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Power Mate for Series 90-30 PLC Standard Mode User`s Manual

1. 2 4 T OC OMNECIORS cs MU M aes UO Eats Moa rd Me A ed 2 5 I OCableandTerminalBlock 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 Linear Feedback Transducer 2 14 Section 2 Installing the Power Mate APM 2 15 Chapter 3 Configuring the Power Mate 3 1 I ORack Configuration 2 3 1 Module 3 1 Setting the Configuration Parameters 3 2 Essential Configuration Parameters 3 14 Important Configuration Considerations 3 16 Chapter 4 Automatic Data Transfers 4 1 Mol Statis BIES erh ierra 4 2 Status Words e Biter eit a Aat e nettes 4 5 Q Discrete Commands 4 8 AQ Immediate 5
2. Module Terminal Connector A Block Description Pin Number Terminal Number Al 12 OV Bl 24 Reserved A2 11 Reserved B2 23 Strobe 2 CTL02 Input A3 10 Strobe 2 CTLO2 Input B3 22 Strobe 1 CTLO1 Input A4 9 Strobe 1 CTLO1 Input B4 15 Common for CTLO03 05 06 Inputs AS 2 Overtravel 1 direction CTL06 Input 5 14 Overtravel 1 direction 05 Input A6 1 Home 1 CTLO3 Input B6 16 Enable Relay 1 Output 7 3 Enable Relay 1 Output B7 17 Analog Output 1 Velocity Command Common 8 4 Analog Output 1 Velocity Command B8 21 OV 9 8 5 V Encoder Power B9 20 Encoder Channel Z1 Linear Feedback 1 input 10 7 Encoder Channel Z1 Linear Feedback 1 input B10 19 Encoder Channel B 14 All 6 Encoder Channel B1 Bll 18 Encoder Channel 1 A12 5 Encoder Channel 1 B12 13 Cable Shield 25 no connection Fused Output an external source applied to this output could open the fuse 2 8 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D GFK 0840D Table 2 5 Cable Connections to Faceplate 1 0 Connector B 2 Axis Power Mate APM Module Terminal Connector B Block Description Pin Number Terminal Number Al 12 OV Bl 24 Analog Input A2 11 Analog Input B2 23 CTL12 Output A3 1
3. 1 8 Table 2 1 Pin Definitions of the Serial COMM Connector 2 3 Table 2 2 Cable Connections to Faceplate I O Connector A 1 Axis Power Mate APM 2 6 Table 2 3 Cable Connections to Faceplate I O Connector 1 Power Mate APM 2 7 Table 2 4 Cable Connections to Faceplate I O Connector A 2 Axis Power Mate APM 2 8 Table 2 5 Cable Connections to Faceplate I O Connector B 2 Power Mate APM 2 9 Table 3 1 Module Configuration 3 2 Table 3 2 Serial Communications Port Configuration Data 3 5 Table 3 3 Axis Configuration Data 2 2 2 2 3 6 Table 3 4 Program Zero Motion Program Commands 3 12 Table 4 1 I Status Bits for the 1 Axis Power Mate APM IC693APU301 4 2 Table 4 2 I Status Bits for the 2 Axis Power Mate APM IC693APU302 4 3 Table 4 3 AI Status Words for the 1 Axis Power Mate APM IC693APU301 4 5 Table 4 4 AI Status Words for the 2 Axis Power Mate APM IC693APU302 4 5 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 IC693APU3
4. 4 11 Chapter 5 Servo System Startup Procedures 5 1 System Troubleshooting Hints 52 Chapter 6 Power Mate APM Motion 1 6 1 Position Feedback Types 6 1 GFK 0840D Table of Contents Contents Quad B Incremental 6 1 Linear Absolute Transducer 6 2 Digital Serial Encoder 6 2 Non Programmed Motion 6 2 Power Mate Home Cycle 6 2 Jogging with the Power Mate APM 6 5 Move at Velocity Command 6 5 Force D ACommnmand eas RR Pee REIR ERA 6 6 Position Increment Commands 6 6 Other Considerations 6 6 Programmed Motion 6 7 Prerequisites for Programmed Motion 6 8 Conditions Which Stop a Motion 6 8 Parameters for Programmed Moves 6 8 Types of Programmed Move Commands 6 11 Programmed
5. 1 Example Program Zero Editor Screen Sample Linear Motion Sample S curve Motion 2 2 2 ed ad arena he Ree EE Edere a Combining PMOVEs and CMOVES Changing the Acceleration Mode During a Profile Not Enough Distance to Reach Programmed Velocity Hanging the Power Mate APM When the Distance Runs Out Dwell cient esha ahi e er dda X nd eaten Unconditional Juxip seret eei eesee rate ees ee merced e e ed Ros Normal Stop before JUMP WithoutStopping dat reir anak bose SR Jump Followed by PMOVE Jumping After the Midpoint of Acceleration or Deceleration Jumping before the Midpoint of Acceleration or Deceleration Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating Maximum Acceleration
6. e e e e e e e e e e e e X 4 31 ub mms WA Power Mate APM CABLE S TERMINAL BLOCK S MODULE Figure 2 3 I O Cable and Terminal Block GFK 0840D 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 Table 2 2 Cable Connections to Faceplate I O Connector A 1 Axis Power Mate Module Terminal Connector A Block Description Pin Number Terminal Number Al 12 OV Bl 24 Reserved A2 11 Reserved B2 23 02 Input A3 10 02 Input B3 22 Strobe 1 CTLO1 Input A4 9 Strobe 1 CTLO1 Input B4 15 Common for CTLO03 05 06 Inputs AS 2 Overtravel 1 direction CTL06 Input B5 14 Overtravel 1 direction 05 Input A6 1 Home 1 CTLO3 Input B6 16 Enable Relay 1 Output 7 3 Enable Relay 1 Output B7 17 Analog Output 1 Velocity Command Common 8 4 Analog Output 1 Velocity Command B8 21 OV 9 8 5 V Encoder Power B9 20 Encoder Channel Z1 Linear Feedback input 10 7 Encoder Channel Z1 Linear Feedback input B10 19 Encoder Channel B 14 All 6 Encoder Channel B1 Bll 18 Enco
7. 6 12 Dwell Command tes I e edt 6 16 Wait Commands t opns sabe ort aate 6 16 S brou tines eoo etel Vete Re es 6 17 Block Numbers and Jumps 6 17 Unconditional Jumps 6 17 Conditional Jumps eee e EE oe oes lace 6 18 5 JUMPS d ariel ache Waste arde lg acid 6 24 Other Programmed Motion Considerations 6 27 Feedhold with the Power Mate 6 28 Feedrate Override orte e ee i eS 6 29 Multi AxisProgramming 6 31 Parameters in the Power Mate APM 6 32 Appendix Error Codes eet sse BES RR PD xr E Ris A 1 AppendixB Parameter Download Using COMM_REQ B 1 AppendixC Specifications is esee snes nas ya ena RR Ray Rn a C 1 Module Specifications C 1 I Obpecificationis de ee a eee t e a C 2 Velocity Command sese e ERE ER RE E ES C2 Enable Relay Output 2 Encoder Inputs 3 eres UE en Lemania 3 Strobe Inputs ene a e des ete Sa C 4 ete eo e en Qk eor eg C 4 General Purpose 24 VDC
8. 2 xo Se ted E Aa dte ates wiPeedrate Overtide x ses Lb ess Ok eda eii ptr ps Multi AxisProgramming Status Code Organization Velocity Command Circuitry Enable Relay Output Encoder and Strobe Input Circuitry Encoder Power Circuitry General Purpose Input Circuitry General Purpose Output Circuitry Analog Input Circuitry i e lie ee Ae enh aide as Waa e eese eg I O Connector Cable Specifications 55 90 Digital 100 Digital 200 Wiring Example of a Linear Displacement Magnetostrictive Transducer LDT Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 1 3 1 6 2 4 2 4 2 5 2 10 2 11 2 12 2 13 2 14 3 10 6 10 6 10 6 12 6 13 6 14 6 15 6 16 6 17 6 21 6 22 6 23 6 24 6 25 6 26 6 27 6 28 6 29 6 30 6 31 A 1 C 2 C 2 C 4 C 4 C 5 C 6 C 7 C 7 D 1 F 2 GFK 0840D Contents Table 1 1 The Motion Programmer Command List
9. 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 accessory 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 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 GFK 0840D AppendixCSpecifications C 9 C 10 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
10. GFK 0840D Chapter 3 Configuring the Power Mate APM 3 3 a L Series Servo Motor Motor Code Motor Model Motor Specification aL3 3000 aL6 3000 aL9 3000 aL25 3000 aL50 2000 acs 200 aC6 2000 aC12 2000 aC22 1500 a HV Series Servo Motor Motor EE Code Motor Model Model Motor Motor Specification a a12HV 3000 3000 a22HV 3000 a30HV 3000 a M Series Servo Motor Motor Code Motor Model Model Motor MotorSpecification aM3 3000 3000 aM6 3000 aM9 3000 b Servo Motor Motor Code Motor Model Motor Specification b 1 3000 b2 3000 3 3000 6 2000 Motor Dir 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 For digital servos POS defines the positive axis direction as counter clockwise CCW motor shaft rotation when viewed looking into the front output shaft end of the motor Power Mate APM for Series 90 30 PLC Standard Mode User s Manu
11. B Baud Rate BLOCK Command Program Zero Blo m Field Motion Programmer 1 7 Block Numbers and Jumps 6 17 C Cable Connections for I O Connector A 1 Axis Cable Connections for I O Connector A 2 Cable Connections for I O Connector 1 Axis Cable Connections for I O Connector B 2 Axis CALL Motion Programmer Command CFG LED 2 2 Clear Error Q Discrete Command 4 10 CMOVE Command Program Zero Bm E Motion Programmer Command 1 8 Command Block Number AI Status Word Command Name Field Motion Program mer 1 7 Command Name Field Program Zero 5 10 uic Position AI Status Word 4 6 Commanded Velocity AI Status Word Comments Field Motion Programmer Com E Among Firmware Releases 1 2 Conditional Jumps Conditions Which Stop a Motion Pro gram iio uration Considerations Important Configuration Modes AQ Immediate Command Configuration Parameters Configuration Parameters Essential 3 14 Configuring the I O Rack B1 Configuring the PM APM Module B 1 Configuring the Power Mate APM B 1 Bic M Absolute Encoder Mode G 3 Home Cycle Position Initialization GFK 0840D GFK 0840D Set Position Command Considerations Incremental Encoder Mode Continuous Move CMOVE 6 11 Control Loop B2 Count 6 CTLO9 CTL12 Output Controls Q Dis crete Command D Data Bits Description of the 2 Disable
