ WORD INT INT CMDTYP BYTECNT MEMTYP CONST IN Q R0202 CONST IN Q RO0203 CONST Q R0204 E501 LEN 00068 LEN 00008 LEN 1000011 1000011 1000011 SEND T0001 de qx MOVE_ MOVE 4 MOVE_ INT INT INT 5 NO_VALS CONST IN 0 0205 CONST IN Q RO0206 CONST Q R0207 00205 LEN 00001 LEN 00016 LEN 1000011 1000011 1000011 4 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August 1996 GFK 0781C KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK ADD LOGIC HERE TO MOVE THE PROPER CONSTANTS INTO THE REGISTERS KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK R208 R239 SO THEY CAN BE SENT TO THE PM APM PARAMETERS Rr E LI E LE E E TL E EE C M CeO M I M E E MM A NOW ACTIVATE THE COMM REO TO SEND THE PARAMETER DATA TO THE
49. 6 2 16 5 4 6 8 6 8 6 10 6 11 6 12 6 13 6 14 6 15 6 19 6 20 6 21 6 22 6 23 6 24 6 25 6 26 6 27 6 30 6 31 6 31 GFK 0781C Contents Figure 6 21 Following Encoder 2 6 32 Figure 6 22 Sample A B Ratios st terere t Be aa ciate UE aa Bede eae 6 33 Figure 6 23 Changing the A B Ratio 6 34 Figure 6 24 Ratio Stepping 6 34 Figure 6 25 Velocity Clamping 2 2 2 6 35 Figure 6 26 Unidirectional Operation 2 2 6 35 Figure 6 27 Encoder 3 and Internal Master Synchronization 6 36 Figure 6 28 Follower Ramp Up Ramp DownCycle 6 37 Figure 6 29 Combined Motion Follower 2 6 38 Figure A 1 Status Code Organization A 1 Figure C 1 Velocity Command Circuitry C2 Figure C2 Enable Relay Output Circuitry seen C2 Figure Encoder Input Circuitry 2 2 2 2 2 2 2 C 3 Figure C 4 Encoder Power Circuitry C4 Figure C 5
50. 664A Follower GFK 0781 2 10 2 11 IC693APU302HJ Standard GFK 0840 6 01 orlater 1 50 or later GFK 0664A Follower GFK 0781 2 50 IC693APU302K Standard GFK 0840 6 01 orlater 1 50 or later GFK 0664A Follower GFK 0781 1 2 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Overview of Power Mate APM Follower Operations The Power Mate APM Follower is an intelligent fully configurable motion control op tion module for the Series 90 30 Programmable Logic Controller PLC The Power Mate APM allows a PLC user to combine high performance follower control with PLC logic solving functions in one integrated system The figure below illustrates the hardware and software needed to set up and operate a follower system This section will discuss briefly each piece of the system to provide an overall picture of system operation 2 gt Q o INTERFACES 245315 SLAVE1 MACHINE rise PS C 1 Y P D U N n poems fo U C T CZ B _____ ENCODER 1 M ji SLAVE2 MACHINE _ DRIVE PRI SN 527 LOGICMASTER 90 30 THE MOTION ENCODER 2 CONFIGURATION 1 PROGRAMMER PACKAGE TAN SOFTWARE MASTER PACKAGE
51. Cshould be1 4to1 2 of the MINIMUM system deceleration time For users familiar with servo bandwidth expressedinrad Bandwidth rad sec 1000 Position Loop Time Constant ms GFK 0781C Chapter 3 Configuring the Power Mate 3 9 For users familiar with servo gain expressedinipm mil Gain ipm mil 60 Position Loop Time Constant ms Gain ipm mil Bandwidth Position Loop Time rad sec Constant ms en fe mm dul 325 Xu Open Loop Mode For applications which do not require feedback or employ very crude positioning systems an Open Loop Mode exists This mode is selected by setting Position Loop Time Constant to zero Note that in Open Loop Mode the only way to generate motion is to program a non zero Velocity Feedforward The Position Error is no longer used to generate motion be cause Position Error is based on feedback and Open Loop Mode ignores all feedback Ratio A and B Values The ratio A B determines the relationship between the axis motion and the master source motion The generated axis motion is the result of the master source motion mul tiplied by the ratio Ratio A can be negative which would result in the slave moving in the opposite direction as the master axis The range for A B ratios is 1 32 to 32 1 Example of Ratio A and B Values make an axis follow the master encoder source but at only forty percent of the master s velocity and thus forty p
52. FANUC GE Fanuc Automation PowerMotion Products Power Mate APM for Series 90 30 PLC Follower Mode User s Manual GFK0781C August 1996 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use Insituations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility fo
53. K 0781C GFK 0781C Table 2 5 Cable Connections to Faceplate I O Connector B 2 Axis Power Mate APM Power Mate APM Terminal Module Block Description Connector B Terminal Number Pin Number 0V Input Fused Output an external source AE to this output could open the fuse N A N N Chapter 2 Installing the Power Mate APM 2 9 Functional Connection Diagrams The figures below illustrate how the Power Mate APM I O is connected to a drive and a machine in a typical follower application Shielded cable should be used as indicated Functional Connection Diagrams for the 1 Axis Power Mate APM VO CONNECTOR A TERMINAL 845316 vo BLOCK CONNECTOR TERMINAL NUMBER NUMBER DRIVE AXIS 1 VEL ES MOTOR is M XQ xX 8 d ENABLE 7 B6 16 ov si 8 SHIELD NOTE FOR SINGLE ENDED B11 18 Aik pod ALT ENCODER DO NOT CONNECT A1 B1 Z1 A12 5 Al X Bit B1 B10 19 A11 6 BiS x 1 AXIS 1 21 21 ENCODER B9 20 in gt 71 xX 21 A9 8 AXIS 1 Bs zi ov ba ov LOAD wu AXIS 1 HOME SWITCH AXIS 1 MASTER AXIS DRIVE OK 4 B i 24 DRIVE OK 1 CTLOS M M HOME 1 CTLO3 HOME 3 CTLO6 Ba d INCOM1 4 SHIELD 24VDC B12 18 79
54. LA TN MOTOR X yd GRE 2 EN I ENABLE ed Emm dum ie 1 SHIELD NOTE 3 FOR SINGLE ENDED A2 A2 ENCODER DO NOT A2 p a 4 A2 CONNECT A2 B2 Z2 B2 B2 B2 PUN 4 B2 po 72 72 ENCODER z2 22 5V 5 AXIS 2 ov gt ov LOAD Iu HOME SWITCH GENERAL AXIS 2 4 gt _ PURPOSE DRIVE OK SWITCH INPUT DRIVE 2 07 HOME 2 CTLO4 2 Yt CTLOS INCOM2 5 4 24VDC SHIELD 79 AIN O GENERAL PURPOSE AIN 1 o ANALOG INPUT 2 Figure 2 7 Functional Diagram for 2 Axis Power Mate APM I O Connector Note For Power Mate APM firmware release 2 10 or later the Z2 input channel is also the CTLO1 input GFK 0781C Chapter 2 Installing the Power Mate 2 13 Functional Block Diagrams for the 2 Axis Power Mate APM The diagram below illustrates the two axes of the Power Mate APM connected in cas cade with encoder 3 or the internal master as the master source for axis 2 and encoder 2 the master source for axis 1 MASTER M ENCODER FEED FORWARD SLAVE RATIO POSITION oeol Loop P gt moron 4 a D FOLLOWER INTERNAL 2 MOTION JOG MASTER PROGRAM MOVE AT VELOCITY 2 ENCODER SLAVE AXIS 2 FEED FORWARD RATIO POSITION po o MM ENABLE a FOLLOWER FO 1 MOTION JOG PROGRAM MOVE AT VELOCITY
55. LL command is encountered the jump is performed These com mands will end jump testing Example 7 Jump Testing Consider the following two program sections In the program on the left the move to position 2000 is completed before jump testing begins The BLOCK command immedi ately after the JUMP command ends jump testing Thus the duration for which the CTL bitis monitored is very short In the program on the right however the JUMP com mand is encountered before the move command This starts jump testing before motion begins and jump testing continues as long as the move lasts If the CTL bit turns ON while the move is being performed the jump will be performed After the move com pletes the BLOCK command ends jump testing and program execution continues nor mally Jump testing would continue during subsequent moves encountered before the BLOCK command ACCEL 5000 ACCEL 5000 VELOC 1000 VELOC 1000 BLOCK 1 BLOCK 1 CMOVE 2000 ABS LINEAR JUMP CTL01 3 JUMP CTL01 3 CMOVE 2000 ABS LINEAR BLOCK 2 BLOCK 2 Normal Stop before JUMP A conditional jump command is similar to Type 2 commands in that jump testing does not start until the Type 3 command immediately after the JUMP is executed If this Type 3 command would normally stop motion then motion will stop before jump testing be gins Type 3 commands that will stop motion are DWELL WAIT End of Program and moves in the opposite direction Thus even though the CTL bit may be ON
56. OG PROGRAM MOVE AT VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 2 10 2 Axis Cascade Master Source Analog Input The following diagram illustrates the two axes of the Power Mate APM connected in par allel with the analog input as the master source for both axis 1 and axis 2 ANALOG INPUT FEED FORWARD 245323 SLAVE eee P of PORTO E SOL 2 ENABLE a 4 4 FOLLOWER 2 MOTION JOG PROGRAM MOVE AT VELOCITY 2 ENCODER SLAVE AXIS 2 FEED FORWARD SLAVE eoo Pato of Poss 1 4 4 4 FOLLOWER 1 MOTION JOG PROGRAM MOVE AT VELOCITY 1 ENCODER SLAVE AXIS 1 Chapter 2 Installing the Power Mate Figure 2 11 2 Axis Parallel Master Source Analog Input 2 15 The diagram below illustrates the two axes of the Power Mate APM connected with en coder 3 or the internal master as the master source for axis 2 and the analog input the master source for axis 1 MASTER 245324 ENCODER FEED FORWARD SLAVE eese Ere oS aida te 2 ENABLE a D 5 FOLLOWER INTERNAL 2 MOTION JOG MASTER PROGRAM MOVE AT VELOCITY 2 ENCODER SLAVE AXIS 2 FEED FORWARD SLAVE ANALOG gt 5 PATIO POSITION b INPUT g AB Loop O a 4 D FOLLOWER 1 MOTION JOG PROGRAM MOVE AT VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 2 12 2 Axis Power
57. Oa re b gea edu 2 5 I O Cable and Terminal 2 5 I O Cable Connections for the 1 Axis Power Mate APM IC693APU301 2 6 I O Cable Connections for the 2 Axis Power Mate APM IC693APU302 2 8 Functional Connection Diagrams 2 10 Functional Connection Diagrams for the 1 AxisPower Mate APM 2 10 Functional Connection Diagrams for the 2 AxisPower Mate APM 2 12 Functional Block Diagrams for the 2 AxisPower Mate APM 2 14 Section2 Installing the Power Mate 2 17 Chapter 4 Configuring the Power Mate APM 3 1 I ORack Baseplate 3 1 Module 3 1 Setting the Configuration Parameters 3 2 Essential Configuration Parameters 3 9 Important Configuration Considerations 3 10 Chapter 5 Automatic Data Transfers 4 1 Jol Status Bits es alte pe bd en cca ee Soa 4 2 WAL Status Words sees oer eevee ates ete a RR Ea 4 6 Q Discrete 1 4 8 AQ Immediate Commands 4 11 Chapter 6 Follower System St
58. Programmed Moves By combining CMOVEs and PMOVES absolute and incremental moves and linear and scurve motion virtually any motion profile can be generated The following examples show some simple motion profiles as well as some cases of incorrect motion program ming Example 1 Combining PMOVEs and CMOVEs This example shows how simple PMOVEs and CMOVEs combine to form motion pro files ACCEL 1000 VELOC 2000 PMOVE 5000 ABS LINEAR VELOC 1200 PMOVE 10000 ABS SCURVE ACCEL 1500 VELOC 2800 CMOVE 6000 INC LINEAR VELOC 1200 CMOVE 23000 ABS SCURVE ACCEL 1000 VELOC 2800 PMOVE 5000 INC LINEAR 245258 Figure 6 3 Combining PMOVEs CMOVEs The move types are indicated under the corresponding move for example P L indicates linear PMOVE The first PMOVE accelerates to programmed velocity moves for a distance and deceler ates to a stop This is because motion stops after all PMOVEs When the first move stops it is at the programmed distance The second move is an scurve PMOVE It like the first accelerates to the programmed velocity moves for a time and decelerates to zero velocity because it is a PMOVE The next move is a linear CMOVE It accelerates to programmed velocity moves for a time and then decelerates to a lower velocity using linear acceleration When a CMOVE ends it will be at the programmed position of the move just completed and at the veloc ity of the next move Thus when
59. RMINAL NUMBER NUMBER DRIVE AXIS 1 FE VEL Dip MOTOR 25 xX X odd EN 4 A7 8 d ENABLE 72 B6 16 ov 5 SHIELD FOR SINGLE ENDED B11 18 pod ATE ENCODER DO NOT 2 E CONNECT 1 B1 Z1 M A1 xX A1 Bit Bi B10 19 11 6 Br X x 1 AXIS 21 21 ENCODER B9 20 is gt 21 X 21 A9 8 ON KN AXIS 1 2 ov X ov LOAD 90 1 HOME SWITCH AXIS 1 MASTER AXIS DRIVE OK 4 swircH Bs m DRIVE OK 1 CTLOS HOME 1 CTLO3 HOME 3 CTLO6 FS INCOM1 e l HIELD 24VDC B12 13 3 79 ie M 4 9 X B2 23 aa 885 10 sim X MASTER E Z3 23 ENCODER A2 11 239 x 23 5V 5V AQ 8 5 A1 12 oy X oy Figure 2 6 Functional Diagram for 2 Axis Power Mate Connector 2 12 Note Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 For Power Mate APM firmware release 2 10 or later the Z3 input channel is also the CTL02 input GFK 0781C CONNECTOR B TERMINAL BLOCK CONNECTOR TERMINAL NUMBER NUMBER A8 4 B7 17 7 3 B6 16 B12 13 B11 18 A12 5 B10 19 A11 6 B9 20 A10 7 A9 8 B8 21 B5 14 A6 1 A5 2 B4 15 B12 13 B1 24 A2 11 245319 DRIVE AXIS 2 VE
60. User Units and Counts 5 7 V Values A and B Ratio Velocity at 10 V Velocity at 10 volts Index 7 Index Index 8 Velocity at 10v Velocity Clamping Velocity Feedforward Velocity Feedforward AQ Immediate Command Velocity FF Velocity Generator Internal Master 6 30 Wait Command Wiring to SS 90 Drives D 1 GFK 0781C
61. a 25 pin D type terminal block connector also has an 8 externalshield pigtail TerminalBlock Weidmuller RD25 910648 or equivalent must beconsistentwithI O cableIC693CBL311 24 pinI OConnector Accessory Kits IC693ACC316 solder eyelet receptacle three types available each kit has enough IC693ACC317 crimp wirereceptacle components to assemble ten single ended IC693ACC318 IDC Ribbon receptacle cables SerialCommunicationsMiniconverter Kit IC690ACC901 GFK 0781C E 1 GFK 0781C Symbols AI Position Error Analog Input ax Commanded Position Commanded Velocity m Position Error Program Command Position l7 Status Code AI Status Words for the 1 AxisPM APM 4 8 AI Status Words for the 2 AxisPM APM IC693APU302 4 6 AQ Immediate Commands External Input Enable Follower i7 Follower A B Ratio Follower Ramp Distance Make up Time 4 17 Force D AOutput 4 13 In Position Zone Integrator Time MEE Internal Master Velocity Jog Acceleration Jog Velocity Load Parameter Immediate Move 4 14 Move At Velocity Null 13 Position Increment 4 13 Position Increment With Position Update 4 14 Position Loop Time Constant Select Return Data 4 15 Set Configuration Complete 4 18 Set Encoder 3 Position 4 15 Set Position 4 13 Velocity Feedforward oI Status Bit Axis Enabled AxisFollower Enabled Command Move Configuration Comp
62. aring Find Home Encoder 3 only will cause the Encoder 3 Home cycle to abort without setting Position Valid Encoder 3 Select Internal Master This bit switches the master axis source from Encoder 3 to the Internal Master Velocity generator The Set Master Velocity AQ Immediate command can be used to change the velocity of the internal master Clear Error When an error condition is reported this command is used to clear the Error status bit and its associated Status Code word Error conditions that are still present such as a Drive OK switch error will not be cleared and must be cleared by some other corrective action Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C AQ Immediate Commands Each PLC sweep 6 words of data are automatically transferred from the CPU data to the Power Mate APM These six words are used to send Immediate Commands from the PLC to the Power Mate APM The first three words offsets 0 through 2 are dedi cated to axis 1 of the Power Mate APM The second three words offsets 3 through 5 are dedicated to axis 2 of the 2 axis Power Mate APM Thus one command may be sent to each axis of the Power Mate APM every sweep Table 4 7 defines the axis dependent commands those that will affect only the axis on which they are commanded Table 4 8 defines the axis independent commands Axis independent commands may be sent using either or both sets of three words In a 1 axi
63. artup Procedures 5 1 Startup Procedures 5 1 System Troubleshooting Hints 5 2 Follower Control Loop Block Diagram 5 4 GFK 0781C Table of Contents v Contents Chapter 7 Power Mate APM Motion 6 1 Non Programmed 6 1 Power Mate APM Home Cycle 6 1 Jogging with the Power Mate APM 6 3 Move at Velocity Command 6 3 ForceD ACommand 6 4 Position Increment Command 6 4 Other Considerations 6 4 Programmed Motion 6 5 Prerequisites for Programmed Motion 6 6 Conditions Which Stop a Motion Program 6 6 Parameters for Programmed Moves 6 6 Types of Programmed Move Commands 6 9 Programmed 6 10 Dwell Command e sic nec cece ned eee eed ewe Eee eps 6 14 Wait Command a sed ere e eere quur ens 6 14 Subroutines v bre bee eb sh ils Mh ed a Si dee Ke A
64. atch Status Only Firmware Hardware Axis Number Mismatch 302 EPROM in 301 module Follower Errors F 1 Status Only Follower Position Error Limit condition encountered error 5 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Appendix Parameter Download Using COMM REQ b This appendix describes an alternate method of loading Power Mate APM Parameter Memory from the PLC using a the COMM REO function block with command code E501h This function block can send up to 16 Power Mate APM Parameter values at once The total data length of the COMM must be set to 68 bytes 34 words organized as shown below 9 0 1 Starting parameter number 0 255 Number of parameters to Is parameter data bytes 2nd parameter data bytes 32 33 64 67 16th parameter data 4 bytes Only the number of parameters specified in word offset 1 will be loaded into parameter memory However the 68 byte data block must always be initialized in the PLC If the last parameter to be loaded is greater than 255 the COMM REO will be rejected A parameter block download is illustrated in the following PLC program segment REFERENCE NICKNAME REFERENCE DESCRIPTION RO195 CMREOST COMM_REQ STATUS WORD Updated by COM_REQ RO196 HDR WDS COMM REQ HEADER LENGTH IN WORDS ALWAYS 4 RO197 NO WAIT NO WAIT ALWAYS 0 RO198 STMEMTP STATUS MEMORY TYPE 8 REG RO199 STLOCM1 STATUS WORD LOCATION MINUS 1 194 R0
65. ate APM from attempting instantaneous accelerations when the Select Internal Master Q bit is toggled Note however that if encoder 3 is undergoing fast acceleration or deceleration the Master Velocity Mismatch bit may not turn OFF because the Encoder 3 Velocity could change more than the 256 counts econd in one PLC sweep Example 10 Encoder 3 and Internal Master Synchronization synchronize the internal master and encoder 3 the Internal Master Velocity is stepped up to an expected encoder 3 velocity When encoder 3 is within 128 cts ec of this velocity the PLC will turn the Select Internal Master Q bit OFF to switch the master source to encoder 3 The shaded area indicates the time when the Select Internal Master Q bit is ON 245336 Encoder 3 Internal Master Master Sources t Following Axis t Figure 6 27 Encoder 3 and Internal Master Synchronization Enabling the Follower with External Input An external trigger signal applied to one of the inputs CTLO1 08 can be used to enable the follower axis The input selected for the Enable trigger is defined with AQ Command 41h When no input is selected the follower is enabled and disabled directly by the Enable Follower Q bit command When an input is selected for the Enable trigger and Q Enable Follower is set the next positive transition of the defined input will instantly enable the follower The follower will remain enabled until the Q Enable Follower
66. before the block with the conditional JUMP and Type 3 command is executed axis motion will stop before program execution contin ues at the jump destination This stopping is NOT a Jump Stop which is described in Example 10 Example 8 Normal Stop before JUMP The following example contains a jump followed by a DWELL command The Power Mate APM because it processes ahead knows it must stop after the CMOVE command Thus it comes to a stop before the DWELL is executed Since jump testing does not be gin until the DWELL is executed testing begins after motion stops Jump testing ends when the following CMOVE begins because of the BLOCK command associated with it Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s The dotted lines in the velocity profile indicate when jump testing is taking place The CTLO3 bit does not turn ON during the program BLOCK 1 ACCEL 5000 VELOC 10000 CMOVE 60000 INC LINEAR BLOCK 2 JUMP CTLO3 4 DWELL 4000 BLOCK 3 ACCEL 10000 VELOC 5000 CMOVE 15000 INC LINEAR BLOCK 4 NULL v a45310 JUMP t TESTING Figure 6 9 Normal Stop before JUMP Jumping Without Stopping If the Type 3 command following a conditional jump is a CMOVE and the Type 3 com mand at the destination is a move command with sufficient distance to fully decelerate to zero when completed the jump will be executed without stopping This is the only way to sustain motion when a jum
67. called it must be completed before it can be called again for the same axis Thus recursion is not allowed Block Numbers and Jumps Block numbers are used as reference points within a motion program and to control jump testing A AI data word displays the current block number which be moni tored to insure correct program execution or to determine when events should occur A block number may also be the destination of a JUMP command Unconditional Jumps Jumps are divided into unconditional and conditional An unconditional jump com mand simply tells the Power Mate APM to continue program execution at the destina tion block number An example of an unconditional jump follows Example 6 Unconditional Jump The program executes a PMOVE dwells for 2 seconds and then unconditionally jumps back to the beginning of the program at block 1 Thus the PMOVE will be repeated until an End of Travel Limit or Overtravel Limit Switch is reached ACCEL 10000 VELOC 30000 BLOCK 1 PMOVE 200000 INC LINEAR DWELL 2000 JUMP UNCOND 1 V 45263 Figure 6 8 Unconditional Jump GFK 0781C Chapter 6 Power Mate APM Motion Control 6 15 o Conditional Jumps A conditional jump is a JUMP command with a CTL bit specified in the command Conditional jumps are Type 1 commands in that they affect program path execution but they are also similar to Type 2 commands because they do not take effect until a Type 3 command following the JUMP command is ex
68. configured High and Low Count Limits When a limit is reached the posi tion rolls over to the other limit and continues changing Encoder 3 can be initialized by performing a Home Cycle for encoder 3 An encoder 3 Home Cycle does not generate any motion Instead it sets the Encoder 3 Actual Position AI data to the configured master source Home Position at the next marker pulse when the Home Switch 3 input is ON It also sets the Encoder 3 Position Valid 1 bit when it sets the position See Chapter 4 Q Discrete Commands Find Home Encoder 3 for details about the encoder 3 Home Cycle Chapter 6 Power Mate APM Motion Control 6 29 Example 1 Following Encoder 3 Master Input In this example a graph of velocity v versus time t shows the velocities of the master in put encoder 3 and the axis which is following the master The Power Mate APM is config ured with Master Source ENC3 INT and the Select Internal Master Q bit is OFE The A B ratio is 1 1 The velocity profile of the following slave axis is identical to the master input V V 845327 4 Figure 6 18 Following Encoder 3 Master Input Internal Master Velocity Generator The Power Mate APM can internally generate a velocity up to one million counts per second When ENC3 INT is configured as the Master Source and the Select Internal Mas ter Q bit is ON the internal master will be used as the master input source The veloc ity generated is initially zero The i
69. cuting a 2 axis program the program commands are scanned independently by each axis and only the data designated for that axis is executed Note that some commands do not specify an axis Block Jump Call and End and therefore will apply to both axes A 2 axis program can contain Sync Block commands to synchronize the 2 motions at designated points When the first axis reaches the Sync Block it will not execute the block until the other axis has also reached the Sync Block Refer to Example 18 for an illustration of this type of operation Several aspects of programmed motion are discussed below GFK 0781C Chapter 6 Power Mate APM Motion Control 6 5 E Prerequisites for Programmed Motion The following conditions must be satisfied before a motion program can be initiated for a multi axis program the conditions must be met for BOTH axis 1 and axis 2 The Enable Drive bit must be ON The Drive Enabled I bit must be ON The Position Valid I bit must be ON The Moving lI bit must be OFF The Program Active oI bit must be OFF The Abort All Moves Q bit must be OFF The axis position must be within the configured End of Travel Limits The Drive OK input must be ON if enabled A Force D A command must not be active The program to be executed must be a valid program stored in the Power Mate APM Conditions Which Stop a Motion Program A motion program will immediately cease when one of the following conditions occurs T
70. d 5 Motion 0 The bit numbers represent an offset to the starting address for 0 references 4 8 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Table 4 6 Q Discrete Commands for the 2 Axis Power Mate APM IC693APU302 Bit Description Bit Description Offset Offset 19 CTLOBIContrl CTLIDBit Control CTLIT Bit Control 06 Reserved Asi 2 PecuteMotionProgram2 08 AbortATIMoves Axis 01 Becute Motion Programd 25 Pecute Motion Programs The bit numbers represent an offset to the starting address for Q references Abort All Moves This command is used to abort a Jog Move at Velocity or Find Home command Abort All Moves has no effect on motion generated by the external or internal Master source Abort All Moves uses the current Jog Acceleration and Jog Acceleration Mode Enable Drive If the Error and Drive Enabled status bits are cleared this command will cause the Drive Enable relay contact to close enabling the drive and the Drive Enabled bit to be set otherwise it has no effect When the Drive Enabled bit is set the path genera tion and position control functions are enabled and servo motion can be commanded Enable Drive must be maintained ON to allow normal servo motion except when using Jog commands Enable Drive must be turned off w
71. e ENCODER 3 Figure 1 1 Hardware and Software Used to Configure and Operate a Power Mate APM Follower System The system shown above can be divided into 4 categories 1 TheSeries 90 30 PLC and Power Mate APM Configuration Software Package Operator Interfaces psc o x Servo Drive and Machine Interfaces The Series 90 30 PLC and Power Mate APM The Series 90 30 PLC and Power Mate APM operate together as one integrated motion control package The Power Mate APM controls axis motion and handles all direct con nections to the drive and machine while the PLC automatically transfers data between PLC tables and the Power Mate APM The PLC also provides a means for connecting Operator Interfaces such as CIMPLICITY 90 ADS which can control and monitor sys tem operation GFK 0781C Chapter 1 Introduction 1 3 Logicmaster 90 30 Configuration software is used to configure the Power Mate APM The PLC and Power Mate APM are tightly integrated and transfer Power Mate APM Commands and Status Data over the back plane through the PLC tables Some data is transferred only when directed by an operator Other data is transferred automatically each PLC sweep Configuration Software Package The Power Mate APM is easily configured using the Logicmaster 90 30 Configuration software The Power Mate APM must be assigned to a particular slot and rack like any other PLC module In addition there are other types of configuration data which must be enter
72. e Ae hehe heats 6 15 Block Numbers and Jumps 6 15 Unconditional 6 15 Conditional Jumps 6 16 SCURVE J tnps v inn Res Et deh eter eese 6 22 Other Programmed Motion Considerations 6 25 Follower eee eee ceed mda repere ce e eer A eds 6 29 Master Sources indagati etaik asena b M as M eld 6 29 ACB RAHO o Peet eee CLA ee wee ta e eren 6 32 Velocity Clamping e AR ieee 6 34 Unidirectional Operation 6 35 Synchronizing Encoder and the Internal Master 6 36 Enabling the Follower with External Input 6 36 Follower Axis Acceleration Ramp Control 6 37 Combined Motion 6 38 Follower Motion Combined with Motion Programs 6 39 vi Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Contents Appendix A EmorCodes wl iwc ase US EUR d a A 1 AppendixB Parameter Download Using COMM B 1 AppendixC Specifications AREE RA Aa Aaa D a Roja C 1 Module Specifications C 1 1 CO5p ci
73. e Decelerating Other Programmed Motion Considerations Maximum Acceleration Time The maximum time for a programmed acceleration or deceleration is 64 seconds for the 1axis Power Mate APM and 128 seconds for the 2 axis Power Mate APM If the time to accelerate or decelerate is computed to be longer than this time the Power Mate APM will compute an acceleration to be used based on 64 or 128 seconds To obtain longer acceleration times multiple CMOVEs with increasing or decreasing velocities must be used GFK 0781C Chapter 6 Power Mate APM Motion Control 6 25 Example 15 Maximum Acceleration Time The following 1 axis program shows a problem with a very long acceleration time and a solution In the first program and profile 120 seconds two minutes is required to reach the programmed acceleration Since this is greater than 64 seconds the Power Mate APM calculates that an acceleration of 188 would allow a velocity of 12000 to be reached in 64 seconds The lefthand velocity profile below shows the slightly higher 188 accel eration used Also shown is a dotted line indicating the programmed acceleration to constant velocity One solution for obtaining a low acceleration for a long period of time breaks the move up into separate moves with individual acceleration times less than 64 seconds This method requires some calculation Each acceleration and deceleration must be broken into moves with acceleration times less than 64 seconds Thus to a
74. e User s Manual August 1996 GFK 0781C Chapter Power Mate APM Motion Control 6 This chapter provides practical information on Power Mate APM Motion Control with a number of examples The main topics discussed are Non Programmed Motion Programmed Motion m Follower Motion m Combined Motion Non Programmed Motion The Power Mate APM can generate motion in an axis in one of five ways without the use of any motion programs Find Home and Jog use the Q bits to command motion m Move at Velocity Force D A Output and Position Increment use AQ immediate commands During Jog Find Home Move at Velocity and Force D A Output any other commanded mo tion programmed or non programmed will generate an error The only exception is Position Increment which may be commanded any time See the description of Position Increment motion for more details Non programmed motions Abort Jog Move at Velocity use the JOG acceleration and acceleration mode Power Mate APM Home Cycle A Home Cycle establishes the Home Position for systems with an incremental feedback device that also provides a marker pulse The configured Home Offset defines the loca tion of Home Position as the offset distance from the Home Marker The Enable Drive Q bit and Drive Enabled I bit must be ON during an entire Home Cycle However the Find Home Q bit does not need to be held ON during the cycle it may be one shot Note that turning ON the Find Ho
75. e method used to find home during a Find Home Cycle HOME SWITCH indicates that a Home Switch is to be monitored to Find Home MOVE and MOVE specify direct positive or negative movement to the next marker at the Final Home Velocity Default HOMESW Essential Configuration Parameters To correctly configure the Power Mate APM many configuration parameters must be properly set This section explains how these parameters affect Power Mate APM opera tion and how the parameters relate to each other While all parameters are important some parameters are absolutely essential to correct operation Velocity at 10 volts All Power Mate APM and servo functions depend on this value being correct for proper operation This should be the velocity of the axis when the Power Mate APM outputs 10 volts to the servo See Chapter 5 Servo System Startup Procedures to determine the cor rect value The allowed range for Velocity at 10 Volts is 400 user units sec v Velocity at 10 Volts v 1 000 000userunits Position Loop Time Constant The lower the Position Loop Time Constant the faster the axis will respond However if the Time Constant is too low the system may become unstable or even oscillate When decelerating especially at high speeds the Power Mate APM could command a servo to stop at a certain point faster than the servo could respond This would result in over shoot For accurate tracking of the commanded velocity profile Pos Loop T
76. ectional Operation Setting one of the Velocity Limits to zero results in unidirectional follower motion Any encoder pulses in the zero limited direction are ignored When a Velocity Limit is zero no error is generated by pulses in the zero limited direction The In Velocity Limit l bit however does reflect the presence of pulses in the zero limited direction Example 9 Unidirectional Operation In this example the negative Velocity Limit is set to zero As shown in the velocity profile below the following axis follows the positive pulses but ignores the negative pulses Note that when the master is moving negative the In Velocity Limit I bit is ON but no status error is generated V 245335 Master Source Following Axis Figure 6 26 Unidirectional Operation GFK 0781C Chapter 6 Power Mate APM Motion Control 6 35 L6 Synchronizing Encoder 3 and the Internal Master Two l bits are provided to help synchronize the Encoder 3 and Internal Master Velocities The Master Velocity Mismatch lI bit is ON if the Encoder 3 and Internal Master Velocities differ by more than 128 cts sec Another l bit the Master Velocity Mismatch Sign bit sig nals the direction in which the Internal Master Velocity must change to equal the Encoder 3 Velocity ON indicates the Internal Master Velocity must change in the positive direction OFF indicates the negative direction Synchronization of encoder 3 and the internal master prevents the Power M
77. ecuted When a conditional JUMP com mand is executed the Power Mate APM examines the specified CTL bit If the bit is ON program execution jumps to the destination BLOCK if the bit is OF the program continues executing the command after the JUMP Note that the Type 3 command after the conditional jump and at the jump destination will affect jump behavior Conditional JUMP commands should not be used with multiaxis programs containing sync blocks unless the Jump is triggered while both axes are testing the same JUMP command Conditional Jump testing starts when the next PMOVE CMOVE DWELL WAIT or END Program command following a Conditional JUMP becomes active When Conditional Jump testing is active the designated CTL bitis tested once every millisecond for the 1 axis Power Mate APM and once every 2 milliseconds for the 2 axis Power Mate APM Conditional Jump testing ends when the designated CTL bit turns ON Jump Trigger occurs or when a new Block Number becomes active If more than one Conditional JUMP is programmed without an intervening PMOVE CMOVE DWELL WAIT or END Program command only the last Conditional JUMP will be recognized Motion Program Example Begin Program 1JUMP CTLO1 2 This JUMP command will be ignored JUMP CTLO2 3 This JUMP command will be recognized CMOVE 1 40000 INC LINEAR 2 CMOVE 1 20000 INC LINEAR 3 PMOVE 1 100000 ABS LINEAR 4 DWELL 1 100 End Program When a new Block Number becomes