12. 5 2 lt S 0 150 000 80 000 B A AXIS 1 30 000 OBSTACLE Figure 6 19 Multi Axis Programming GFK 0840D Chapter 6 Power Mate Motion Control 6 31 If this program segment is not at the beginning of a program and for some reason axis 2 has not yet reached Block 20 when axis 1 has moved 30 000 counts an error would occur Axis 1 would continue to 80 000 counts and the Power Mate 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 Foll
13. Ans curve motion 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 6 10 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D 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 a
14. L5 Dwell Command 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 6 16 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 progr
15. 2 5in 24in 2in 2 9 05nsec in I 1000 0 516 milliseconds Note The update time of the LDT should not be greater than 3 6 milliseconds Consider a lower resolution or lower value for recirculations if necessary 4 Determine LDT specifications Example The specified LDT stroke is 24 inches The specified number of recirculations 2 The Power Mate APM counter frequency is 16 896 MHz The Power Mate APM clock divider 1 Note When ordering an LDT specify stroke and recirculations The manufacturer of the LDT will adjust the sensor to specification The actual resolution obtained is based on the gradient of the specific sensor 5 The Logicmaster 90 30 configuration of the Power Mate APM LINEAR feedback will make an on line calculator available to you Zoom into the APU module and select Fdback Type LINEAR Page down into the axis dependent configuration Observe the following fields Clk Divider Always 1 in current releases Recircs Number of recirculations Gradient The gradient specified for the LDT MaxLen in The maximum stroke available Counts Inch The LDT resolution The LogicMaster configuration will calculate the resolution and maximum stroke length automatically Enter a value for Recircs and if necessary change Gradient to calculate MaxLen in and Counts Inch 6 Another method of calculating the counts per inch is to use the formula Rt O G F Example Rt 2 recirculations 9 05nsec in 16 8
16. Jog Velocity Jog Velocity AQ Immediate Command 15 Jogging with the PM APM 5 JUMP Command Program Zero ta Programmer Command 1 8 Jump Stop 6 22 Jump Testing Jumping Without Stopping Jumps and Block Numbers 6 17 L LDT Interface LED Indicators 2 2 Limitations on Total Travel Linear Acceleration Linear displacement magnetostrictive transducer F 1 LOAD Command Program Zero Motion Programmer Command 1 8 Load Parameter Immediate AQ Im mediate Command 4 17 Loss of Encoder Battery Power Low Limit 3 6 GFK 0840D GFK 0840D Maximum Acceleration Time Models of Serial Encoders G 1 Modem Turn Around Time Modes Serial Encoders G 2 Module Configuration Data AI Position Error 3 2 Control Loop Feedback T Ref Adr Module Specifications C 1 Motion Control Motion Programmer Features Instruction Format Block Number Field Command Name Field Comments Field 1 7 Operand Fields 1 7 Block Indicator Field 1 7 Overview Motion Non Programmed 6 2 Motion Programmed 6 7 Move AQ Immediate Command Move At Velocity AQ Immediate Com mand Move at Velocity Command 6 5 Move Commands 6 11 Move and Move Modes 6 4 Moving 1 Status Bit 4 3 Multi AxisProgramming Multidrop Connection Index N Negative End Of Travel Non P rogrammed Motion Normal Stop before JUMP Null AQ Immediate Command
17. NN TERM DRIVE AXIS 2 7 VEL MOTOR B7 E VEL COM Pos A7 3 ENT ENABLE B6 16 ENS ov B 43 SHIELD wees FOR SINGLE ENDED B11 18 2 5 4 Ber ENCODER DO NOT 12 5 A2 A2 CONNECT A2 B2 Z2 B10 19 Be Bos B2 B2 11 6 AXIS 2 B9 20 22 Z2 ENCODER 10 7 22 22 7 AQ 8 5 5 AXIS 2 B8 21 ov ov LOAD 7 NEGATIVE POSITIVE OVERTRAVEL OVERTRAVEL LIMIT SWITCH HOME SWITCH AD LIMIT SWITCH 5 2 OT CTLOB m HOME 2 CTLO4 B5 14 OT CTLO7 INCOM2 B4 15 co e 4 is d CTLO9 is a CTL010 2AVDG 5V TLO11 A3 10 el CMOS B2 23 CTL012 5 OUTPUTS ov A1 2 gt SHIELD B12 13 7 E AIN i AIN NE GENERAL PURPOSE A2 11 Z ANALOG INPUT uw Figure 2 7 Functional Diagram for 2 Axis Power Mate APM I O Connector Chapter 2 Installing the Power Mate 2 13 Linear Feedback Transducer 2 14 VO CONNECTOR or CONNECTOR B 2 AXIS Power Mate a47103 VO TERM BLK CONN TERM DRIVE VEL VELCOM X X 22 pu B7 17 CMD 3 EN EE ENABLE B6 16 EN X x ov B12 13 SHIELD B11 18 UNUSED A12 5 UNUSED B10 19 UNUSED LINEAR A11 6 m UNUSED i TRANSDUCER B9 20 1 1 10 7 X t0 Xt YY A9 8 5V 1 B8 21 ov 1 o
18. The Power Mate APM is easily configured using the Logicmaster 90 30 Configuration software The Power Mate APM is assigned to a particular slot and rack like any other PLC module In addition other types of configuration data must be entered such as m I Oaddresses where the CPU to Power Mate APM transfers take place m Serial Port Setup for connecting the Motion Programmer m PM Power Mate APM Setup Data Anoptional 20 line motion program Program Zero All of the Power Mate APM configuration data is discussed in detail in Chapter 3 Configuring the Power Mate APM The Power Mate APM and the Servo System The Power Mate APM communicates through the A and B connectors to the servo drive and position feedback device The Power Mate APM controls an axis by sending an ana log voltage to a servo It interprets what the servo or axis does by reading a position feedback device Position Error is one of the controlling factors in closing the position loop The Power Mate APM produces a velocity command output proportional to the position error The Power Mate APM also has Home Switch inputs Overtravel Limit Switch inputs and other control inputs and outputs The Power Mate APM and Digital Servos Firmware release 2 50 allows the Power Mate APM to operate with a Digital Servo Inter face module DSI to control GE Fanuc a or b series servo amplifiers and motors The combination of the Power Mate APM controller module and Digital Servo I
19. The acceleration rate used during Jog Find Home Move at Velocity and Abort operations The Jog Acceleration is used when an acceleration has not been programmed Default 10000 Jog Acc Mod Jog Acceleration Mode LINEAR or SCURVE The acceleration mode for Jog Find Home Move at Velocity and Abort operations LINEAR causes commanded veloc ity to change linearly with time SCURVE causes commanded velocity to change more slowly than the linear mode at the beginning and end of acceleration intervals Default LINEAR Hi Limit High Count Limit User Units When moving the Actual Position will roll over to the low limit when this value is reached The Count Limits are used for rotary applications Default 8 388 607 Lo Limit Low Count Limit User Units When moving the Actual Position will rol lover to the high limit when this value is reached The Count Limits are used for rotary applications Default 8 388 608 If Hi Low Count limits are both set to zero the Power Mate APM uses default limits 8 388 607 8 388 608 instead Home Positn Home Position User Units The value assigned to Actual Position at the end of a Find Home cycle Default 0 Home Offset Home position Offset User Units The offset of the servo final stopping point at the completion of a Find Home cycle Home Offset adjusts the final servo stop ping point relative to the Encoder marker Default 0 Fnl Home Vel Final Home Velocity User Units se
20. 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 GFK 0840D 5 1 10 11 12 the Power Mate APM 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 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 witha 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 confi