78. ed as linear moves Only Linear acceleration moves should be programmed in the Follower mode If there is no master command the axis can be commanded solely from the stored motion program data Thus with no master input to axis 2 and Encoder 2 selected as the master source for axis 1 a stored program can be used to control axis 2 with axis 1 following per the designated ratio When PMOVEs are executed with Follower not enabled the in zone I bit must be set at the end of the move before programmed motion will continue When Follower is enabled since in zone may not turn on while also following a master command the in zone indication will not be required to continue The next move will take place when the Commanded distance for the previous move has completed The in zone l bit will always indicate the true in zone condition The active commanded position updated and used by the stored motion program is referred to as Program Command Position Each time a program is selected for execution this position register is initialized in one of the two ways listed below 1 Ifthe follower is not enabled the Program Command Position is set to the current Commanded Position Actual Position Position Error 2 If the follower is enabled the Program Command Position is set to the Program Reference Position 0 Since the Program Command Position is only updated by internally generated commands and not by the master command it will then indicate
79. ed by the Master Axis input is not reflected in Commanded Velocity Actual Velocity Actual Velocity user units sec is a value maintained by the Power Mate APM that is derived from the feedback device Therefore it represents the velocity of the axis movement For Encoder 3 units are counts Position Error Position Error user units is equal to Commanded Position Actual Position for each follower axis Analog Input Analog Input returns the digital value representing the voltage applied to the analog input terminals 10 V is indicated by 32 000 and 10 V by 32 000 GFK 0781C Chapter 4 Automatic Data Transfers 4 7 Q Discrete Commands The following Q Outputs representing Discrete Commands are sent automatically to the Power Mate APM from the CPU each PLC sweep A command is executed simply by turning on the Output Bit of the desired command The actual addresses of the Discrete Command bits depend on the starting address con figured for the Q references See Table 3 1 Module Configuration Data The bit num bers listed in the following table are offsets to this starting address Table 4 5 Q Discrete Commands for the 1 Axis Power Mate APM IC693APU301 Bit Description Bit Description Offset Offset 36 06 Reseed Asi 2 PecuteMotionProgram2 Reserved 2 Pecute Motion rogram Resee
80. ed such as m 1 0 addresses where the CPU to Power Mate APM transfers take place m Serial Port Setup for connecting a monitor m Power Mate APM Setup Data Operator Interfaces Operator interfaces provide a way for the operator to control and monitor the servo sys tem through a control panel or CRT display These interfaces communicate with the PLC through discrete I O modules or an intelligent Series 90 PLC module such as CIM PLICITY 90 Alphanumeric Display Coprocessor module or a Programmable Coproces sor Module PCM Operator data is automatically transferred between the PLC and the Power Mate APM through 1 AI Q and AQ references which are specified when the module is con figured This automatic transfer of data provides a flexible and simple interface to a vari ety of operator interfaces in addition to the Motion Programmer Servo Drive and Machine Interfaces The servo drive and machine interface is made through two 24 pin male connectors This interface carries the signals that control axis position such as the Velocity Command and Encoder Feedback signals Also provided are Home Switch and Drive OK Switch inputs as well as other control inputs and outputs Standard cables which connect directly to Weidmuller style terminal blocks simplify user wiring Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Chapter Installing the Power Mate APM GFK 0781C 2 This chapter describes
81. efinitions are as follows Pos Data Byte 2 specifies data returned in AI Commanded Position location 00h normal Commanded Position 01h Program Command Position Op Modes Byte 3 specifies Follower operation modes 00h normal 01h Ramp Chapter 4 Automatic Data Transfers 4 17 4 18 Set Configuration Complete This command sets the Configuration Complete 1 bit Once set the Configuration Complete bit is only cleared when the PLC resets or reconfigures the Power Mate APM The PLC can monitor the bit to determine if it must resend other WAQ commands such as In Position Zone or Jog Acceleration This would only be necessary if the 76 AQ commands were used to override Power Mate APM configuration data programmed with the PLC configuration software Load Parameter Immediate This command is executed from the PLC to immediately change a Power Mate APM parameter value Parameters are only used by motion programs A command for each parameter change is required Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Chapter Follower System Startup Procedures 5 Startup Procedures 1 Connect the motor to the servo amplifier according to the manufacturer s recommendations 2 Connect the Power Mate APM Drive Enable Relay and Velocity Command outputs to the servo amplifier Connect the position feedback device A Quad B Encoder to the Power Mate APM encoder inputs Note If these connecti
82. er Mate I O Connector Functional Diagram for 2 AxisPower Mate APM I O 2 Axis Cascade Master Source Encoder3 Internal Master 2 Axis Parallel Master Source Encoder 3 Internal Figure 2 10 2 Axis Cascade Master Source Analog Input Figure 2 11 2 Axis Parallel Master Source Analog Input Figure 2 12 2 Axis Power Mate APM Axis 2 Master Source Encoder 3 Internal Master Axis 1 Master Source Analog Input Figure 2 13 2 Axis Power Mate APM Axis 2 Master Source Analog Input Figure 5 1 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Axis 1 Master Source Encoder 3 Internal Master Axis Follower Control Loop Block Diagram Sample Linear Motion ther E eee ae We dole rt Sample 5 curveMOHOD sie ues dee dene eb C eb E ete deu reise eee Combining PMOVEs CMOVEs Changing the Acceleration Mode During a Profile Not Enough Distance to Reach Programmed Velocity Hanging the Power Mate APM When the Distance Ru
83. er Mate APM would be Word 2 Word 1 Word 0 Command 0033 E23A 0023 Set Position 3 400 250 Setting up word 0 as a hex word and words 1 and 2 as a double integer in the PLC would simplify immediate command entry GFK 0781C Chapter 4 Automatic Data Transfers 4 11 4 12 Table 4 7 Axis S Immediate Commands Using the 6 Byte Format Ec Axis 2 Command PositionIncrement Without PositionUpdate Incr 128 127 User Units Velocity Move At Velocity Lp Vel 1 000 000 1 000 000 User Units sec Position Set Position D Output Force D A Incr PositionIncrement With Positi iion Update TI Incr 128 127 User Units In PositionZone In PositionZone nia a 2 07 Velocity og Velocity EB Vel 1 1 000 000 User Units sec Acceleration og Acceleration OBEN LI Acc 232 8 388 607 User Units Time Constant 2Ah Position Loop TimeConstant oT mm a a 000 VFF Velocity Ra n7 Eo Umm Integr TC 2Ch Time Constant 0 10 10 000 ms RatioB RatioA 2Dh FollowerA B Ratio Ratio B 1 432 767 The word numbers represent an offset to the starting address for AQ references Only 00 of FFh are acceptable xx don t care Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Table 4 8 Axis Independent Immediate Commands Using the 6 Byte Format Byte 5 Byte 4 Byte 3
84. er value position and continuing with step 2 In this case the In Zone indication could be used to indicate when step 1 is complete This method is possible because the Program Command Position is set to the Actual Position Position Error when execute motion program is commanded with the follower disabled 6 42 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Appendix A GFK 0781C Error Codes The Status Code word of the AI Status Words contains a code which describes the error indicated when the Error status bit is set There are three categories of errors reported by the Status Code m Programming errors which generate a Status Only warning message m Programming errors that halt the servo m Hardware errors encoder out of sync PLC Run switches off loss of programmer comm etc Note The Status LED on the faceplate of the module flashes slow 4 times for Status Only errors and fast 8 times sec for errors which cause the servo to stop Error Codes are placed in the Status Code AI word The format for the Status Code word is Bits 0 7 Error Number 0 FFh Bits 8 11 Axis Number low nibble 0 Axis Independent 1 Axis1 2 Axis2 Bits 12 15 Response Method high nibble 0 Status Only 1 Stop Normal 2 Stop Fast Figure A 1 Status Code Organization Response Methods 1 Status Only Errors Set the error flag and status code but do not affect motion
85. ercent of the acceleration and distance set Ratio A to 2 and Ratio B to 5 This ratio is 0 4 or forty percent If the master source moves at a velocity of 500 counts per second a distance of 2000 counts the axis following the master with ratio 2 5 would move at a velocity of 200 counts per second and only go a distance of 800 counts Important Configuration Considerations TheIntegrator will attempt to remove all Position Error and can be used in two modes IN ZONE and CONTINUOUS IN ZONE mode allows the integrator to run when the In Zone status bit is set For Fol lower systems In Zone is set when Jog or Move at Velocity is not commanded and when Position Error is lt the configured In Position Zone Therefore IN ZONE mode can allow the integrator to operate while a slave axis is actively following a master input provided that Position Error is lt In Position Zone CONTINUOUS mode causes the integrator to always operate and is useful for Follower systems which do not require rapid velocity changes CONTINUOUS mode is not rec ommended for point to point positioning applications Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C The Integrator Time Constant is the amount of time in which 63 of the Position Error will be removed To prevent instability the Integrator Time Constant must be five to ten times greater than the Position Loop Time Constant High and Low Count Limits determine where pos
86. et to a value approxi mately 20 higher than the position error required to produce a 10 volt command The Position Error User Units required to produce a 10V command with 0 Velocity Feed forward is Position Error user units Position Loop Time Constant ms x Servo Velocity 10v user units sec 1000 If Velocity Feedforward is used to reduce the following error a smaller error limit value can be used but in general the error limit value should be 10 20 higher than the largest expected following error Note An Out of Sync error will occur and cause a fast stop if this Error Limit Value is exceeded by more than 1000 counts The Power Mate APM attempts to prevent an Out of Sync error by temporarily halting the internal command generator whenever position error exceeds the Position Error Limit Halting the command generator allows the position feedback to catch up and reduce position error below the error limit value If the feedback does not catch up and the position error continues to grow the Out of Sync condition will occur Possible causes are 1 erroneous feedback wiring 2 feedback device coupling slippage 3 servo drive failure GFK 0781C Chapter 3 Configuring the Power MateAPM 3 7 In Pos Zone In Position Zone User Units When the magnitude of servo position error is less than or equal to this value and no motion is commanded the In Zone status bit will be set Note that In Zone can be set even when the foll
87. f several master input sources m external encoder 3 input m internal master velocity generator m The analog input m Ina 2 axis Power Mate APM axis 1 can select the axis 2 encoder to be its master input source If ENC3 INT is configured for an axis the Select Internal Master Q bit is used to choose between the external encoder 3 input and the internal master generator In a two axis Power Mate APM if both axes are configured with ENC3 INT as the Master Source then both axes will always use the same master source because the Select Internal Master Q bit applies to any axis configured with ENC3 INT as master Note that follower motion is additive with Jog Move at Velocity or Motion Programs If an axis is following the internal master at velocity A and a Jog is commanded at velocity B the axis will move at velocity A B Encoder 3 Master Input When ENC3 INT is configured as the Master Source and the Select Internal Master Q bit is OFE encoder 3 will be the master input source The Power Mate APM always tracks and reports the position of encoder 3 in Encoder 3 Actual Position AI data A 2 axis Power Mate APM also computes and reports the en coder 3 velocity in Encoder 3 Actual Velocity AI data A 1 axis Power Mate APM will re port encoder 3 velocity only if the module is configured with AI Pos Err DISABLED In this case the Encoder 3 Actual Velocity is reported in place of Position Error Encoder 3 has
88. fications certet repe MeL Rd C 2 Velocity Command see eR RR RR EUN SERE AI ERU C2 Enable Relay Output C2 Encoder Inputs e vase icin e eau a ee e te edi EA Ve ted C 3 POW Cris 2n etta uto dE RE RI Et Dre td C 4 General Purpose 24 V Digital Inputs C 4 Analog Input c6 ool voveo a beats cce bere eds C 5 I O Connector Cable Specifications C 6 AppendixD Wiring to 55 90 D 1 AppendixE OrderingInformation E 1 GFK 0781C Table of Contents vii Contents Figure 1 1 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Hardware and Software Used to Configure and Operate a Power Mate APM Follower System Connecting Power Mate APM Modules in a Multidrop Configuration Multidrop Cable for the Power Mate APM I O Cable and Terminal Block Functional Diagram for 1 Axis Power Mate APM I O Connector Functional Diagram for 1 Axis Power Mate APM I O Functional Diagram for 2 AxisPow
89. ge 32 1 to 1 32 or a status error will be generated Internal Master Velocity counts second This axis independent command loads the internal velocity generator which may be used as an alternate source for the master in put The maximum allowed velocity will be 1 000 000 counts second Set Encoder 3 Position counts This axis independent command allows the position of Encoder 3 to be set without using a home cycle Select Return Data This command allows alternate data to be reported in the AI Commanded Position location for each axis The alternate data includes information such as Program Command Position Parameter Register contents and the Power Mate APM module s Firmware Revision The Select Return Data command uses a mode selection and an offset selection The mode selection byte offset 1 of the six byte command determines the Return Data type The offset selection byte offsets 2 3 of six byte command selects an individual data item for some modes Setting the mode to 00h causes the default Commanded Position to be reported The following Return Data selections are allowed GFK 0781C Chapter 4 Automatic Data Transfers 4 15 Selected Return Data Data Mode Data Offset Commanded Position 00h not used Program Command Position 01h not used Parameter Register 08h Parameter Number 0 255 APM Firmware Revision 10h not used Absolute Feedback Offset is the position offset that is used to initialize Actual Position when
90. he Abort All Moves Q bit turns ON The Enable Drive Q bit turns OFF The Drive OK input turns OFF when Drive OK is configured to be enabled A Stop Error occurs See Appendix A Error Codes Parameters for Programmed Moves Programmed moves have three parameters 1 2 3 The distance to move or position to move to The type of positioning reference to use for the move and The type of acceleration to use while performing the move 6 6 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Types of Positioning Reference For the type of reference to use for the move the choices are ABSOLUTE and INCRE MENTAL This reference determines how the first parameter the distance to move or position to move to is interpreted Absolute Positioning In an absolute positioning move the first parameter is the position to move to The fol lowing is an example of an absolute positioning move PMOVE 5000 ABS LINEAR This move will move the axis from its current position whatever it may be to the posi tion 5000 Thus the actual distance moved depends upon where the axis is when the move is encountered If the initial position was 0 the axis would move 5000 user units in the positive direction If the initial position was 10000 the axis would move 5000 user units in the negative direction And if the initial position was 5000 no motion would be generated Incremental Positioning In an i
91. he combination of all position commands from the follower Master Axis inputs the axis Move at Velocity or Jog com mands or Stored Program commands Note Altemate data may be returned in this location Refer to AQ Immediate Commands Select Return Data and Configuration Mode for details Program Command Position defined below is one selection Program Command Position Program Command Position is the reference position for stored motion programs It is updated only by internally generated MOVE commands and does NOT include commands from the Master input The 6AQ Configuration Modes command 45h or Select Return Data 40h may be used to configure the Power Mate APM to return Program Command Position instead of Commanded Position Actual Position Actual Position user units is a value maintained by the Power Mate APM to represent the physical position of the axis It is set to an initial value by the Set Position command or to Home Position by the Find Home cycle It is updated by the motion of the feedback device For Encoder 3 units are counts If Actual Position is counted past either of its Count Limits it will rollover to the other limit and continue counting in the direction of the axis motion Commanded Velocity Commanded Velocity user units sec is a value generated by the Power Mate APM that indicates the instantaneous velocity commanded by a Jog Move at Velocity Find Home or Execute Program command Axis motion caus
92. he following profile would appear if the CTL bit turned on during the first PMOVE at the dotted line and the Jog Acceleration was 75000 Because the first move completed early due to the CTL bit and a faster acceleration Jog Acceleration versus programmed acceleration the second move would not have to move as far to get back to 0 position as it did in the DWELL example Note that because the motion programmed at the jump destination is in the opposite direction as the initial motion the profile would be identi cal if the moves were CMOVEs instead of PMOVEs ACCEL 30000 VELOC 15000 BLOCK 1 JUMP CTL09 2 PMOVE 120000 ABS LINEAR DWELL 4000 BLOCK 2 PMOVE 0 5 V 245268 Figure 6 11 Jump Stop GFK 0781C Chapter 6 Power Mate APM Motion Control 6 21 Example 11 Jump Followed by PMOVE In this JUMP example the command after the JUMP is a PMOVE in the same direction The velocity profile below shows the acceleration and movement for the first CMOVE and the deceleration to the PMOVE s velocity The CTLO1 bit OFF when the PMOVE begins turns ON at the dotted line Motion stops after a PMOVE even if a conditional jump goes to another block Thus the CTLO1 bit triggers a deceleration to zero before the final CMOVE begins BLOCK 1 ACCEL 2000 VELOC 8000 CMOVE 76000 INC LINEAR BLOCK 2 ACCEL 1000 VELOC 4000 JUMP CTL01 3 PMOVE 50000 INC LINEAR BLOCK 3 ACCEL 6000 VELOC 6000 CMOVE 36000 INC LINEAR
93. henever power is removed from the servo drive If this is not done any servo drift could cause a rapid jump of the servo when power is reapplied to the drive Find Home Axis 1 2 This command causes the Power Mate APM to establish the Home Position for systems with an incremental feedback device that also provides a marker pulse A Home Limit Switch Input from the I O connector roughly indicates the reference position for home and the next marker encountered indicates the exact position A configuration option allows the Home Switch to be ignored The configured Home Offset defines the location of Home Position as the offset distance from the Home Marker Position Valid indication is set at the end of the Home cycle Refer to Home Cycle in Chapter 6 Power Mate APM Motion Control for a description of the Find Home cycle Jog Plus When this command bit is ON the axis moves in the positive direction at the current Jog Acceleration and Jog Velocity as long as the Jog Plus command is main tained GFK 0781C Chapter 4 Automatic Data Transfers 4 9 4 10 Jog Minus When this command bit is ON the axis moves in the negative direction at the current Jog Acceleration and Jog Velocity as long as the Jog Minus command is main tained Enable Follower When this bit is set and the I Follower Enabled status bit indicates the Follower is enabled motion commanded by the external or internal master will act as an input to the follower loop Clear
94. ing When the Power Mate APM is used with the SS 90 Servo Digital 100 Digital 200 use the connection diagram below The pin numbers shown correspond to the 25 pin female connector of the IC693CBL311A and also the terminals on the recommended terminal block Machine inputs such as Overtravel and Home Switches are not shown in this diagram Refer to Chapter 2 Installing the Power Mate APM for connection diagrams D 1 Note that the FAC and FAC pins on the SS 90 as well as the RAC and RAC pins MUST be closed for the SS 90 to work Refer to the following documents for more information GFT 106 SS 90 Servo System Product Selection Guide GFK 0776 Digital 100 Digital 200 Brushless Servo Amplifier Instruction Manual GFK 0777 Analog 100 Brushless Servo Amplifier Instruction Manual D 2 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Appendix Ordering Information E Ordering Information Series 90 30 Power Mate APM IC693APU301 1 Axis with FollowerOption IC693APU302 2 Axis with Followeroption Motion ProgrammerSoftware 1C641SWP065 I OCable 10 feet 3 meters IC693CBL311 I OCable 3 feet 1 meter IC693CBL319 Consists of a 24 pin I O connector a cable and a 25 pin D type terminal block connector LO Cable 10 feet 3 meters w external shield wire IC693CBL317 I O Cable 3 feet 1 meter w external shield wire IC693CBL320 Consists of a 24 pin I O connector a cable and
95. ing Enable Follower disconnects the follower loop from the master source Jog Move at Velocity and Execute Program commands will be al lowed regardless of the state of Enable Follower When the Follower is enabled Jog Move at Velocity or Execute program commands will be superimposed on the master command Find Home is not allowed unless Enable Follower is cleared Execute Motion Program 1 6 These commands are used to select stored programs for immediate execution Each command uses a one shot action thus a command bit must transition from OFF to ON each time a program is to be executed Only one Motion Program can be executed at a time per axis the Program Active l sta tus bit must be OFF or Motion Program execution will not be allowed to start A multi axis Motion Program uses both axis 1 and axis 2 so both Program Active bits must be OFF to start a multi axis Motion Program Find Home Encoder 3 Setting this bit does not cause any motion instead it initial izes the Encoder 3 hardware to wait for a marker pulse transition when the Home Switch 3 input is ON When the Home Switch Marker condition is satisfied the Encoder 3 Actual Position will be set to the configured Home Position and the Position Valid Encoder 3 status bit will be set The Home Switch input may be disabled by a configuration selec tion allowing the Encoder 3 Home Cycle to only wait for a marker transition Find Home must be maintained ON until Home is located Cle
96. isolated current limited 5 V supply is available at the PM APM front panel I O connectors for use by one or more encoders Maximum load must be limited to 500 mA 40C 300mA 55C 845112 IN OUT 5V ENCODER REG zu POWER ov OV Figure C 4 Encoder Power Circuitry General Purpose 24 V dc Digital Inputs I OCONNECTOR A m Axis 1 Home Switch CTL03 m Axis 1 Drive OK Switch CTL05 m Axis Encoder Home Switch CTL06 I O CONNECTOR B m Axis 2 Home Switch CTL04 m Axis 2 Drive OK Switch CTL07 CTLO8 Optically Isolated with the following specifications m Optically isolated DC source sink bidirectional input optocoupler m Input ON threshold 18 0 V to 30 0 V Input OFF threshold 0 V to 4 0 V Input resistance 5000 ohms 10 Input filtering 5 ms nominal m Isolation voltage 1500 V peak transient Power Mate APM for Sseries 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Analog Input GFK 0781C COM gt e e NOTE Connector A is shown 5000 OHMS 45110 1K Vs ES OPTICAL COUPLER I 5000 OHMS t EA ES ig 1K Vs Ne OPTICAL COUPLER 6 5000 OHMS AV e OPTICAL COUPLER 9 ov TRE m iz INCOM on Connector A is isolated from INCOM on Connec
97. it m End of Program Type 1 commands can redirect the program path execution but do not directly affect positioning Call executes a subroutine before returning execution to the next command Jump either continues execution at another location or it tests CTL bits and based on the bit condition may or may not alter the program path Type 2 commands also do not affect position The Block command provides an identi fication or label for the following Type 3 command If no Block is found in the current program block the previous Block is used The Velocity and Acceleration commands specify velocity and acceleration rates for motion Type 3 commands start or stop motion and thus affect positioning control Positioning and Continuous moves command motion Dwell Wait and End of Program stop mo tion A program block consists of one and only one Type 3 command with any number and combination of preceding Type 1 and 2 commands Type 2 commands are optional a program block could contain a single Type 3 command Type 2 commands and Condi tional Jumps do not take effect until the following Type 3 command is executed While the Power Mate APM is executing one program block the following program block is processed into a buffer command area to minimize the transition time from one block to another Thus parameters used in a move must be loaded before the move two blocks previous completes execution When a 2 axis Power Mate APM is exe
98. it and continue Absolute programmed commands can also be used for applications that do not require going beyond the high lowcountlimits Any internally generated move command can be immediately terminated by the Abort All Moves command The return data for Commanded Position by default will indicate Actual Position Position Error This can be changed to indicate the Program Command Position by using the AQ command for Configuration Modes The following application example illustrates how a stored program can be used to control positioning operations relative to the detected edge of the moving object as it moves along at a rate indicated by the follower master command GFK 0781C Chapter 6 Power Mate APM Motion Control 6 41 EXAMPLE 12 Follower Motion Combined with Motion Program Applicationsthat require modifying parts on the fly such as notching marking riveting spot welding spot gluing and so forth would make use of the point to point moves superimposed on follower motion and enable follower at input features A typical configuration and control sequence required for these applications is shown below Follower Home Carriage Part Sensor PN Edge zt Sensor 1 Master motion PART Enc3 od lt gt Follower Axis Control Sequence 1 With Enable Follower OFE the PLC sends Follower axis to home position where Actual Position amp Program Comma
99. ition 4 Theaxisis stopped at the configured Jog Acceleration rate and with the configured Jog Acceleration Mode 5 Aninternal Set Position sets the Commanded and Actual Positions to the configured Home Position value the Power Mate APM sets the Position Valid l bit to indicate the Home Cycle is complete Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Jogging with the Power Mate APM The Jog Velocity Jog Acceleration and Jog Acceleration Mode are configurable in the Power Mate APM These values are used whenever a Jog Plus or Jog Minus Q bit is turned ON Note that both bits ON generates no motion The Jog Acceleration and Jog Acceleration Mode are also used during a Find Home Cycle and when a Move at Velocity immediate command is performed Programmed motions use the Jog Velocity and Jog Acceleration as defaults A Jog may be performed when no other motion is commanded The Enable Drive Q bit does not need to be ON to Jog but it may be Turning on a Jog Q bit will automatically close the Enable Relay and turn on the Drive Enabled lI bit Move at Velocity Command A Move at Velocity command is generated by placing the value 22h in the first word of data assigned to an axis The second and third words together represent a signed 32 bit velocity Note that the third word is the most significant word of the velocity Once the command is given the AQ data may be cleared by se
100. itionrolloveroccurs When a Count Limit is reached the reported position wraps around to the opposite limit where it contin ues changing The distance between High and Low Count Limits can be set to the dis tance used in a cyclic operation At the end of each cycle the High Count Limit would be reached and the next cycle would begin at the Low Count Limit High and Low Count Limits are needed for most rotary applications Velocity Limitsspecify the maximum velocity at which an axis will follow the master in put If the master velocity exceeds the limit the axis will continue at the limit the In Ve locity Limit YI bit will be set and an error will be reported This error indicates that the follower axis is no longer locked to the master at the specified A B ratio An exception is when a Velocity Limit is set to zero Instead no motion in that direction is generated and no error is generated The Power Mate APM will not accept a configuration with both Velocity Limits set to zero The Drive OK Switch is an external hardware switch fromthesystem The switch state is returned in status bits CTL05 axis 1 and CTLO7 axis 2 Drive OK turning OFF usually indicates a system problem requiring corrective action If the configuration for the Drive OK switch is enabled the Power Mate APM will not generate motion while the Drive OK switch is OFE If the Drive OK switch turns OFF while the axis is moving the Power Mate APM will command a Fast Stop and rep
101. le Follower Q bit is set causing the slave axis to follow the mas ter input While the slave axis is following the Jog Plus Q bit is set The following axis accelerates from its master s velocity to it s master s velocity added to the current Jog Velocity This acceleration will be just as if the axis was not following a master source at the time When the Jog Plus Q bit is cleared the following axis decelerates to its mas ter s velocity In the velocity profiles below the dotted lines indicate when the Jog Plus bitis turned ON and then OFF V V 245337 Master Source t Following Axis t Figure 6 29 Combined Motion Follower Jog Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August 1996 GFK 0781C s Follower Motion Combined with Motion Programs Motion commands from stored programs or the AQ Move Command can also be combined with the master command to drive the follower axis These point to point move commands can come from one of the stored motion programs 1 through 6 and any stored subroutines they may call The AQ Move Command is treated as a single line motion program which uses the present Jog Velocity and Jog Acceleration Program execution is started by the PLC setting a program select Q bit or sending a AQ Move Command All the existing program commands will be supported in the follower mode however if any PMOVEs and CMOVEs with S curve acceleration mode exist in the program they will be process
102. lete Drive Enabled 4 3 Error Faceplate Input Status CTL01 08 4 4 In Error Limit In Velocity Limit 4 4 Index In Zone Master Velocity Mismatch Master Velocity Mismatch Sign 4 5 PLC Control Active Position Valid 4 3 Position Valid Encoder 3 Program Active 91 Status Bits l Status Bits for the 1 Axis PM APM IC693APU301 4 2 l Status Bits for the 2 AxisPM APM IC693APU302 1 3 Q Discrete Commands 4 8 Abort All Moves 4 9 Clear Error 4 10 Enable Drive 4 9 Enable Follower Execute Motion Program 1 6 4 10 Find Home Axis 1 2 4 9 Find Home Encoder 3 Jog Minus Jog Plus 4 9 Select Internal Master Q Discrete Commands for the 1 Axis PM APM IC693APU301 4 3 Q Discrete Commands for the 2 Axis PM APM 1 9 A Ratio BE Moves Q Discrete Command 4 9 Absolute Positioning 6 7 Acceleration Ramp Control Follower Axis le 37 Acceleration Time Maximum Acceleration Linear Acceleration S Curve Acceleration Types of Actual Position AI Status Word 7 Actual Servo Velocity Actual Velocity AI Status Word 1 7 Analog Input AI Status Word Analog Input Master 6 31 Analog Input Maximum Velocity Index 1 Index Index 2 Appendix A Error Codes A 1 B Parameter Download Using COMM REQ B 1 C Specifications D Wiring to Drives E Ordering Information E 1 Axis Configuration Data B 6 Counts Disable Delay 3 6