21. 0840D Symbols AI Position Error AI Status Words 4 5 Actual Position 4 6 Actual Velocity Analog Input 4 7 Command Block Number 4 6 perf Commanded Position 4 6 Commanded Velocity 4 6 Status Code 4 6 4 Strobe Position da 7o AI Status Words for the 1 AxisPM APM IC693APU301 44 5 AI Status Words for the 2 Axis PM APM IC693A PU302 14 5 Jog Velocity Load Parameter Immediate 17 Move 4 14 Move At Velocity Null 1 13 Position Increment 4 13 Position Increment With Position Up date 4 14 Rate Override Select Return Data Set Configuration Complete 4 17 Set Position Torque Limit 4 1 Update Flash Memory 4 17 Velocity Feedforward 4 15 Velocity Loop Gain oI Status Bit Axis Enabled Configuration Complete Drive ME Error 4 inp anus CTL01 08 4 4 4 4 In Error Limit 4 In Zone Moving PLC Control Active Position Strobe 4 4 Position Valid 4 3 Program Active Index 9 Status Bits ol Status Bits for the 1 AxisPM APM IC698APU301 l Status Bits for the 2 AxisPM APM IC693A PU302 Q Discrete Commands 4 8 Abort All Moves 4 9 Clear Error CTL09 CTLI2 Output Controls Enable Drive 4 9 Execute Motion Program 0 10 4 10 Feedhold Off Transition 4 9 Feedhold On Transition Find Home Jog Minus 4 10 Jog Plus Reset Strobe Flag Q Discrete Commands for the 1 Axis PM APM IC693APU301 4 8 Q Discrete Commands for t
22. 2 axis programs Synchronizing Block Indicator Field This field appears only when editing multi axis programs is optional An X will appear to indicate a block number is a sync block Command Name Field This field is required It is an English language designation for the command The commands are selected from function keys at the top of the editor screen Operand Fields Any operand field displayed is required When a Command name is en tered the required Operand fields will be displayed with default values The number of Oper and fields displayed varies from one to four depending on the Command name Operand field 1 is reserved for the axis number The content of the other 3 fields vary depending on the com mand Comments Field This field is optional It allows approximately 30 characters of comment for each program instruction A separate 80 character comment can be added on a separate line GFK 0840D Chapter 1 Introduction 17 Table 1 1 The Motion Programmer Command List Command Name Field Operand 1 Operand 2 Operand 3 Operand 4 Acceleration Axis USER UNITS sec sec n a n a ACCEL 1 2 1 134 217 727 or Parameter Number 0 255 Call Subroutine n a Subroutine Number 1 40 n a n a CALL Continuous Move Axis USER UNITS Positioning Mode Acceleration Mode CMOVE 1 2 8 388 608 8 388 607 ABS INCR LINEAR SCURVE Parameter Number 0 255 Jump n
23. 6000 CMOVE 36000 INC LINEAR 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 24 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D 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
24. 7 OV 0 SHLD 1 1 SHLD L W w CONNECTOR 1 _ CONNECTOR 2 15 PIN 10 15 PIN FEMALE MALE NOTES xX X 1 Cables may be daisy chained for more CPUs or Power Mate amp Mn 10 E gt 2 Connector 1 is 15 D shell 11 BD female 12 SD A KG 13 SD B KG 3 Connectors 2 and 3 are 5 a 15 D shell male with 15 CTS gt right angle hood wires exiting Gls 8 F m PIN 1 end 71 ov 1 SHLD ELE CONNECTOR 3 15 PIN MALE Figure 2 2 Multidrop Cable for the Power Mate APM 2 4 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D 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 Axis 1 Connector B contains connections for Axis 2 and general purpose connections including the Analog Input and the Control Outputs The tables briefly describe the function of the I O connections 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 to a terminal block Refer to Figure 2 3 below and Tables 2 2 through 2 5 845113
25. AQ ref type CPU Dependent 000001 or next higher 6 words reference 96 AI Pos Err On Single Axis Power Mate DISABLED DISABLED APMs this parameter adds ENABLED Position Error to AI Data Fdback Type Feedback Type ENCODER ENCODER n a LINEAR RESOLVR CUSTOM 1 2 CUSTOM 2 2 DIGITAL 1 Ctl Loop Control Loop Type STANDARD STANDARD FOLLOWER CCL1 CCL2 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 purpose applications only 3 For information about the Follower Control Loop Type refer to GFK 0781 Series 90 30 Power Mate Follower Mode User s Manual 4 Twoaxis PowerMate APM IC693APU302H or later NOTE Refer to Appendix F for a discussion of LINEAR feedback 3 2 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Fdback Type ENCODER selects A quad B x4 incremental encoder input mode LINEAR selects linear 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 CUSTOM2 configure the Power Mate APM inputs for special applications DIGITAL feedback is only supported in Power Mate APM fir
26. Axis 2 Find Home switch input CTLO5 Axis 1 Overtravel switch input CTLO7 Axis 2 Overtravel switch input 06 Axis 1 Overtravel switch input CTLO8 Axis 2 Overtravel switch input Note In Digital mode CTL04 CTLO7 CTL08 are not available because faceplate connector B is used for the Digital Servo Interface module communications cable In this mode CTLO05 is used for the axis 2 Home Switch if axis 1 Overtravel switches are disabled in the configuration software Configuration Complete The Configuration Complete status bit is set by AQ 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 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 Mo tion Programmer is used instead of the PLC to control the Power Mate APM a capability not yet imple
27. Cable assembly for the PM APM modules consisting of a 24 pin connector a cable and a 25 pin D type terminal block 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 C 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 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Table C 2 1 0 Cable Wire Coding for IC693CBL317 and IC693CBL320 Pin Number 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
28. Delay Drive Enabled 1 Status Bit Dwell Command DWELL Command Program Zero ui Motion Programmer Command 1 8 E EN1 LED p2 EN2 LED 2 2 Enable Drive Q Discrete Command Error I Status Bit Error Codes A 1 Essential Configuration Parameters Example Jump Followed by PMOVE 6 24 Jump Stop Jump Testing 6 JUMP Without Stopping Maximum Acceleration Time Normal Stop before JUMP Example 1 Combining PMOVEs and CMOVEs Example 10 Jumping Before the Mid point of Acceleration or Deceleration 26 Example 11 Jumping to Higher Veloc ity While Accelerating or Jumping to a Index Lower Velocity While Decelerating 6 27 Example 13 Feedhold 6 29 Example 14 Feedrate Override 6 30 Example 15 Multi Axis Programming l 31 Example 2 Changing the Acceleration Mode During a Profile 6 13 Example 3 Not Enough Distance to Reach Programmed Velocity Example 4 Hanging the PM APM When the Distance Runs Out Example 5 Dwellj6 16 Example 6 Unconditional Jump Example 9 Jumping After the Midpoint of Acceleration or Deceleration 6 25 Execute Motion Program 0 10 Q Dis crete Command F Faceplate Input Status CTL01 08 I Sta tus Bit dal Features of the Power Mate APM 1 1 Feedback Type 2 Feedback Types Position 6 1 Feedhold Off Transition Q Discrete Command 4 9 Feedhold On Transition Q Discrete Command Feedhold with the 6 28 Fe
29. Digital Inputs C 5 General Purpose Outputs 6 Anal gInput Ee Ee C 7 I O Connector Cable Specifications C 7 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Contents AppendixD Wiring to 55 90 D 1 AppendixE OrderingInformation E 1 Appendix LDT Interface 4524 scan Dewi neh ters A Ee dew wade ney F 1 TEMPOSONICSr or LDT Interface to Power Mate APM F 1 Accuracy Resolution and Response Considerations F 2 How to select an LDT for interface to the Power Mate APM APU301 302 F 5 AppendixG Serial Encoders 532 br a dr d G 1 Serial Encoder 16 G 1 Serial Encoder First Time Use or Use After Loss of Encoder Battery Power G 1 Serial Encoder Modes aee denos eed ps G 2 Limitations on Total Travel for EOT Mode G 2 Incremental Encoder Mode Considerations G 3 Absolute Encoder Mode Considerations G 3 Absolute Encoder Mode Position Initialization G 3 Absolute Encoder Mode Power Mate APM Power U
30. Drive Enable relay contact to close enabling the drive and the Drive Enabled bit to be set otherwise it has no effect When the Drive Enabled bit is set the path generation and position control functions are enabled and servo motion can be commanded Enable Drive must be maintained ON to allow normal servo motion except when using Jog commands Enable Drive must be turned off whenever 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 Chapter 4 Automatic Data Transfers 4 9 4 10 Find Home 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 Limit Switch to be ignored The configured Home Offset defines the location of Home Position as the offset distance from the Home Marker Position Valid indication is set at the conclusion of the Home cycle 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 con figured Jog Acceleration and Jog Velocity as long as the Jog Plus command is maintained and the configured
31. Execute ProgramwhileD A Forced 84 Status Only Execute Program while Program Selected 85 Status Only Execute Program while Abort All Moves bit set 86 Status Only Execute Program while Position Valid not set 87 Status Only Execute Program while Drive Enabled not set Status error is reported command is not executed Appendix A Error Codes A 3 Table A 1 Status Word Error Codes Continued Error Number Response Description Hexadecimal Program Synchronous Block Errors 8C Status Only Sync Block Error during CMOVE 8D Status Only Sync Block Error during Jump EEPROM Errors 90 Status Only Flash EEPROM memory programming failure Hardware Limit Switch Errors AO Stop Fast Limit Switch error Al Stop Fast Limit Switch error Hardware Errors 8 Stop Fast Out of Sync error A9 Stop Fast Encoder Loss of Quadrature or Linear Feedback Loss of Signal error AA Stop Normal Analog Input Failure Digital Servo Configuration Errors B1 CRC SCRDY or SAL1 SALO error during configuration B2 Wait gt 10 seconds for initial PM J communications B3 PCGACK not 1 error PCGACK not 0 error B5 DSI not ready for control mode Digital Servo Control Errors B8 DSI interruptmissing B9 CRC error Communication to DSI BE Communicationsalarm from DSI BF Hardwarealarm from DSI Co Servo not ready when MCON command is on may be caused by E STOP input to amplifier 1 Serial Enc
32. LI AS m PORUM CONTROLLER 1 SHLD 24VDG sso DRIVE OK SSO t 24VDC COM VEL ves ACOM ves oV Re ET Lo EN ENABLE EN ENABLE PM APM CONNECTIONS AXIS 1 OR AXIS 2 SERIAL P6 5VDC SHLD 79 T SHLD XMT E RCY XMT EM RCY COM 7 RCY m XMT RCY EET XMT i 2 USER TERMINAL ASCII SERIAL TERMINAL VT 52 REQUIRED FOR SET UP NOT REQUIRED FOR OPERATION SS90COM SOFTWARE AVAILABLE FOR USE WITH P C DIGITAL 100 200 AMPLIFIER Figure D 1 SS 90 Digital 100 Digital 200 Wiring Note that the FAC and FAC pins on the 55 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 Standard Mode User s Manual August1996 GFK 0840D Appendix Ordering Information E Series 90 30 Power Mate APM IC693APUS01 1Axis IC693APU302 2Axis Motion ProgrammerSoftware 1C641SWP065 I O Cable 10 feet 3 meters IC693CBL311 I OCable 3 feet 1 meter IC693CBL319 Consists of a 24 pin IO connector a cable and a 25 pin D type terminal block connector LO Cable 10 feet 3 meters w external shield wire IC693CBL31
33. Mate APM Operations The Power Mate APM is an intelligent fully programmable motion control option mod ule for the Series 90 30 Programmable Logic Controller PLC The Power Mate APM allows a PLC user to combine high performance motion control with PLC logic solving functions in one integrated system The figure below illustrates the hardware and soft ware needed to set up and operate a servo system This section will discuss briefly each piece of the system to provide an overall picture of system operation a45114 OPERATOR ol INTERFACES 0 4 1 alo L ao DRIVE CT M I L 27 m ENCODER 1 j MACHINE 2 DRIVE 4 e Et o o T oy LOGICMASTER 90 30 D THE MOTION ENCODER 2 CONFIGURATION PROGRAMMER PACKAGE SOFTWARE PACKAGE Figure 1 1 Hardware and Software Used to Configure Program and Operate an Power Mate APM Servo System The system shown above can be divided into 4 categories 1 Power Mate APM and the Series 90 30 PLC 2 The Power Mate APM and the Servo System 3 Motion Programming Packages 4 Operator Interfaces It is helpful to become familiar with the following Power Mate APM terms Commanded Velocity the velocity generated by
34. PUT THE COMMAND TYPE E501 IN THE FIRST DATA WORD R202 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 J 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 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 DATAST PAR_NO 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 Standard Mode User s Manual August 1996 GFK 0840D KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK ADD LOGIC HERE TO MOVE THE PROPER CONSTANTS INTO THE REGISTERS KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK
35. Positive End Of Travel limit is not encountered Jog Plus may be used to jog off of the Negative End of Travel Limit Switch if the Q Clear Error bit is also maintained on Jog Minus When this command bit is ON the axis moves in the negative direction at the configured Jog Acceleration and Jog Velocity as long as the Jog Minus command is maintained and the configured Negative End Of Travel limit is not encountered Jog Minus may be used to jog off of the Positive End of Travel Limit Switch if the Q Clear Error bit is also maintained on Reset Strobe Flag Position Strobe I status bit flag informs the PLC that a Strobe Input has captured an axis position that is now stored in the Strobe Position status word When the PLC acknowledges this data it may use the Reset Strobe Flag Q command bit to clear the Position Strobe I status bit flag Once the Position Strobe I bit is set additional Strobe In puts will not cause new data to be captured The flag must be cleared before another Strobe Position will be captured As long as the Reset Strobe Flag Q command bit is set the Position Strobe bit flag will be held in the cleared state In this condition the latest Strobe Input position is reflected in the Strobe Position status word although the flag cannot be used by the PLC to indicate when new data is present CTLO9 CTL12 Output Controls These command bits control the CMOS digital outputs on Faceplate I O Connector B The bits may also b
36. Power Mate APM is configured to use a Linear absolute feedback transducer Position Valid is automatically set whenever a correct transducer signal is received When A Quad B encoder feedback is used the Position Valid status 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 0 10 or a AQ Move command 27h is executing on that axis On a two axis Pow er Mate APM executing a multi axis program will set both Program Active bits Moving The Moving status bit is set when commanded velocity is non zero otherwise it is cleared All Positioning Move Continuous Move Jog and Move at Velocity commands will cause the Moving bit to be set The Force D A Output command will not set the Moving bit In Zone The In Zone status bit indicates that the position error is equal to or less than the configured In Position Zone value This condition occurs at the end of each Positioning Move command or any time the axis commands are halted and the ac
37. Switch CTL06 I O Connector B m Axis 2 Home Switch 04 Axis2 Positive Overtravel Switch CTL07 m Axis 2 Negative Overtravel Switch CTL08 Optically Isolated with the following specifications m Optically isolated DC source sink bidirectional input optocoupler Input ON threshold 18 0 V to 30 0 V Input OFF threshold 0 V to 4 0 V Input resistance 5000 10 Input filtering 5 ms nominal Isolation voltage 1500 V peak transient 5000 OHMS 245110 gt A A e e MfIA allis KS Vs Ne OPTICAL 4 COUPLER 4 5000 OHMS gt A A e o 4 Mf LIA 2s KS s le OPTICAL T e COUPLER 5000 OHMS gt M e UE 4 ME A Vs d 1 ji benda d INCOM gt COUPLER 0v NOTE O Connector A is shown INCOM on Connector A is isolated from INCOM on Connector B Figure C 5 General Purpose Input Circuitry GFK 0840D AppendixCSpecifications C 5 General Purpose Outputs m CTLO9 m CTL10 m m CTL12 5V signal level 5V power generated by PM APM m Driver is a CMOS buffer with 20 Ohm Output Impedance m Suitable for driving indicators or logic inputs Mustnotbe used to drive inductive loads including relay coils 45109 Pe 47 5 T DBIVER CTLO9 OUTPUT me 47 5 gt CTL010 OUTPUT cos 4
38. VE a Programmer Command 1 8 O OK LED Open Loop Mode 8 15 Operand Field Program Zero Operand Fields Motion Programmer 1 7 Operations Overview 1 3 Ordering Information E 1 Other Considerations 6 6 Other Programmed Motion Consider ations Out of Sync b 7 Overtravel Limit Switch Overview of PM APM Operations P Parameter Download Using COMM REQ Parameters for Programmed Moves Parameters in the PM APM 6 32 Parity Pin Definitions of the Serial COMM Con nector 2 3 PLC Configuration Complete I Status Bit lA PLC Control Active I Status Bit 4 4 PMOVE Command Program Zero Motion Programmer Command 1 8 Position Error Limit 8 6 Position Feedback Types Position Increment AQ Immediate Com mand fia 1d Index 5 Index Index 6 Position Increment Command 6 6 Position Initialization Position Loop Time Constant Position Strobe I Status Bit 4 Position Valid 1 Status Bit Positioning Move PMOVE 6 11 Positive End Of Travel 8 6 Power Up Prerequisites for Programmed Motion 6 8 Program Active 1 Status Bit Program Zero Program Zero Commands Program Zero Programmer Instruction Format Operand Field 5 12 Program Zero Programmer Intstruction Format Command Name Field 3 10 Program ZeroCommands BLOCK Programmed Moves R Rate Override AQ Immediate Com mand 8 6 Ref Adr Reset Strobe Flag Q Disc