103. llow an acceleration of 100 during acceleration and deceleration three moves will be required The second program and profile those on the right show how the first program can be broken into three parts The distance at the midpoint of each acceleration when velocity is 6000 is calculated to be 180 000 one fourth the distance required to accelerate to 12000 An initial CMOVE uses this distance The next CMOVE will then accelerate to its velocity at the same acceleration rate The final PMOVE is the midpoint distance 180 000 user units from the final position The second CMOVE will automatically decel erate to the PMOVE s velocity as it approaches its final position The dotted lines indi cate when the second CMOVE begins and ends ACCEL 100 ACCEL 100 VELOC 12000 VELOC 6000 PMOVE 1500000 INC LINEAR CMOVE 180000 INC LINEAR VELOC 12000 CMOVE 1 140000 INC LINEAR VELOC 6000 PMOVE 180000 INC LINEAR a45312 V 345314 ZN Figure 6 16 Maximum Acceleration Time Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Multi Axis Programming Sync Blocks may be used in a multi axis program to synchronize the axis motion com mands at positions where timing is critical Example 16 Multi Axis Programming This example assumes that axis 1 controls vertical motion and axis 2 controls horizontal motion The objective is to move a piece of material from point A to point C as quickly as po
104. ltiples of 10 millisec ms time onds dleTime Maximumlinkidletime SNP ID SNP ID 6 char consisting of A F and 0 9 A00001 n a 1st char must be A F Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August 1996 GFK 0781C GFK 0781C Master Source Configuration Data These Master Source Configuration items are available when the Follower Control Loop is selected Table 3 3 Master Source Configuration Data Configuration Description Values Defaults Units Parameter Enc3Hi Lim Encoder 3 PositionHigh 8 388 608 8 388 607 8 388 607 Counts Count Limit Enc3 Lo Lim Encoder 3 Position Low 8 388 608 8 388 607 8 388 608 Counts CountLimit 5385 608 8386807 0 Coms HomeSwitch Enable ENABLED DISABLED ENABLED Anlg Max Vel AnalogMaximum 0 1 000 000 Counts Velocity second Enc3 Hi Lim Encoder 3 Position High Count Limits Counts The maximum position which encoder 3 will reach before rolling over to the Low Limit Enc3 Lo Lim Encoder 3 Position Low Count Limits Counts The minimum position which encoder 3 will reach before rolling over to the High Limit Home Position Encoder 3 Home Position Counts The position to which Encoder 3 Actual Position is set at the completion of an encoder 3 Find Home Cycle Home Switch Encoder 3 Home Switch Enable Determines whether CTL06 the En coder 3 Home Switch is monitored during an encoder 3 Find Home Cycle Anlg Max Vel Analog Input Maxi
105. mand To obtain a specific output voltage from the Power Mate APM to the servo use the Force D A immediate command Command values between 32 000 and 32 000 are scaled to the range 10V to 10V Thus 43 200 is 1V The Drive Enabled I bit must be on for the Force D A command to work An exception is the second axis of a one axis Power Mate APM Since there is no axis 2 Enable Drive bit on a one axis Power Mate APM plac ing the Force D A command code in the second axis AQ data automatically enables the servo drive The Force D A command is the only command that must be maintained in the AQ data for proper operation If any other immediate command is sent to the Power Mate APM the Force D A operation will end A one shot Force D A command will operate only dur ing the sweep in which it appears Position Increment Command To generate small corrections between the axis position and the Power Mate APM track ing the Position Increment commands can be used to offset Actual Position by a specific number of user units If the Drive Enabled I bit ON the axis will immediately move the increment amount If the position increment without position update is used command 21h the Actual Position reported by the Power Mate APM will remain un changed If the position increment with position update is used AQ command 25h the Actual Position and Commanded Position reported by the Power Mate APM will be changed by the increment Position I
106. me bit immediately turns OFF the Position Valid I bit until the end of the Home Cycle The Abort All Moves Q bit halts a Home Cycle but the Position Valid bit does not turn back ON No motion programs can be executed unless the Position Valid bit is ON GFK 0781C 6 1 Home Switch Mode If the Find Home Mode is configured as Home Switch the Home Switch input from the I O connector is used to roughly indicate the reference position for Home The next marker encountered when traveling in the negative direction indicates the exact loca tion An open Home Switch indicates the servo is on the positive side of the Home Switch An OFF to ON transition of the Find Home command yields the following Home Cycle Unless otherwise specified acceleration is at the current Jog Acceleration and con figured Jog Acceleration Mode If initiated from a position on the positive side of the Home Switch the cycle starts with step 1 otherwise the cycle starts with step 3 1 The axis is moved in the negative direction at the configured Find Home Velocity until the Home Switch closes 2 The axis decelerates and is stopped 3 The axis is accelerated in the positive direction and moved at the configured Find Home Velocity until the Home Switch opens 4 The axis decelerates and is stopped The axis is accelerated in the negative direction and moved at the configured Find Home Velocity until the Home Switch closes 6 The Power Mate APM continues negative
107. mmand ADWELL command is used to generate no motion for a specified number of millisec onds A DWELL after a CMOVE will make the CMOVE perform similar to a PMOVE even if the specified dwell duration is zero A DWELL command using a parameter to set the dwell time will be treated as a NULL command if the parameter value is 65000 This feature allows a DWELL P command between a CMOVE and another Move to be skipped if the DWELL P value is 65000 The CMOVE continues to the Move following the DWELL without stopping Example 5 Dwell Asimple motion profile which moved to a specific point waited and returned to the original point could use the following program and would have the following velocity profile ACCEL 30000 VELOC 15000 PMOVE 120000 ABS LINEAR DWELL 4000 PMOVE 0 ABS LINEAR V 45262 P1 P2 Figure 6 7 Dwell Wait Command The WAIT command is similar to the DWELL command instead of generating no mo tion for a specified period of time a WAIT stops program motion and monitors a CTL bit until itis ON Thus motion will stop any time a WAIT is encountered even if the CTL bit is on before the WAIT is reached in the program The trigger to continue the program may be any of the twelve CTL bits If in the previous example WAIT was substituted for DWELL the motion profile would be the same except the second PMOVE would not start until the CTL bit turned ON If the CTL bit was ON when the program reached the WAIT the sec
108. mmand has not been encountered in the motion program the Jog Acceleration is used as a default A CMOVE does not stop when completed unless it is followed by a DWELL or a WAIT the next programmed velocity is zero or it is the last program command It does not wait for the position to be IN ZONE before going to the next move A CMOVE reaches its pro grammed position at the same time it reaches the velocity of the following Move command A special form of the CMOVE command can be used to force the Power Mate APM to reach the programmed CMOVE position before starting the velocity change associated with the next move command that is execute the entire CMOVE command at a constant velocity Programming an incremental CMOVE command with an operand of 0 CMOVE INC 0 will force a delay in the servo velocity change for the next move command in sequence The following sequence of commands illustrates this effect Command Data Comments VELOC 10000 Set velocity of first move 10000 CMOVE 15000 ABS LINEAR Reach velocity of second move at position 15000 VELOC 20000 Set velocity of second move 20000 CMOVE 0 INC LINEAR Force next velocity change to wait for next move command CMOVE 30000 ABS LINEAR Stay at velocity 20000 until position 30000 then change to velocity 5000 VELOC 5000 Set velocity of third move 5000 PMOVE 45000 ABS LINEAR Final stop position 45000 GFK 0781C Chapter 6 Power Mate APM Motion Control 6 9 L5
109. mmediate command Internal Master Velocity can be used to set the generated velocity There is no acceleration control of the internal velocity generator One method of pre venting the instantaneous acceleration attempt when Enable Follower is turned ON is to incrementally step up the internal velocity using the Internal Master Velocity AQ com mand Example 2 Following the Internal Master When following the internal master the following axis simply moves at the current in ternal velocity In this example dotted lines indicate the times when a master velocity change takes place using the Internal Master Velocity command The Power Mate APM is configured with Master Source ENC3 INT and the Select Internal Master Q bit is ON The A B ratio is 1 1 The velocities commanded are the following initially 0 then 11 thousand 15 thousand 4 thousand 7 thousand and finally 0 again The velocity of the following axis is identical to the internal master velocity Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C v k 245328 Figure 6 19 Following the Internal Master Analog Input Master When ANALOG is configured as the Master Source the faceplate Analog Input is the master input source The Power Mate APM converts the Analog Input into a velocity command The Analog Maximum Velocity configuration parameter sets the velocity gen erated when the Analog Input is 10V Zero velocity is
110. mp up are stored and when the follower axis reaches the master velocity they will be inserted at a rate determined by this configured distance make up time The velocity time profile below indicates the make up time period immediately after the axis ramp up The total time to achieve following velocity can be calculated as Time to exact following velocity Velocity Acceleration distance make up time Acceleration Make up distance Follower ud Disabled x Velocity make up time 1 0 Time Velocity time Profile Follower Enabled at t 0 The following table indicates the amount of velocity overshoot for different values of distance make up time where T acceleration time in seconds Velocity Acceleration For most applications the distance make up time in seconds should be set so that it is gt DT so the velocity overshoot is lt 10 The resulting velocity including the overshoot must not exceed the servo drive maximum velocity to ensure that no master command counts are lost For applications where lost counts do not matter set the distance make up time 0 to prevent Velocity overshoot Distance Velocity Make Up Time Overshoot Configuration Modes This command is used to configure the Follower Ramp features and the axis command position data returned in the AI data Commanded Position location This command must be sent only when the Follower is not enabled Configuration d
111. mum Velocity Counts The velocity which will be produced by 10V on the Analog Input 0V always produces a velocity of 0 Counts per second Chapter 3 Configuring the Power MateAPM 3 5 Axis Configuration Data Power Mate APM Axis Configuration Data consists of base values for configuration pa rameters The configuration parameters are described only briefly here with the intent of providing enough information for entering them on the configuration screen The table below describes the configuration data for the Power Mate APM when the FOL LOWER Control Loop is selected Table 3 4 Axis Configuration Data heres __ VeloctyFeed Forward 02400 po DmgrTC integrator Time Constant 010 1000 Rev Comp ReversaiCompensaion 0 p a 31 FomePositn HomcTusiton 8388609 8388607 userunits HomeOffset Ofiservalue 276 970 1 Unit measure user units is the ratio of the parameters User Units to Counts In Follower mode both User Units and Counts are fixed at 1 and cannot be changed ENC2 cannot be selected for Axis 2 3 6 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C User Units and Counts The ratio of User Units to Counts is 1 1 and cannot be changed Thus 1 user unit always equals 1 count Ratio A and B Values The ratio of A over B sets the master slave gear ratio Axismotion u
112. n Parameters Configuration Parameters Essential 3 9 Position Loop Time Constant Ratio A and B Values Velocity at 10 volts Configuration Parameters Important 5 10 Drive OK Switch 3 11 High Count Limit 3 11 Integrator Mode Integrator Time Constant 3 10 Low Count Limit 3 11 3 Negative Velocity Limit Positive Velocity Limit Servo Disable Delay GFK 0781C GFK 0781C Configuration Software Package Configuration Power Mate APM Configuring the PM APM B 1 Considerations Other Continuous Move 6 9 Control Loop B2 Control Loop Type Control Sequence for Application Example Counts b d D Data Bits 4 Description of the Power Mate Disable Delay Disable Delay Servo B 8 311 Drive Enabled 95I Status Bit Drive OK Switch B 6 Drives Digital Wiring to Dwell Command E LED 2 2 EN2 LED 2 2 Enable Drive Q Discrete Command Enable Follower Q Discrete Command k 10 Enabling Follower with External Input b 36 Encoder Axis 2 Master 6 32 Encoder 3 and Internal Master Synchronizing Encoder 3 Home Position B 5 Encoder 3 Home Switch Enable 3 5 Encoder 3 Master Input 6 29 Encoder 3 Position High Count Limit Encoder 3 Position Low Count Limit 3 5 Error 1 Status Bit Index Error Codes Error Codes list of 2 Error Codes Response 1 Essential Configuration Parameters Example
113. ncrement may be used at any time though simulta neous use with the Force D A command is impossible because the Force D A command must continuously appear in the AQ data Other Considerations Other considerations when using non programmed motion are as follows m ON Abort All Moves bit will prevent any non programmed motion from starting m Turning ON the Abort All Moves bit will immediately stop any current non programmed motion at the current Jog Acceleration m A Set Position command during non programmed motion will cause a status error m Turning OFF the Enable Drive bit while performing a Home Cycle or Move at Velocity will cause a stop error m Changing the Jog Velocity or Jog Acceleration will not affect non programmed moves in progress 6 4 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August 1996 GFK 0781C s Programmed Motion Programmed Motion refers to motion caused by the execution of motion programs The AQ Move Command 27h is treated as a single line motion program within the Power Mate APM and is included in the programmed motion category The Power Mate APM executes program motion commands sequentially in a block by block fashion once a program is selected The program commands can be categorized as follows Type 1 Commands m Call Subroutine Jump Type 2 Commands m Block m Null m Acceleration m Velocity Type 3 Commands m Positioning Move m Continuous Move m Dwell Wa
114. ncremental move the first parameter is interpreted as the distance to move from the position where the move begins The Power Mate APM translates incremental move distances into absolute move positions so no error accumulates The following is an ex ample of an incremental positioning move PMOVE 5000 INC LINEAR This incremental move will move the axis from its current position to a position 5000 user units greater With an incremental move the first parameter specifies the actual number of user units the axis moves GFK 0781C Chapter 6 Power Mate APM Motion Control 6 7 Types of Acceleration Choices for the last parameter which specifies the type of acceleration to use while per forming the move are LINEAR and SCURVE Linear Acceleration A sample profile of a linear move plotting velocity versus time is shown in Figure 6 1 The straight lines on the graph show that a linear move uses constant acceleration The area under the graph is the distance moved ACCEL 1000 VELOC 2000 PMOVE 6000 INC LINEAR V 45256 Figure 6 1 Sample Linear Motion S Curve Acceleration Note Power Mate APM firmware release 2 10 does not allow SCURVE acceleration when the Follower control loop is selected Any SCURVE accelerations encountered in a program will be converted to linear accelerations For additional information refer to the Important Product Information documentation included with the Power Mate APM module Ans curve motion
115. nd Position are synchronized and set to Home Position value Position valid indicates when this step is complete PLC sends the External Input Enable Follower command to select the part edge sensor input as the Follower enable trigger The PLC also sets the Enable Follower Q bit command When the Part edge sensor trips the Power Mate APM enables the Follower axis to start following the master Encoder 3 inputs The followerenabled l bit indicates when the axis is following the master command Once the follower is enabled the PLC sends the execute motion program Q bit to start execution of the selected program for the follower axis At the time the program is selected Program Command Position will be set to program reference position 0 because the follower is enabled Program execution is then relative to the moving part edge as the follower axis tracks the part Program Command Position now contains the position of the follower axis relative to the part edge and Actual Position indicates the total distance the follower axis has moved from home point master program commands At the end of program the PLC turns Enable Follower OFF and loops back to step 1 to repeat for next part Note Since the Power Mate APM saved the Follower enable input trigger command position in a parameter 253 for axis 1 252 for axis 2 step 1 this time could be used to execute another program with an absolute move command back to the paramet