39. VELOC 85000 ACCEL 100000 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 0840D Chapter 6 Power Mate Motion Control 6 25 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
40. When this LED is ON the servo drive for Axis 2 is enabled On a 1 Power Mate APM this LED is ON only when a Force D A Immediate command is used for the analog out put on Connector B Serial COMM Connector The Power Mate APM Front Panel contains a single 15 pin female D connector for serial communications It is used to connect the computer running the Motion Programmer software to the Power Mate APM The Power Mate APM port uses the GE Fanuc propri etary SNP protocol and is RS 485 compatible 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 ft cable is available for this purpose The port is configured using the Logicmaster Configuration Package or the 90 30 PLC Hand Held Programmer 2 2 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D GFK 0840D The pin definitions for the Power Mate APM serial port are listed below Table 2 1 Pin Definitions of the Serial COMM Connector Pin Signal Description Pin Signal Description 1 Shield CableShield 9 RT 120 Ohm Termination for RXD A 2 DCD A Carrier Detect 10 RD A Receive Data 3 DCD Carrier Detect 11 RD
41. before the Midpoint 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 Standard Mode User s Manual August 1996 GFK 0840D s Example 14 SCURVE Jumping to a Higher Velocity While Acceler ating or Jumping to a Lower Velocity While Decelerating In this example a JUMP command is triggered during the initial phase of acceleration before the first dotted line and the velocity at the jump destination is higher than that of the current move The first dotted line indicates the maximum acceleration of the first CMOVE This value is held as the axis continues to accelerate until it 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 t
42. configuration parameters are defined and briefly described here Table 3 3 Axis Configuration Data Configuration Description Values Defaults Units Parameter Drs foi p f mere Constant 0 1010000 m Rev Comp Reversal Compensation 0 255 _ Home Posin Home Position 8358608 838807 0 sermi Hoon fie ime Oe vane rei Find in Vd Find Home Mode HOMES W MOVEH HOMESW LEN MOVE Posn Offset Position Offset 8 388 608 8 388 607 o userunis Transducer Gradient 8500 12000 9050 TransducerReciroulations 1 128 Scaling dependent configuration parameter value range depends upon user scaling User Units Counts The ratio of User Units to Counts sets the number of programming units for each feedback count This allows the user to program the Power Mate APM in units appropriate for the application The RANGE for user units and counts is 1 to 65 535 The RATIO of user units to counts must be in the range 8 1 to 1 32 For example if there is 1 000 inch of travel for 8000 feedback counts a user units counts ratio of 1000 8000 sets 1 user unit 0 001 inch Default is 1 1 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D GFK 0840D OT Limit Sw Selects whether the Power Mate APM uses the hardware Overtravel Limit Switch inputs If Limit Switches are DISABLED the Limit Switch inputs may be used as
43. following the JUMP command is executed 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 OFF 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 multi axis 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
44. graph shows a 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 Standard Mode User s Manual August 1996 GFK 0840D s Example 4 Hanging the Power Mate APM When the Distance Runs Out 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 0840D Chapter 6 Power Mate Motion Control 6 15
45. lost when motor shaft rotation causes the encoder to pass a reference point similar to a marker signal within one revolution of the motor shaft The diagram below describes this situation as well as the state of the DS internal signal The signal DS is not directly available to the user but serves to illus trate the sequence of events The DS signal indicates that absolute position data is available If no battery pack is used DS will be reset on each power cycle Absolute Data in One Revolution Incremental Data 2 e Power ON Reference Point Reference Point Encoder Counts prior to ye This Point are Lost DS GFK 0840D G 1 Note The a Series digital encoder must be rotated up to one full revolution after the absolute mode battery has been reattached Within one revolution the encoder will reference itself and report a referenced status DS 0 to the Power Mate APM The encoder will set it s internal counts accumulator to zero at the point where DS switches to a logic zero Counts accumulated prior to the DS transition are lost Serial Encoder Modes The a Series pulse encoders can be operated in either Incremental mode or Absolute mode The Incremental mode is selected by setting the Power Mate APM s Logicmaster 90 30 configuration field Inter Mode Integrator Mode to OFF or to IN ZONE Absolute mode is selected by setting the Power Mate APM s Logicmaster 90 30 configuration field I
46. ly even during servo motion IN ZONE means the integrator only runs when the In Zone status bit is set Default OFF When Digital Servo Mode is selected the position error integrator is not used The Inte grator Mode field is used to configure Incremental or Absolute feedback type for the digital serial encoder OFF or IN ZONE means that feedback counts from the serial en coder will be interpreted as INCREMENTAL counts encoder battery alarms are not re ported CONTINUOUS means the serial encoder feedback will be considered as ABSO LUTE battery alarms will be reported See Appendix G for more information about using absolute mode encoders Rev Comp Reversal Compensation User Units A compensation factor which allows the servo to reverse direction and still provide accurate positioning in systems exhibiting backlash Default 0 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D DisDly ms Servo Drive Disable Delay milliseconds The time delay from zero veloc ity command to the drive enable output switching off Disable Delay is effective when the Enable 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 dur ing a Jog operation Default 1000 Jog Acc Jog Acceleration Rate User Units second second
47. number of a parameter 0 255 as appropriate for the configured command Parameters 1 20 can be loaded with data using the LOAD P command Table 3 4 Program Zero Motion Program Commands Command Definition Range Default Name NULL Do nothing 0 0 BLOCK Define Block Number 1 65 535 1 BLOCK SYNC Define Synchronous Block Number 1 65 535 1 CMOVE AL Continuous move Absolute Linear 8 388 608 8 388 607 1 CMOVE AL P Continuous move Absolute Linear Use 0 255 1 data in Parameter CMOVE AS Continuous move Absolute S curve 8 388 608 8 388 607 1 CMOVE AS P Continuous move Absolute S curve Use 0 255 1 data in Parameter CMOVE IL Continuous move Incremental Linear 8 388 608 8 388 607 1 CMOVE IL P Continuous move Incremental Linear 0 255 1 Use data in Parameter CMOVE IS Continuous move Incremental S curve 8 388 608 8 388 607 1 CMOVE IS P Continuous move Incremental S curve 0 255 1 Use data in Parameter PMOVE AL Positioning move Absolute Linear 8 388 608 8 388 607 1 PMOVE AL P Positioning move Absolute Linear Use 0 255 1 data in Parameter PMOVE AS Positioning move Absolute S curve 8 388 608 8 388 607 1 PMOVE AS P Positioning move Absolute S curve 0 255 1 Use data in Parameter PMOVE IL Positioning move Incremental Linear 8 388 608 8 388 607 1 PMOVE IL P Position
48. offset entered with this command the Update Flash Memory AQ command must also be used Normally the Absolute Feedback Offset is calculated automatically by the Set Position or Find Home commands Refer to Appendix D Serial Encoders for additional information Set Configuration Complete This command sets the Configuration Complete 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 AQ commands were used to override Power Mate APM configuration data programmed with the PLC configuration software Update Flash Memory This command copies important RAM data including Motion Programs and the latest Absolute Feedback Offset into Flash memory Normally the Update Flash Memory command is sent after a Set Position or Find Home operation when an Absolute Digital Encoder is used Updating the Flash memory permanently saves the Absolute Feedback Offset so that Actual Position can be restored correctly after a system loss of power Refer to Appendix D Serial Encoders for additional information Load Parameter Immediate This command is executed from the PLC to immediately change an Power Mate APM parameter value Parameters are only used by motion programs A command for each parameter change is required GFK 0840D Chapter 4 A
49. physical position before positioning control is allowed This position alignment can be accomplished using the Set Position AQ Immediate command described in Chapter 4 or the Home Cycle described later in this chapter under Non Programmed Motion The Home Cycle makes use of the encoder Marker channel which is a once per revolution pulse produced at a known encoder shaft angle Successful completion of the Home Cycle or a Set Position command causes the Power Mate APM to set the axis Position Valid I bit Position Valid must be set before motion programs will be allowed to execute Position Valid is only cleared by an encoder Quadrature Error Quad A and Quad B switching at the same time or by turning on the Find Home and Abort Q bits simultaneously GFK 0840D 6 1 L5 Linear Absolute Transducer Linear Absolute transducers for use with the Power Mate APM provide an output signal that has constant frequency and variable on time The on time of the signal represents the absolute position reported by the transducer The Power Mate APM continuously measures the on time to update the AI Actual Position data Because the transducer provides an absolute position the Position Valid I bit is automatically set by the Power Mate APM as soon as a valid signal is received from the transducer If the transducer signalis lost for more than 20 milliseconds the Power Mate APM will report a Loss of Feedback error and stop all motion until the error is cl
50. ported 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 A command of 32 000 will produce an output of 10 V and 32 000 will produce an output of 10 V In Digital mode a D A Output value of 4095 will produce a motor output of 4095 RPM and 4095 will produce a motor output of 4095 RPM GFK 0840D Chapter 4 Automatic Data Transfers 4 13 The Enable Drive Q bit must be active with no other motion commanded for the Force D A Output command to operate Force D A output is the only continuous AQ immediate com mand It must remain continuously in the AQ data for proper operation Thus any other immediate command will remove the Force D A command For the single axis Power Mate J only a Force D A Output immediate command and a D A Output value in the AQ Words 3 5 will operate the analog output on I O connector A A D A Output value of 32000 will produce 10 00 Vdc and a D A Output value of 32000 will produce 10 00 Vdc Position Increment With Position Update user units This command is similar to the Position Increment without position update command 21h except that Actual and Commanded Position returned in AI data are both updated by the increment value If the servo is enabled the Power
51. s Manual August1996 GFK 0840D s The following profile would appear if the CTL bit turned on during the first PMOVE at the dotted line and the Jog Acceleration was 75000 Because the first move completed early due to the CTL bit and a faster acceleration Jog Acceleration versus programmed acceleration the second move would not have to move as far to get back to 0 position as it did in the DWELL example Note that because the motion 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 ABS LINEAR V 245268 Figure 6 11 Jump Stop GFK 0840D Chapter 6 Power Mate Motion Control 6 23 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
52. 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 correct value The range for Velocity at 10 Volts will depend upon the user scaling The allowed range is 400 user units counts lt Velocity at 10 Volts lt 1 000 000 user units counts For digital servos he Velocity at 10 v configuration field should be set to a conversion constant value of 139820 multiplied by the decimal value of the User Units to Counts ratio For example with a User Unit value of 1 and a Counts value of 2 the decimal value of the ratio would be 0 5 The conversion constant multiplied by 0 5 yields the value 69910 for the Velocity at 10 v 1 2 139820 69910 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 L
53. to a program block using the strobe position as the destination of a CMOVE or PMOVE command Commanded Velocity Commanded Velocity user units sec is a value generated by the Power Mate APM that indicates the instantaneous velocity command that is producing axis mo tion At the beginning of a move it will increase at the acceleration rate and once the pro grammed velocity has been reached it will stabilize at the programmed velocity value Actual Velocity Actual Velocity user units sec is a value maintained by the Power Mate APM that is derived from the feedback device Therefore it represents the velocity of the axis movement Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D Position Error Position Error user units is the difference between Commanded Position and Actual Position at any instant in time Analog Input Analog Input returns the digital value representing the voltage applied to the analog input terminal 10 V is indicated by 32 000 and 10 V by 32 000 The Analog Input is not available in Digital mode because faceplate connector B is used for the Digital Servo Interface module communications cable GFK 0840D 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 c
54. used to select the reporting of alternate data in the Commanded Position location 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 If Actual Position moves past either of the count limits it will roll over to the other limit and continue in the direction of the axis motion Strobe Position Strobe Position user units contains the axis position when a Strobe Input occurs When a Strobe Input occurs the Position Strobe bit is set to indicate to the PLC that new Strobe data is available in the Strobe Position status word The PLC must set the Reset Strobe Flag Q bit to clear the Position Strobe I bit Strobe Position will be maintained and will not be overwritten by additional Strobe Inputs until the Position Strobe 1 bit has been cleared If the Reset Strobe Flag output is left in the On state thus holding Position Strobe input flag in the cleared state then each Strobe Input that occurs will cause the axis position to be captured in Strobe Position The axis 1 Strobe Position is also placed in parameter 255 for use within motion programs In a 2 axis Power Mate APM the axis 2 Strobe Position is also placed in parameter 254 This feature allows the strobe input to trigger a Conditional JUMP
55. 0 CTL11 Output B3 22 CTL10 Output A4 9 CTLO9 Output B4 15 Common for CTL04 07 08 Inputs AS 2 Overtravel 2 direction CTL08 Input B5 14 Overtravel 2 direction 07 Input A6 1 Home 2 CTL04 Input B6 16 Enable Relay 2 Output 7 3 Enable Relay 2 Output B7 17 Analog Output 2 Velocity Command Common 8 4 Analog Output 2 Velocity Command B8 21 OV A9 8 5 V Output B9 20 Encoder Channel Z2 Linear Feedback 2 input 10 7 Encoder Channel Z2 Linear Feedback 2 input B10 19 Encoder Channel B2 All 6 Encoder Channel B2 Bll 18 Encoder Channel A2 12 5 Encoder Channel A2 B12 13 Cable Shield 25 no connection Fused Output an external source applied to this output could open the fuse Chapter 2 Installing the Power Mate 2 9 Functional Connection Diagrams The Figures below illustrates how the 1 and 2 Axis Power Mate APM I O are connected to a drive and a machine in a typical application Shielded cable should be used as indi cated Functional Connection Diagrams for the 1 Axis Power Mate APM VO CONNECTOR 245313 VO TERM BLK CONN TERM DRIVE AXIS 1 d VEL MOTOR B7 17 X CMDS A7 3 ENABLE B6 16 ENT ov B12 13 ce 1 NOTE FOR SINGLE ENDED B11 18 A1 a AUR ENCODER DO NOT A12 5 Al 11 A1 CONNECT A1 B1 Z1 B10 19 Bi 1 1 11