116. nding a NULL com mand or changed as desired Move at Velocity will not function unless the servo drive is enabled Q Enable Drive and I Drive Enabled are set Also the Drive OK input must be ON if itis enabled The listing of AQ immediate commands shows the words in reverse order to make understanding easier For example to command a velocity of 512 user units per second in a Power Mate APM configured with AQ data starting at AQ1 the following values should be used 0022h 34 decimal in AQ1 0200h 512 decimal in AQ2 and 0 in AQ3 When the Power Mate APM receives these values if Drive Enabled I is ON Abort All Moves Q is OFE and no other motion is commanded it will begin moving the axis at 512 user units per second in the positive direction using the current Jog Accelera tion and Acceleration Mode The Drive Enabled 1 bit must be ON before the Power Mate APM receives the immedi ate command or an error willoccur Also if a Move at Velocity command is already in the data the velocity value must change while the Drive Enabled bit is ON for the Pow er Mate APM to accept it The Power Mate APM detects a Move at Velocity command when the AQ values change A Move at Velocity can be stopped without causing an error in two ways a Move at Velocity command with a velocity of zero or turning the Abort All Moves Q bit ON for at least one PLC sweep GFK 0781C Chapter 6 Power Mate APM Motion Control 6 3 L6 Force D A Com
117. near transducer absolute feedback input mode DIGITAL selects GE Fanuc Digital AC servo encoder input mode If DIGITAL is selected the SERVO CMD configuration parameter must also be set to DIGITAL CUSTOM1 and CUSTOM2 configure the Power Mate APM inputs for special applications DIGITAL feedback is only supported in Power Mate APM firmware revisions greater than 2 10 Default ENCODER Ctl Loop STANDARD selects the normal Power Mate APM motion controlloop The STANDARD loop provides a velocity command proportional to position error with optional Velocity Feedforward and Integrator gain terms CCL1 and CCI2 Customer Control Loops are individually designed for special applications FOLLOWER selects a control loop that allows ratio tracking of a master input with zero following error Default STANDARD Servo Cmd This parameter defines the type of command output provided to the servo system ANALOG selects a C 10 volt velocity command for standard servo drives DIGITAL selects a special digital output for GE Fanuc Digital AC servo drives Digital AC servos are only supported in Power Mate APM firmware versions greater than 2 10 Default ANALOG Motor Type Selects the type of GE Fanuc Digital AC servo motor to be used with the Power Mate APM Refer to the FANUCAC servo drive and Powermate J documentation for additional information Digital AC servos are only supported in Power Mate APM firmware versions greater than 2 10 Default 0
118. nnector The Power Mate APM Front Panel contains a single 15 pin female D connector for serial communications This port can be used for status information and monitoring The Power Mate APM port uses the GE Fanuc proprietary SNP protocol and is RS 485 com patible The baud rate is selectable from 300 to 19 200 baud The connection between the programming computer and the Power Mate APM is typi cally made from the RS 232 port of the computer through an RS 232 to RS 485 RS 422 converter to the Serial Communications Connector A Miniconverter Kit IC690ACC901 which includes a converter and 6 foot cable is available for this purpose The portis configured using the Logicmaster 90 30 20 Micro Configuration Software or theSeries90 30 20 MicroHand Held Programmer The pin definitions for the serial port are listed in Table 2 1 2 2 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Table 2 1 Pin Definitions of the Serial COMM Connector 1 Shield CableShield RT 120 Ohm Terminationfor RXD A DOA DA 5 bcp j RDO Converter Power 75 Redytosemd 14 Rexytosed E 5 aosa Multidrop Connection Power Mate APM modules can be connected in multidrop fashion A sample setup is shown in the figure below One cable is necessary for each Power Mate APM in the system Included in Miniconverter Kit IC690ACC901 Mini Converter 245254
119. ns deti o Meu idiot MM TAE Mot MP Unconditional unap esus evi emt ach era me eb ev nU es does Normal Stop before Figure 6 10 JUMP Without Stopping Figure 6 11 JUMP St p eee de eg atc Ie rcs Cte CO d ci ate d ed Figure 6 12 Jump Followed by PMOVE Figure 6 13 Jumping After the Midpoint of Acceleration or Deceleration Figure 6 14 Jumping before the Midpoint of Acceleration or Deceleration Figure 6 15 Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating Figure 6 16 Maximum Acceleration Figure 6 17 Multi AxisProgramming Figure 6 18 Following Encoder 3 Master Input Figure 6 19 Following the Internal Master Figure 6 20 Following the Analog viii Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 1 3 2 3 2 4 2 5 2 10 2 11 2 12 2 13 2 14 2 14 2 15 2 15 2 1
120. of Acceleration or Deceleration The second case involves jumping to a higher velocity while accelerating or a lower ve locity while decelerating When this occurs the Power Mate APM continues to the first move s acceleration or deceleration This acceleration or deceleration is maintained sim ilar to be a linear acceleration until the axis approaches the new velocity Then the nor mal scurve is used to reduce acceleration or deceleration to zero Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Example 14 SCURVE Jumping to a Higher Velocity While Accelerat ing or Jumping to a Lower Velocity While Decelerating In this example a JUMP command is triggered during the initial phase of acceleration before the first dotted line and the velocity at the jump destination is higher than that of the current move The first dotted line indicates the maximum acceleration of the first CMOVE This value is held as the axis continues to accelerate until it scurves back to constant velocity Constant velocity the second dotted line indicates the beginning of the second CMOVE This move continues until it decelerates to zero at the end of the program ACCEL 50000 VELOC 30000 BLOCK 1 JUMP CTLO2 2 CMOVE 150000 INC SCURVE BLOCK 2 VELOC 90000 ACCEL 25000 CMOVE 500000 INC SCURVE V 245267 t Figure 6 15 Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity Whil
121. ommand Position will not change Table 6 1 Command Input Effect on Position Registers COMMAND Follower oput Follower Affected by input MasterCommands Noneaffeeted oc 8 from selected Mastersource Actual Positionis Updated Commanded Position AI is Updated Actual Psn Psn Err Program Command Position is Not Affected Actual Velocity is Updated Commanded Velocity is Not Affected ProgramCommands Actual Position is Updated Commanded Position AI is Updated Actual Psn Psn Err Program Command Positionis Updated Actual Velocity is Updated Commanded Velocity is Updated by Prog cmd vel only Actual Position is Updated by Prog cmd Master cmd Commanded Position AI is Updated Actual Psn Psn Err Program Command Position is Updated by Prog cmd only Actual Velocity is Updated by Prog cmd vel Master cmd vel Commanded Velocity is Updated by Prog cmd vel only Other Internally Actual Positionis Updated Generated Move Commanded Position AI is Updated Actual Psn Psn Err Commands Program Command Position is Updated but not used Home Jog and Actual Velocity is Updated Move at Velocity Commanded Velocity is Updated by Internal cmd vel only Yes Actual Position is Updated by Internal cmd Master cmd Home Commanded Position AI is Updated Actual Psn Psn Err is not Program Command Position is Updated but not used allowed
122. on Follower Enabled This status bit indicates when the Follower is enabled for the axis The Follower is enabled by the Q Enable Follower bit and an optional CTLO1 CTLOS faceplate trigger input If follower ramp acceleration control is active when Follower Enabled turns on the axis accelerates to the master velocity command and when it turns off the axis decelerates to zero master velocity command PLC Control Active Normally the PLC Control Active status bit is set indicating that the Q discrete commands or AQ immediate commands from the PLC can control the Power Mate APM PLC Control Active is cleared only when the Status screen in the Motion Programmer is used instead of the PLC to control the Power Mate APM a capa bility not yet implemented Error This status bit is set when the Power Mate APM detects any error When set the AI Status Code word identifies the error condition Clear Error is the only command that will clear the Error status bit and the associated Status Code word If the condition causing the error is still present the Error status bit will not be cleared GFK 0781C Chapter 4 Automatic Data Transfers 4 5 Status Words The following AI Status Words are transferred automatically from the Power Mate APM to the CPU each sweep The actual addresses of the Status Words depend on the starting address configured for the AI references See Table 3 1 Module Configuration Data The word numbers listed in the
123. on Complete The Configuration Complete status bit is set by Immedi ate command 49h This status bit is cleared whenever the PLC sends a reset command or new configuration to the Power Mate APM Configuration Complete can be set by a PLC program after other AQ Immediate commands such as In Position Zone or Position Loop Time Constant have been sent to the Power Mate APM The status bit can then be monitored by the PLC If the bit is ever cleared then the Power Mate APM has been re set or reconfigured and the PLC should resend all necessary AQ configuration com mands before setting the bit again Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Position Valid Encoder 3 Position valid indication for Encoder 3 Input Master Velocity Mismatch The Master Velocity Mismatch indication is set when the dif ference between the Encoder 3 Velocity and the Internal Master Velocity is more than 128 cts sec This I bit allows the PLC to detect synchronization of the internal and external master velocities before switching the Select Internal Master Q discrete command bit Master Velocity Mismatch Sign The Master Velocity Mismatch Sign bit indicates the sign of the velocity change needed to make Internal Master Velocity Encoder 3 Velocity 0 indicates that Internal Master Velocity must change in the positive direction 1 indi cates that Internal Master Velocity must change in the negative directi
124. ond PMOVE would begin immediately when the first PMOVE finished Also if WAIT was used instead of DWELL in the previous example CMOVEs and PMOVEs would generate similar velocity profiles The WAIT will stop motion whether the previous move is a CMOVE or PMOVE Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s Subroutines The Power Mate APM can store up to ten separate programs and forty subroutines Sub routines can be defined as two types single axis and multi axis Commands within single axis subroutines do not contain an axis number this allows single axis subroutines to be called from any single axis program written for either axis 1 or axis 2 Commands within multi axis subroutines contain axis numbers just like commands within multi axis pro grams Multi axis subroutines can only be called from multi axis programs or subrou tines Single axis subroutines can only be called from single axis programs or subrou tines On two axis Power Mate APM a single axis program for axis 1 and a single axis program for axis 2 may call the same single axis subroutine simultaneously The CALL command is used to execute a subroutine with the subroutine number specified as an argument Program execution continues at the start of the subroutine and resumes at the command after the CALL command when the subroutine finishes Subroutines can be called from another subroutine but once a subroutine has been
125. onfiguration Data The bit numbers listed in the following table are offsets to this starting address Table 4 1 I Status Bits for the 1 Axis Power Mate APM IC693APU301 Bit Bit Offset Description Offset Description Asi 16 FrontPanelinputTO0ISmtus Position Valid Axisi 17 FrontPenelInputCTLOZStatus 06 in Asi 22 Front Panel nputCTLO7Status Reseed 1 ConfigurationComplete 09 Reserved 25 PostienVilid Encoder The bit numbers represent an offset to the starting address for I references 4 2 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C GFK 0781C Table 4 2 I Status Bits for the 2 Axis Power Mate IC693APU302 Bit Bit Offset Description Offset Desdipion 00 AxsEnabed 16 FrontPanellnputCTLOI Status i Front Panel Input CTL01 Status Front Panel Input CTL02 Status Front Panel Input CTL03 Status Home 1 Front Panel Input CTL04 Status Home 2 06 22 Front Panel npat CTUU7 Status DeiveZ OK Ae 2 ConfigerstionCompiete 09 Position Valid Az 5 Fositionvalid Encoder The bit numbers represent an offset to the starting address for I references Axis Enabled The Axis Enabled status bit is On when the Power Mate APM is ready to re ceive command
126. ons are incorrect or there is slippage in the coupling to the Feedback Device an Out of Sync error condition can occur when motion is commanded 3 If a Drive relay contact is used 24 Vdc wire it to the correct Power Mate input Otherwise the Drive OK input must be disabled using Configuration Software If a Home switch is used 24 Vdc wire it to the correct Power Mate APM input The Home switch must be wired so that it is ALWAYS ON when the axis is on the negative side of home and ALWAYS OFF when the axis is on the positive side of home 4 Usethe Configuration Software to set the desired configurable parameters Store the configuration to the PLC 5 Clear the program from the PLC turn off all Power Mate APM Q bits and place the PLC in RUN mode Monitor the I bits for CTL03 Home 1 CTL04 Home 2 CTL06 Home 3 CTL05 Drive 1 and CTL07 Drive 2 and confirm that each bit responds to the correct switch 6 Tum on the Q Enable Drive bit and place the command code for Force D A Output 0 in the AQ table Confirm that the servo amplifier is enabled If the motor moves adjust the amplifier zero offset until the motor stops moving Note The Q Enable Drive bit must be maintained on in order for the Force D A Output command to function 7 Send the command code for Force D A Output 3200 1 0v Confirm that the motor moves in the desired POSITIVE direction and the Actual Velocity reported in the Power Mate APM
127. opposite direction m When a CMOVE is active and the Jump destination block contains a CMOVE or PMOVE representing motion in the same direction with insufficient distance for the axis to stop m When a CMOVE is active and the Jump destination block contains DWELL WAIT or END program command If the axis does STOP before a Conditional Jump the JOG acceleration and acceleration mode will be used Unconditional Jumps do not force the axis to stop before jumping to a new program block For example a CMOVE followed by a JUMP Unconditional to another CMOVE will behave just as if the two CMOVES occurred without an intervening Unconditional JUMP If Conditional Jump testing is active when the Power Mate APM command processor encounters a CALL SUBROUTINE command the axis will stop and terminate jump testing before the CALL is executed If Conditional Jump testing is active when the Power Mate APM command processor encounters an END SUBROUTINE command the axis will stop and terminate jump testing before the END SUBROUTINE is executed Chapter 6 Power Mate APM Motion Control 6 17 Jump Testing Conditional jumps perform jump testing If the CTL bit is ON the jump is immediately performed If the CTL bit is OFE the Power Mate APM watches the CTL bit and keeps track of the JUMP destination This monitoring of the CTL bit is called jump testing If during jump testing the CTL bit turns ON before a BLOCK command another JUMP command or a CA
128. ort an error The Servo Drive Disable Delay specifies how long the Power Mate APM will wait after zero velocity is commanded before the Drive Enable Output is deactivated Error condi tions which instantly zero the velocity command such as loss of encoder quadrature should allow the servo to stay activated long enough to decelerate the axis to a complete stop Thus to allow the Power Mate APM to command a fast stop without coasting of the axis the Disable Delay should be longer than the deceleration time of the servo from maximum speed GFK 0781C Chapter 3 Configuring the Power Mate 3 11 Chapter 4 GFK 0781C Automatic Data Transfers This chapter defines the data that is transferred automatically each sweep without user programming between the CPU and the Power Mate APM This data is categorized as follows Input Status Data Transferred from Power Mate APM to CPU m Status Bits 32 bits of I data m Status Words 15 words of AI data for 1 axis Power Mate 28 words of AI data for 2 axis Power Mate APM Output Command Data Transferred from CPU to Power Mate APM m Discrete Commands 32 bits of Q data m Immediate Commands 6 words of AQ data 4 1 l Status Bits The following 1 Status Bits are transferred automatically from the Power Mate APM to the CPU each sweep The actual addresses of the Status Bits depend on the starting ad dress configured for the I references See Table 3 1 Module C