56. 015 are often specified Custom LDTs may be ordered for certain radial motion applications There is a large selection of mounting options output types and resolutions available when ordering LDTs The magnet of a vertically positioned LDT may even be mounted in a floatation device to measure liquid level LDT used to provide feedback to the Series 90 30 Power Mate APM must be specified as TEMPOSONICS II DPM Digital Personality Module with Internal Interrogation or compatible Additionally an external power supply may be required to power the LDT electronics Accuracy Resolution and Response Considerations To specify and use a particular LDT for an application requires an understanding of some terminology particular to this type of transducer The DPM option specified above will convert the LDT pulse duration to a differential TTL RS422 line driver signal The logical ON duration of the differential TTL signal is proportional to the position of the magnet along the rod of the transducer The Power Mate APM measures the ON time of the LDT output and converts the duration of the signal to a position or distance Physical Length The LDT you specify as a certain stroke length will actually be several inches longer than you need The waveguide portion of the rod has a Dead Zone 2 5 inches nominal for TEMPOSONICS at the tip and a Null zone nominal 2 inches for TEMPOSONICS II from the mounting flange end The additional length of the ro
57. 02 4 9 Table 4 7 Immediate Commands Using the 6 Byte Format for both 1 and 2 AxisPower Mate APM 4 12 Table A 1 Status Word Error Codes 2 2 2 A 2 Table C 1 I O Cable Wire Coding for IC693CBL311 and IC693CBL319 C 8 Table C 2 I O Cable Wire Coding for IC693CBL317 and IC693CBL320 C 9 lable F 1 Sources tor EDS eel Ee Pu be dhe F 5 GFK 0840D Table of Contents ix Chapter 1 Introduction The Power Mate APM is a high performance easy to use 1 or 2 axis motion control module 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 Standard control loop mode For in formation on the operation of the Power Mate APM in Follower control loop mode refer to GFK 0781 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual Features of the Power Mate APM GFK 0840D High Performance a EN1 STAT m Fast Servo Loop Update 1 ms for IC693APU301 EN2 2 ms for IC693APU302 CFG m Block Processing time under 5 ms m Velocity Feed forward and Position Error Integrator to AXIS
58. 4 seconds Thus to allow an acceleration of 100 during acceleration and deceleration three moves will be required The second program and profile those on the right show how the first program can be broken into three parts The distance at the midpoint of each acceleration when velocity is 6000 is calculated to be 180 000 one fourth the distance required to accelerate to 12000 An initial CMOVE uses this distance The next CMOVE will then accelerate to its velocity at the same acceleration rate The final PMOVE is the midpoint distance 180 000 user units from the 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 845312 V 345314 LoS t t Figure 6 16 Maximum Acceleration Time Feedhold with the Power Mate APM 6 28 Feedhold is used to pause program execution without ending the program often to examine some aspect of a system It causes all axis motion to end at the programmed acceleration When feedhold is ended program execution resumes Interrupted motion will resume at the programmed acceleration and velocity Feedhold is asserted by turning ON the Feedhold Q bit and lasts until the Q bit is turned OFE T
59. 6 B1 I B1 AXIS 1 B9 20 21 Lg 21 ENCODER Ato 7 zi Xu 21 AQ 8 5V 5 AXIS B8 21 ov X it x ov LOAD NEGATIVE POSITIVE OVERTRAVEL O OVERTRAVEL LIMIT SWITCH HOME SWITCH LIMIT SWITCH gt AS 2 OT CTLO6 AG 1 Homer rers 4t Ht B5 OT CTLO5 is 1 5 24VDC m i SHIELD B3 25 STROBE CTLO1 5V M 9 STROBE CTLO1 X lt DRIVER 12 9v GENERAL PURPOSE 5V INPUTS B2 23 STROBE 2 CTLO2 d 5V 10 STROBE 2 X DRIVER Iw Figure 2 4 Functional Diagram for 1 Axis Power Mate APM I O Connector A 2 10 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D CONNECTOR B 245120 TERM BLK S TERM of GENERAL PURPOSE 24V SWITCH INPUTS i CTLO4 B5 14 CTL07 24VDC 8 5 CTLO8 INCOM2 CTLO9 A4 9 0105 _ CTLO10 B3 22 4 p CTL011 CMOS CTL012 gt B8 21 A p 4 VEL FON VELCOM GENERAL PURPOSE B7 E ANALOG OUTPUT EN2 WITH 7 P ENABLE RELAY B6 16 EN2 B12 13 SHIELD E m AINA GENERAL PURPOSE A2 11 AN ANALOG INPUT QU Figure 2 5 Functional Diagram for 1 Axis Power Mate APM I O Connector GFK 0840D Chapte
60. 7 I O Cable 3 feet 1 meter w external shield wire IC693CBL320 Consists of a 24 pin IO connector a cable and 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 0840D E 1 Appendix LDT Interface TEMPOSONICSS II or LDT Interface to Power Mate Release 2 10 of the Series 90 30 Power Mate APM catalog numbers IC693APU301 302 firmware includes an LDT interface or LINEAR feedback option The LINEAR feedback option is for the STANDARD control loop and will not work in FOLLOWER mode This appendix explains what an LDT interface is and how to specify one for use with the Series 90 30 Power Mate APM TEMPOSONICS II is a brand name for a device more commonly known as a linear displacement magnetostrictive transducer LDT An LDT is a sealed stainless steel tube constructed to contain a waveguide A conductor is threaded coaxially through the waveguide Electronics at one end of the waveguide tube transmit accurately timed interrogation pulses down the conductor and measure the amount of time required for the i
61. 7 5 HORNER _ CTL011 OUTPUT 47 5 CMOS __ CTL012 OUTPUT Figure C 6 General Purpose Output Circuitry C 6 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Analog Input 12 bit plus sign A D converter with the following specifications m Input range 10 0 V Input impedance 50 k Q m Common mode range 20 V m Resolution 12 bits magnitude plus sign bit m Linearity lt 1 LSB Accuracy 2 of reading 4 LSBs Scale Factor 10 0 V 32 000 10V 32 000 m Update Rate 16 ms does not include PLC scan time 51K 20K a45108 ANALOG IN AA A e TO A D 51K CONVERTER ANALOG IN 20K ov Figure C 7 Analog Input Circuitry 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 C 1 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 lt _ 3 METERS 245119 Le 7 0 I lo 9o 9 o 09 nO 29 m 02 34e y 0 vO TERMINAL BLOCK CONNECTOR CONNECTOR Figure C 8 I O Connector Cable Specifications GFK 0840D AppendixC Specifications C 7 l O Cables An IO
62. 96 MHz 305 8 Note Truncate the value for Rt to the integer In the above example truncate 305 8 down to 305 counts inch Logicmaster will calculate this value automatically This example is included to illustrate how the counts inch value is achieved TEMPOSONICS is a registered trademark of MTS Systems Corporation Quick Stik 15 a trademark of GEMCO Inc Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D Appendix Serial Encoders G Serial Encoder Models There are three pulse encoder models that will function with the Power Mate APM 8K 32K or 64K counts per revolution All encoders return position information in the form of a 32 bit value To maintain equal number of counts scaling per motor revolution the 8K encoder position increments its absolute position word data by eight counts whereas the 32K encoder increments its data by two counts and the 64K encoder increments its data by one count However the Power Mate APM overrides these additional count inputs thus 8K 32K and 64K encoders are identical for a Power Mate APM The Power Mate APM will always sense 8192 counts per motor shaft revolution from a serial encoder The one million count 1M encoder is not supported Serial Encoder First Time Use or Use After Loss of Encoder Battery Power The encoder temporarily provides incremental data during the first use or after restoring encoder battery power The incremental data is
63. A leading Channel B indicates motion in positive direction a45338 Motion in Positive Direction Motion in Negative Direction cna LOT L LT L GFK 0840D AppendixCSpecifications C 3 Strobe Inputs m Input Type 5V differential or single ended Input Impedance 4000 Ohms common mode m Input Threshold Single ended 1 5 V nominal 0 4V Differential 0 5 V nominal 0 4V Input Common Mode Range 15 V m Single Ended Input Voltage 15 V maximum m Minimum microsecond pulse width is required A pulse on the strobe input causes the latest value of Actual Position to be reported in the Strobe Position portion of AI data Position Capture Delay 0 to 1 ms IC693APU301 0 to 2 ms APU302 a45272 LINE 2K RCVR 2K 0v 0 75V Figure C 3 Encoder and Strobe Input Circuitry Encoder Power m 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 40C 300 mA 55C a45112 IN OUT 5V ENCODER REG POWER ov ov Figure C 4 Encoder Power Circuitry 4 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D General Purpose 24 VDC Digital Inputs I OConnector A m Axis 1 Home Switch CTLO3 m Axis1 Positive Overtravel Switch CTL05 m Axis 1 Negative Overtravel