129. ort operations Default 10000 Hi Limit High Count Limit User Units When moving the Actual Position value will roll over to the low limit when this value is reached Default 48 388 607 Lo Limit Low Count Limit User Units When moving the Actual Position value will roll over to the high limit when this value is reached Default 8 388 608 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Home Positn Home Position User Units The value assigned to Actual Position at the end of a Find Home cycle Default 0 Home Offset Home position Offset User Units The offset of the servo final stopping point at the completion of a Find Home cycle Home Offset adjusts the final servo stop ping point relative to the Encoder marker Default 0 Home Vel Final Home Velocity User Units second The velocity at which the servo seeks the final Home Switch transition and Encoder Marker pulse at the end of a Find Home cycle Final Home Velocity must be slow enough to allow a 10 millisecond filter time delay between the final Home Switch transition and the Encoder Marker pulse Default 500 Find Home Vel Find Home Velocity User Units second The velocity at which the ser vo seeks the initial Home Switch transitions during the Find Home cycle If desired Find Home Vel can be set to a high value to allow the servo to quickly locate the Home Switch Default 2000 Home Mode Find Home Mode Th
130. ove Commands Continuous Move CMOVE Positioning Move PMOVE Programmed Moves Parameters Programming Multi Axis R Ratio A and B Values Ratio A Value Ratio B Value Ratio A B Ref Adr Reversal Compensation S S Curve Acceleration SCURVE Jumps 6 22 Select Internal Master Q Discrete Command Select Return Data AQ Immediate Command 4 15 Serial COMM Connector 2 Serial Communications Port Configuration Data Baud Rate 3 4 Data Bits 3 4 Idle Time B 4 Modem Turn Around Time 8 4 Parity SNPTD B 4 Stop Bits Series 90 30 PLC and PM APM 1 3 Servo Command Servo Drive and Machine Interfaces Servo Drive Disable Delay Servo Interface Type Servo Velocity Actual Index Set Configuration Complete WAQ Immediate Command Set Encoder 3 Position AQ Immediate Command Set AQ Immediate Command 4 13 Setting the Configuration Parameters SNP ID 3 4 Software Package Configuration Sources Master Specifications C 1 Startup Procedures Status Code AI Status Word 1 7 Status LED 2 2 Status Word Error Codes A 2 Stop Bits 3 4 Stop Jump 6 20 Stopping Jumping Without 6 19 Subroutines 6 15 Sync Out of B7 Synchronizing Encoder 3 and the Internal Master 36 T Testing Jump 6 18 Types of Acceleration Types of Positioning Reference U Unconditional Jumps Unidirectional Operation 6 35 User Units
131. ower A B Ratio AQ command can be used to change the A B ratio at any time even while following However an invalid ratio will generate a status error and be ig nored An invalid ratio is a ratio with B equal to or less than zero or A B greater than 32 1 or less than 1 32 Ratios from 1 1024 to 1024 1 can be obtained with a 2 axis Power Mate APM if the slave axes are cascaded When axis 2 follows encoder 3 and axis 1 follows axis 2 if both ratios are 32 1 the ratio of axis 1 to encoder 3 is 1024 1 When following with a non 1 1 ratio the velocity profile of the master and follower will look somewhat different Horizontal lines indicating constant velocity and slanted lines indicating acceleration and deceleration will be different If the A B ratio is less than 1 the follower velocity and acceleration will be less than the master Likewise if the A B ratio is greater than 1 the follower velocity and acceleration will be greater than the master The duration of motion and time that the slave axis will accelerate deceler ate or stay at constant velocity are the same for the master and follower The distance moved which in a velocity profile is the area between the graph and the time axis will be that of the master multiplied by the A B ratio If A is zero no following motion will be generated If A is negative the following axis will move with the direc tion of motion reversed Power Mate APM for Series 90 30 PLC Follower Mode User
132. ower slave axis is actively following a master input Default 10 Pos Loop TC Position Loop Time Constant milliseconds The lower the value the faster the system response Values which are too low will cause system instability and oscillation For accurate tracking of the commanded velocity profile the Position Loop Time Constant should be 1 4 to 1 2 of the MINIMUM system deceleration time Setting Position Loop Time Constant to 0 will place the follower loop in open loop mode where only velocity Feedforward is used to produce the analog velocity command output Position Loop Time Constant will not be accurate unless the Vel at 10v value is set cor rectly Default 1000 Vel at 10v Actual Servo Velocity User Units second for an Power Mate APM velocity command output of 10v This value must be configured correctly in order for the Pos Loop TC and Vel FF factors to be accurate The Power Mate APM s Force D A Output AQ immediate command and the Actual Velocity AI status word can be used to deter mine the proper configuration value Default 4000 Vel FF Velocity Feedforward gain percent The percentage of Commanded Veloc ity that is added to the Power Mate APM velocity command output Increasing feedfor ward causes the servo to operate with faster response and reduced position error Opti mum feedforward values are 80 90 The Vel at 10v value must be set correctly for proper operation of velocity feedforward Default 0 Intgr TC
133. p is performed GFK 0781C Chapter 6 Power Mate APM Motion Control 6 19 Example 9 JUMP Without Stopping This is a simple example of a conditional jump from one CMOVE to another While jump testing the CTLO3 bit the first CMOVE accelerates to the programmed velocity Before the dotted line the CTL093 bit is OFE but at the dotted line the CTLO3 bit turns ON Program execution is immediately transferred to block 3 and the CMOVE there begins Because the velocity at the jump destination is different the velocity changes at the acceleration programmed of the jump destination block Finally as the second CMOVE completes velocity is reduced to zero and the program ends BLOCK 1 ACCEL 2000 VELOC 10000 JUMP CTL03 3 CMOVE 120000 INC LINEAR BLOCK 3 ACCEL 20000 VELOC 5000 CMOVE 15000 INC LINEAR V 245264 Figure 6 10 JUMP Without Stopping Jump Stop A jump stop is a stop caused by a jump When a jump stop occurs the Jog Acceleration and Jog Acceleration Mode are used instead of any programmed acceleration Note that scurve motion will achieve constant velocity before using the Jog Acceleration and begin ning to decelerate See the scurve jump examples for more details The Jog Accelerationis used because a jump stop may indicate something is wrong The current Jog Acceleration which can be changed with an immediate command provides more versatility than the programmed acceleration There are two ways of generating a jump s
134. r some reason axis 2 has not yet reached Block 20 when axis 1 has moved 30 000 counts an error would occur Axis 1 would continue to 80 000 counts and the Power Mate APM would report a Block Sync Error during a CMOVE in the Status Code If it is imperative that the axes synchronize at Block 20 then changing Block 10 to a PMOVE would guarantee synchronization but then axis 1 would always stop momen tarily at 30 000 counts Parameters in the Power Mate APM The Power Mate APM maintains 256 double word parameters 0 through 255 in memory These values may be used as a parameter in ACCEL VELOC DWELL PMOVE and CMOVE motion commands Note that range limits still apply and errors may occur if a parameter contains a value out of range The last ten parameters are spe cial purpose parameters The Power Mate APM can load data into these parameters which might overwrite user data The following table describes the function of the spe cial purpose parameters Parameter Number Special Purpose Function 246 251 Reserved for future use 252 Stores Axis 2 Commanded Position user units when Follower Enable Trigger occurs 2 Axis Power Mate APMonly Stores Axis 1 Commanded Position user units when Follower Enable Triggeroccurs 254 Stores Axis 2 Strobe Positionvalue user units 2 AxisPower Mate APM only Stores Axis 1 Strobe Positionvalue user units Parameters are all reset to zero after a power cycle or after a Power Mate APM configura
135. r the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply Thefollowing are trademarks of GE Fanuc Automation North America Inc Alarm Master GEnet PowerMotion Series One CIMPLICITY Genius ProLoop SeriesSix CIMPLICITYPowerTRAC Genius PowerTRAC PROMACRO Series Three CIMPLICITY 90 ADS Helpmate Series Five VuMaster CIMSTAR Logicmaster Series90 Workmaster Field Control Modelmaster Copyright 1993 1996 GE Fanuc Automation North America Inc All Rights Reserved Preface Note This manual describes the Power Mate APM module follower mode operation This module was previously referred to as the Axis Positioning Module Content of This Manual Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Appendix A Appendix B Appendix C Appendix D Appendix E Related Publications GFK 0781C GFK 0664 GFK 0840 Introduction This chapter provides a brief overview of the software and hardware used to setup and operate a servo system Installing the Power Mate APM This chapter describes all the user in terfaces of the Power Mate APM and how to install the module on the Series 90 30 baseplate Configuring the Power Mate APM This chapter explains how to config ure the APM using the Logicmaster configuration package Automatic Data Transfers This chapter describes the 1 AI Q and data
136. remotebaseplates Maximum 2 in CPU baseplate and 3 in each expansion remote baseplate limited by powersupply Note that a Model 351 or 352 system can have up to 8 baseplates CPU baseplate and 7 expansion remotebaseplates Refer to GFK 0867B or later version for product standards and general specifications CPU model 352 will be available in 48 Quarter 1996 GFK 0781C C 1 I O Specifications The specifications and circuitry for the I O connections are provided below Velocity Command Output of D A converter with the following characteristics m Resolution 13 bits including sign m Linearity 02 of full scale output m Offset Voltage 500 uVmaximum Maximum Output 10 0V 03V Minimum Load Resistance 2000 ohms m Voltage Between Analog Common and Ground 1 0 V 100 uH 2347102 VOUT 1 VEL CMD 1 100 uH VOUT 2 gt VELCMD 2 125A FUSE ACOM O 0 gt VEL CMD 1 COMMON a iut ov 125AFUSE 0 7 VEL CMD 2 COMMON 47 5 ov ov Figure C 1 Velocity Command Circuitry Enable Relay Output Normally open dc solid state relay contact Contacts rated at 30 V 100 mA dc Resistive load only The off state leakage current is 10 LA maximum 845106 CETERI ENABLE gt gt 552 OPTICAL ov COUPLER gt ENABLE Figure C 2 Enable Relay Output Circuitry
137. resent in the PLC baseplates This is done by completing setup screens which represent the modules in a baseplate and saving the information to a con figuration file which is then downloaded to the CPU Once a baseplate and slot location for the Power Mate APM are defined you can contin ue to the second part of Power Mate APM configuration Module Configuration Module Configuration This section is divided into three parts m Setting the Configuration Parameters m Essential Configuration Parameters Important Configuration Considerations GFK 0781C 3 1 Setting the Configuration Parameters 3 2 Aswith I O Rack Configuration Module Configuration is done by completing screens in the Logicmaster 90 30 20 Micro Configuration software The Hand Held Programmer can only configure the Module and Serial Port Configuration Data Power Mate APM module configuration data consists of 4 types m Module Configuration Data Serial Communications Port Configuration Data Master Source Configuration Data m Axis Configuration Data Module Configuration Data During each CPU sweep certain data is automatically transferred both ways between the Power Mate APM and the CPU Power Mate APM to CPU Interface data references the starting locations for the automatic transfers The configuration parameters in Module Configuration Data are described in the following table Table 3 1 Module Configuration Data Ref Adr Start address for I ref
138. ry kit as listed below Three types of connectors are available solder pin crimp pin and ribbon cable Each accessory kit contains enough components D connectors backshells contact pins etc to assemble ten single ended cables of the type specified for each kit IC693ACC316 FCN 361J024 A U Soldereyelet receptacle FCN 360C024 B Backshell for above IC693ACC317 FCN 363J024 Crimp wirereceptacle FCN 363 A U Crimp pin for above 24 needed FCN 360C024 B Backshell for above IC693ACC318 FCN 367 024 AUF IDC ribbon receptacle closed cover FCN 367 024 AUH IDC ribbon receptacle open cover Power Mate APM for Sseries 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Note that additional tools from Fujitsu are required to properly assemble the crimped contact and ribbon cable type connectors The solder eyelet connectors as provided in IC693ACC316 do not require any special tooling Crimped Contact Connectors as provided in IC693ACC317 require Hand Crimping Tool FCN 363T T005 H Contact Extraction Tool FCN 360T T001 H Ribbon Cable Connectors as provided in IC693ACC318 require Cable Cutter FCN 707T T001 H Hand Press FCN 707T T101 H Locator Plate FCN 367T T012 H These tools can be ordered from an authorized Fujitsu distributor Three of the largest US distributors for Fujitsu connectors are Marshall at 800 522 0084 Milgray at 800 MILGRAY and Vantage at 800 843 0707 If none of these distributor
139. s Power Mate APM the only effective commands for the second set of AQ words are Force D A Output Analog Output 2 and the axis independent commands Even though the commands are sent each sweep the Power Mate APM will act on a command ONLY if it changed since the last sweep When any of the 6 byte data changes the Power Mate APM will accept the data as a new command and respond ac cordingly The 6 byte format for the Immediate Commands is defined in Tables 4 7 and 4 8 The actual addresses of the Immediate Command Words depend on the starting address configured for the AQ references See Table 3 1 Module Configuration Data The word numbers listed in the following table are offsets to this starting address The word offsets are shown in reverse order and in hexadecimal to simplify the data entry The following example sends a Set Position 3 400 250 command to axis 1 The first word word 0 contains the actual command number For the Set Position com mand the command number is 0023h The second and third words contain the data for the Set Position command which is a position The second word word 1 is the least sig nificant word of the position and the third word word 2 is the most significant word To set a position of 3 400 250 first convert the value to hexadecimal 3 400 250 decimal equals 0033E23A hexadecimal For this value 0033 is the most significant word and E23A is the least significant word The data to be sent to the Pow
140. s and control a servo An error condition which stops the servo will turn Axis Enabled Off Position Valid The Position Valid status bit indicates that the value in the AI Actual Position status word has been initialized by a Set Position command or successful comple tion of the Find Home cycle The Position Valid bit can be cleared by PLC commands To do this the PLC should send the Q commands for Find Home and Abort on the same PLC sweep Drive Enabled The Drive Enabled status bit indicates the state of the Enable Drive discrete command and the relay contact supplied by the Power Mate APM The ON state of the Drive Enabled status bit corresponds to the CLOSED state of the relay contact Drive Enabled is cleared following power up or an error condition which stops the servo Program Active The Program Active status bit for each axis indicates that a Motion Pro gram 1 6 or a Move Command is executing on that axis On a two axis Power Mate APM executing a multi axis program will set both Program Active bits Command Move The Command Move status bit represents only the state of the internal motion generator for each follower axis Therefore a Jog Move at Velocity Find Home or Execute Program Command will set Command Move Command Move is also set when the fol lower acceleration ramp control is accelerating to the master velocity command or decelerat ing from the master command Axis Follower motion caused by the external or
141. s service your area then contact Fujitsu Microelectronics in San Jose California USA via telephone at 408 922 9000 or via fax at 408 954 0616 for further information It is recommended that you order any necessary connector tooling with sufficient lead time to meet your assembly requirements for these connectors These tools are generally not stock items and can have significant lead times from distribution If you have any further questions about this issue please feel free to contact the GE Fanuc PLC Hotline at 1 800 828 5747 or 804 978 5747 GFK 0781C AppendixC Specifications C 9 Appendix D GFK 0781C Wiring to 55 90 Drives 25 PIN FEMALE IC693CBL31 1 PIN FOLLOWER MODE ONLY a45252 USER DEFINED PINS ENCODER OUT INCOM CI PLI JY r T H CONTROLLER P1 SHLD DRIVE OK 24VDC SSO VEL SSO 79 24VDC COM ACOM VCS ov EN VCS 4 ENABLE EN ENABLE PM APM CONNECTIONS AXIS 1 OR AXIS 2 SHLD SERIAL P6 5VDC XMT SHLD gt 3 XMT COM RCY RCY RCY RCY COM XMT XMT USER TERMINAL DIGITAL 100 200 AMPLIFIER ASCII SERIAL TERMINAL VT 52 REQUIRED FOR SET UP NOT REQUIRED FOR OPERATION SS90COM SOFTWARE AVAILABLE FOR USE WITH P C Figure D 1 SS 90 Digital 100 Digital 200 Wir
142. ser units A B x Master Reference user units The range for A is 32 768 to 432 767 and B is 1 to 432 767 The ratio must be in the range of 32 1 to 1 32 When A is negative the slave axis will move in the opposite direc tion from the master Mstr Source Master Axis Source The master reference for Axis 1 can be selected as encoder3 internal master encoder 2 or the Analog Input A 1 axis Power Mate APM does not have an encoder 2 selection for master The master reference for Axis 2 only applicable for 2 axis Power Mate APMs may be encoder 3 internal master or the Analog Input Default ENC3 INT Vlim cts ms Master Velocity Limit The positive velocity for each axis is limited to this value This allows velocity clamping or unidirectional operation Vlim cts ms Master Velocity Limit The negative velocity for each axis is limited to this value This allows velocity clamping or unidirectional operation Pos Err Lim Position Error Limit User Units The maximum Position Error Com manded Position Actual Position allowed when the Power Mate APM is controlling a ser vo Position Error Limit should normally be set to a value 10 to 20 higher than the highest position error encountered under normal servo operation Default 4096 The range formula for Position Error Limit is 256 x user units counts lt Position Error Limit lt 60 000 x userunits counts If Velocity Feedforward is not used Position Error Limit can be s
143. ssary adjust the configured velocities and the location of the Home Switch for consistent operation The final Home Switch transition MUST occur at least 10 ms before the Encoder Marker Pulse is encountered The physical location of Home Position can be adjusted by changing the Home Offset value with the Configuration Software Monitor servo performance and use the Q Jog Plus and Jog Minus bits to move the servo motor in each direction The Pos Loop Time Constant can be temporarily modified by placing the correct command code in the AQ table For most systems the Position Loop Time Constant can be reduced until some servo instability is noted then increased to a value approximately 50 higher Once the correct time constant is determined the Power Mate APM configuration should be updated using the Configuration Software Velocity Feedforward can also be set to a non zero value typically 80 90 for optimum servo response Note For proper servo operation the Configuration entry for Vel at 100 MUST be set to the actual servo velocity in User Units sec caused by a 10 V command System Troubleshooting Hints 1 The Power Mate APM Follower requires PLC firmware release 3 52 or greater and Logicmaster 90 30 20 Micro software release 4 0 or greater The default Power Mate APM configuration for the Drive OK inputs is ENABLED Therefore 24 vdc must be applied to the Drive OK inputs or the Power Mate APM will not operate If Drive OK inpu
144. ssible while avoiding the obstacle which prevents moving directly from A to C A simple way would be to move from point A to point B and then from point B to point C This sequence however wastes time A better way would begin the horizontal movement before reaching point B It has been determined that after axis 1 has moved to a position of 30 000 user units axis 2 could then start and still clear the obstacle The program segment could be programmed as follows BLOCK 10 CMOVE 30000 INC AXIS 1 BLOCK 20 SYNC PMOVE 50000 INC AXIS 1 PMOVE 150000 INC AXIS 2 When this program is executed axis 1 immediately begins its 30 000 unit move Axis 2 would ignore the first command because it applies only to axis 1 and see the Sync Block Axis 2 waits for axis 1 to reach the Sync Block before it continues executing the program When axis 1 reaches the 30 000 unit mark it begins the 50 000 unit PMOVE at the Sync Block without stopping the first move was a CMOVE Now that axis 1 has reached the Sync Block axis 2 begins its 150 000 unit move Looking at the position pro file below axis 1 completes its move first and stops at the end of the PMOVE When axis 2 reaches point C it also stops 245271 P AXIS 2 0 150 000 80 000 e B C A AXIS 1 30 000 OBSTACLE Figure 6 17 Multi Axis Programming GFK 0781C Chapter 6 Power Mate APM Motion Control 6 27 If this program segment is not at the beginning of a program and fo
145. t Limit 3 68 11 Low Count Limit Actual Position Machine Interfaces and Servo Drives 1 4 Master Axis Source B 7 Master Source 3 6 Master Source Configuration Data B 5 Analog Input Maximum Velocity Encoder 3 Home Position 3 5 Encoder 3 Home Switch Enable Ex 3 Position High Count Limit 3 5 ES 3 Position Low Count Limit 3 5 Master Sources 6 29 Master Velocity Limit Master Velocity Limit Master Velocity Mismatch I Status Bit Master Velocity Mismatch Sign 1 Status Bit 4 5 Master Analog Input Master Encoder Axis 2 Maximum Acceleration Time Modem Turn Around Time 4 Module Configuration 1 Module Configuration Data AI Position Error B 2 Control Loop Feedback Type B 2 Ref Adr 52 Module Specifications C 1 Motion Control PM APM Je 1 Motion Program Conditions Which Stop a Index 5 Index Index 6 Motion Programs with Combined Follower Motion Motion Combined 6 38 Motion Follower Motion Non Programmed Motion Programmed 6 5 Motor Direction Motor Direction for Positive Velocity Command 3 3 Motor Type Move AQ Immediate Command Move At Velocity Immediate Command Move at Velocity Command e 3 Move Commands 6 9 Move and Move Modes 6 2 Moves Programmed 6 10 Multi Axis Programming Multidrop Connection 2 3 N Negative End Of Travel 3 6 Negative Velocity Limit B 6 B 11 Non Programmed Motion
146. the fourth move begins it is already at its programmed velocity 6 10 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s The fourth move is a CMOVE so as it approaches its final position it accelerates to be at the velocity of the fifth move when it completes The graph shows the acceleration of the fourth move is scurve Finally the fifth move begins and moves at its programmed velocity for a time until it decelerates to zero Any subsequent moves after the fifth would begin at zero velocity because the fifth move is a PMOVE Example 2 Changing the Acceleration Mode During a Profile The following example shows how a different acceleration and even acceleration mode can be used during a profile using CMOVEs The first CMOVE accelerates linearly to the programmed velocity Because the second CMOVE s velocity is identical to the first the first CMOVE finishes its move without changing velocity The acceleration of the second move is scurve as it decelerates to zero velocity ACCEL 2000 VELOC 6000 CMOVE 13000 ABS LINEAR ACCEL 4000 CMOVE 15000 INC SCURVE V 45259 t Figure 6 4 Changing the Acceleration Mode During a Profile GFK 0781C Chapter 6 Power Mate APM Motion Control 6 11 6 12 Example 3 Not Enough Distance to Reach Programmed Velocity CMOVES and PMOVES can be programmed which do not have enough distance to reach the programmed velocity The following graph shows a
147. to the Position Increment without position update command 21h except that Actual and Commanded Position returned in 6AI data are both updated by the increment value If the servo is enabled the Power Mate APM will immediately move the axis by the increment value In Position zone This command can be used to set the active In Position zone to a value different than the configured value The In Position zone is used by the Power Mate APM to determine when a PMOVE is complete and also when the axis motion feedback position is close enough to the commanded position to allow position critical operations such as Set Position to take place The In Zone l bit is set to indicate this If the Power Mate APM is power cycled or the PLC CPU is reset for any reason the configured In Position zone value will be reinstated Move Command This command will produce a single move to the commanded position each time it is sent The current Jog acceleration and velocity which can also be changed by AQ commands will be used for the move The data field for this command may contain the move position or distance in bytes 2 5 with the command type as defined below Move Type byte 1 00 2 Abs Pmove Linear 01 Abs Cmove Linear 10 Abs Pmove S 11 Abs Cmove 5 40 Inc Pmove Linear 41 Inc Cmove Linear 50 2 Inc Pmove S 51 2 Inc Cmove S The data field for this command may contain a parameter number in byte 2 bytes 3 5 un
148. top each de scribed below A conditional JUMP triggered during a PMOVE will always generate a jump stop Be cause a PMOVE always stops before continuing to a subsequent motion a jump stop always occurs when a jump takes place during a PMOVE When a conditional jump trigger occurs during a CMOVE however a jump stop will not occur if the motion programmed at the jump destination is a PMOVE or CMOVE repre senting sufficient distance in the same direction Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C s In an scurve move a jump stop will do one of two things If the jump takes place after the midpoint of the acceleration or deceleration the acceleration or deceleration is com pleted before the jump stop is initiated If the jump occurs before the midpoint of the acceleration or deceleration the profile will immediately begin leveling off Once accel eration or deceleration is zero the jump stop begins See the scurve jump examples Example 10 Jump Stop The following is an example conditional jump with a jump stop An enhancement on Example 5 DWELL would be to watch an external CTL bit which would indicate a problem with the positive motion If the CTL bit never turns on the profile for the fol lowing program will be identical to the profile shown in the DWELL example If the CTL bit turned on during the first PMOVE or the DWELL the reverse movement would immediately commence T
149. tor B Figure C 5 General Purpose Input Circuitry 12 bitplussign A D converter with the following specifications Inputrange 10 0V Input impedance 50 k ohms Common mode range 20V Resolution 12 bits magnitude plus sign bit Linearity 1 LSB Accuracy 2 of reading 4 LSBs Scale Factor 10 0 V 32 000 10V 32 000 Update Rate 16 ms does not include PLC scan time 51K 20K 245108 ANALOG IN A A e TO A D 51K CONVERTER ANALOG IN 20K 0v Figure C 6 Analog Input Circuitry AppendixCSpecifications C 5 I O Connector Cable Specifications The cable that connects from the I O connector to an external terminal block can be shortened to meet the requirements of your installation Refer to Table 14 to correctly match cable wires with connector pins Also refer to Figures 2 4 through 2 7 and Tables 2 2 through 2 5 for specific wiring requirements Lo 4 3 METERS 4919 Bs 0 00 o BE 2 00 e o 0 o 9 O 09 99 0 CREE ccm n M CO Vo TERMINAL BLOCK CONNECTOR CONNECTOR Figure 7 I O Connector Cable Specifications C 6 Power Mate APM for Sseries 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C l O Cables An IO Cable assembly for the PM APM modules consisting of a 24 pin connector a cable and a 25 pin D type terminal block
150. ts are not used the Power Mate APM configuration should be set to Drive OK inputs DISABLED The ENABLE DRIVE Q control bit must be set continuously to 1 or no motion other than Jogs will be allowed If no STOP errors have occurred the DRIVE ENABLED 96 status bit will mirror the state of the ENABLE DRIVE Q bit A STOP error will turn off DRIVE ENABLED even though ENABLE DRIVE is stilla 1 The error condition must be corrected and the CLEAR ERROR Q control bit turned on for one PLC sweep to re enable the drive 5 2 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C 4 Ifthe ERROR I status bit is 1 and the AXIS ENABLED and DRIVE ENABLED 1 status bits are 0 then a STOP error has occurred Status LED flashing fast In this state the Power Mate APM will not respond to any commands other than the CLEAR ERROR Q control bit The CLEAR ERROR Q control bit uses one shot action Each time an error is gen erated the bit must be set to 0 then set to 1 for at least one PLC sweep to clear the error 5 The CFG OK LED must be ON or the Power Mate APM will not respond to PLC commands If the LED is OFF then a valid Power Mate APM configuration has not been received from the PLC GFK 0781C Chapter 5 Follower System Startup Procedures 5 3 Follower Control Loop Block Diagram
151. type CPU Dependent 100001 or next higher n a 32 bits reference Ref Adr Start address for Q ref type CPU Dependent Q00001 or next higher n a 32 bits reference n a Ref Adr Start address for AI ref type Dependent 100001 or next higher 15 words for 1 axis 28 words reference for 2 axis Ref Adr Start address for AQ ref type CPU Dependent 26A Q00001 or next higher n a 6 words reference 96 AI Pos Err On Single Axis Power Mate DISABLED DISABLED APMs this parameter adds ENABLED Position Error to AI Data Configuration Description Values Defaults Units Parameter PU Fdback Type Feedback Type ENCODER ENCODER n a LINEAR RESOLVR CUSTOM 1 CUSTOM 2 DIGITAL Ctl Loop Control Loop Type STANDARD STANDARD n a FOLLOWER CCL1 2 CCL2 2 Servo Cmd Servo Interface Type ANALOG ANALOG DIGITAL Motor Type GE Fanuc Motor Type 0 127 0 no motor Motor2 Type 4 Motor Dir Motor direction for POS POS Motor2 Dir 4 positive velocity command NEG 1 Reserved for future use not implemented at this time Forspecial purposeapplications only 3 For information about the Standard Control Loop Type refer to GFK 0840 Series 90 30 Power Mate APM PM Power Mate APM Standard Mode User s Manual Twoaxis PowerMate APM IC693APU302H or later Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C Fdback Type ENCODER selects A quad B x4 incremental encoder input mode LINEAR selects li
152. used with the command type as defined below Move Type byte 1 80 2 Abs Pmove Linear 81 Abs Cmove Linear 90 Abs Pmove S 91 Abs Cmove S Inc Pmove Linear C1 Inc Cmove Linear D0 2 Inc Pmove S D1 2Inc Cmove S All of the moves defined above can be sent and executed when the Power Mate APM is configured for Standard mode In the Follower mode only the moves marked Linear should be executed Power Mate APM for Series 90 30 PLC Follower Mode User s Manual August1996 GFK 0781C This move is executed as a single move motion program and the Program Active I indication will be on while the move is in process All the restrictions that apply to motion program execution will also apply to it For example if a program is already active for axis 1 then an attempt to send this command for axis 1 will result in an error condition reported Note that for the Follower mode configuration an absolute move type will act just like an incremental move if the Follower is Enabled It will operate as an absolute move only if the Follower is not enabled This is because an absolute move reference position of 0 is used when the move is sent with the Follower enabled and if the Follower is not enabled the actual position is used for the reference Jog Velocity user units sec This command sets the velocity used when a Jog Q bit is used to jog in the positive or negative direction Jog Acceleration user units sec sec
153. user units This command changes the axis position register value with out moving the axis The Commanded Position and Actual Position values will both be changed so that no motion command will be generated The Actual Position will be set to the value designated and the Commanded Position will be set to the value Position Error Set Position cannot be performed when the I Command Move bit is ON The position value must be within the End of Travel Limits and the Count Limits or a status error will be generated Position Valid indication is set after a successful Set Position command Force D A Output This command forces the Velocity Command D A outputs at the I O connector to a constant output level The Force D A Output command sets the output to any value within the 10 volt range This command will not be allowed if Enable Fol lower is set or if any other motion is in progress A Force D A Output command is the only continuous AQ command It must remain continuously in the AQ data for proper operation Thus any other AQ command will remove the Force D A command A command of 32 000 will produce an output of 10 V and 32 000 will produce 10 V GFK 0781C Chapter 4 Automatic Data Transfers 4 13 In a 1 axis follower Power Mate APM placing this command into axis two AQ data will automatically enable axis 2 Axis 2 enabled is indicated by the EN2 LED turning on Position Increment With Position Update user units This command is similar

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