64. 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 A maximum a45106 E ENABLE c IPEA OPTICAL COUPLER gt ENABLE Figure C 2 Enable Relay Output Circuitry C 2 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Encoder Inputs Input Type 5V differential or single ended Input Impedance 4000 common mode Input Threshold Single ended 1 5 V nominal 0 4V Differential 0 5 V nominal 0 4V Input Common Mode Range 15 V Single 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 Quadrature Tolerance 90 degrees 30 degrees Quadrature Error Detection Simultaneous transitions on the Channel A and Channel B inputs will be detected as loss of quadrature 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 microseconds Encoder direction of travel Channel
65. Control of Fanuc digital servos using Power Mate J Digital Servo Interface module Firmware Compatibility Tables 1 Axis Power Mate APM Released PLC Motion Motion Firmware Control Loop PowerMate Programmer Programmer Programmer Version CatalogNumber Capability APMManual Version Version Manual 1 00 1 10 ICG93APU301A D GFK 0707A 3 50orlater 1 01orlater GFK 0664 2 02 IC693APU301E H Standard GFK 0840 4 01 or later 1 50 or later GFK 0664A Follower GFK 0781 2 11 IC693APUS301J Standard GFK 0840 6 01 orlater 1 50 or later GFK 0664A Follower GFK 0781 2 50 IC693APU Standard GFK 0840 6 01 orlater 1 50 or later GFK 0664A Follower GFK 0781 The I axis Power Mate APM firmware release 2 02 requires PLC Programmer version 4 50 or later to allow configuration in Follower mode 2 Axis Power Mate APM Released PLC Motion Motion Firmware Control Loop Power Mate Programmer Programmer Programmer Version Catalog Number Capability APMManual Version Version 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 0664A 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 Standard Mode User s Manual August 1996 GFK 0840D Overview of Power
66. E representing motion in the opposite direction m When a CMOVE is active and the Jump destination block contains a CMOVE or PMOVE representing motion in the same direction with insufficient distance for the axis to stop m When a CMOVE is active and the Jump destination block contains 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 Motion Control 6 19 6 20 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 comman
67. FANUC GE Fanuc Automation PowerMotion Products Power Mate APM for Series 90 30 PLC Standard Mode User s Manual GFK0840D 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
68. KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK 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 Be Be eR Me Re SEND 70001 _ NOTE SYSID HIGH BYTE COMM_REQ RACK DESTINATION SYSID LOW BYTE COMM_REQ SLOT DESTINATION HDR_WDS RO196 TASK ALWAYS 0 FOR COMM_REQ CONST SYSID 0007 CONST TASK 00000000 GFK 0840D Appendix B Parameter Download Using COMM_REQ B 3 Appendix 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 104F derated to 300 mA 55C 131F Maximum Numberofmodules system Model 311 313 321 323 PLCs 31C693APU301 modules in CPU baseplate limited by power supply 21C693APU302 modules in CPU baseplate limited by AI data Model 331 PLC 81C693APUS01 or 4IC693APU302 modules in CPU expansionand remote baseplates limited by AI data Maxim
69. MHz 16 896 MHz for APU301 302 Example Rt 3 recirc 9 05nsec in 16 896 MHz 458 ct in Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Temperature coefficient Expressed as PPM or is the degree to which the output signal and therefore the indicated position is affected by ambient temperature changes For example given LDT with less than or equal 40 PPM C temperature coefficient at 20C ambient outputs a value for 6 inches Should the ambient temperature increase 10C the same LDT at the same position would indicate a position change of less than or equal 0 0024 inches 6 0 00004 The temperature induced offset remains repeatable to within indicated resolution at the new constant temperature Non Linearity Hysteresis and Repeatability These factors may also be a consideration to overall system performance Non linearity is basically the deviation in full scale travel from one end of the rod to the other Hysteresis is the difference in indicated position when the same point on the rod is reached from two different directions Repeatability refers to the difference in position indicated when the same point on the rod is reached from the same direction with different moves Table F 1 Sources for LDTs Name of Company Type of LDT to Specify MTSSystemsCorporation 919 677 0100 TEMPOSONICS Research Triangle Park NC DPM Internal Interrogate GEMCO 810 435 0700 Quick
70. 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 Jn 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 value set by this command will be lost and the In Position zone value set by configuration software will be reinstated Move Command This command will produce a single move to the commanded position each time it is sent The current Jog acceleration and velocity which can also be changed by AQ commands will be used for the move The data field for this command may contain the move position or distance in bytes 2 5 with the command type in hexadecimal format as defined below Move Type byte 1 00h Abs Pmove Linear 01 Abs Cmove Linear 10h Abs Pmove S 11 Abs Cmove 40h Inc Pmove Linear 41h Inc Cmove Linear 50h Inc Pmove S 51 Inc Cmove S The data field for this command may contain a parameter number in byte 2 bytes 3 5 unused with the command type in hexadecimal format as defined below Move Type byte 1 80h Abs P
71. RENCE 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 R0195 RO200 NO USE1 NOT USED ZEROED BY BLKMV RO201 NO USE2 NOT USED ZEROED BY BLKMV RO202 CMDTYP COMMAND TYPE E501 FOR PM 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 0840D B 1 OE E OK CK A AAA AAA AA 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 OK OK KE OK KAA AAA 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
72. Receive Data 4 ATCH HHP Attach Input 12 SD A Transmit Data 5 5 V 5 V HHP 422 232 13 SD B TransmitData Converter Power 6 RTS A Ready to Send 14 RTS Ready to Send 7 OV 0 V Signal Common 15 CTS A Clear to Send 8 CTS B Clear to Send Chapter 2 Installing the Power Mate APM 2 3 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 sys tem a45254 Included in Mniconverter Kit IC690ACC901 Multidrop Multidrop Mini Cable Cable Converter 1 sq RS 232 2 2 3 Power Mate Power Mate PC CPU APM APM Logicmaster PLC Figure 2 1 Connecting Power Mate APM Modules in a Multidrop Configuration The multidrop cable should be made according to the following diagram PIN PIN 845251 50 Sb 10 E 10 RD A E SD B 11 E P 11 0 0 RD A 12 4 12 SD A gt o 13 aa 13 SD B ES ICTS 6 r4 6 E gt 0 9 ICTS B 14 Lg Lg 14 RTS B KG 0 RTS A 15 dg dg 15 CTS A LK 00 5 8 8 CTS KG 00 5 5 i 5 5 0 GND 7 e
73. Stik II Series 951VP Clawson MI Variable Pulse Internal Balluff 606 727 2200 2 1 Florence KY pulse width recirc Internal How to select an LDT for interface to the Power Mate APM APU301 302 GFK 0840D Begin with the known requirements for the application D required stroke length E resolution needed divide this value by two to increase output stability E update time required less than 3 6 milliseconds preferred for Power Mate APM Example An application has a required stroke length of 24 inches The desired resolution is 0 0linches divided by two to increase stability 0 005inches It is necessary to calculate the LDT update time from the first two variables 1 Divide the stroke length by the desired resolution to calculate the minimum number of counts required Example 24inI 0 005in count 24 800 counts Note This result must not exceed the 16 bit count 65 535 ability of the Series 90 30 Power Mate APM linear counter input Use a lower resolution if necessary 1 2 Calculate number of recirculations from the formula Recirculations G F R Example 11 9 05 16 896 MHz 0 005 in 1 3 round up to 2 Note Round the result of the recirculation calculation up to the next integer Appendix F LDT Interface F 5 F 6 3 Calculate LDT update time from the formula DZ 5 N C G 1000 Update milliseconds Example
74. Travel Limit and the Drive Enable Relay was immediately turned OFF because of the error the servo would continue moving until it coasted to a stop Thus to allow the Power Mate APM to command and control a fast stop the Drive Disable Delay should be longer than the deceleration time of the servo from maximum speed Chapter 3 Configuring the Power Mate APM 3 17 Chapter Automatic Data Transfers 4 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 Status Bits 32 bits of I data Status Words 15 words of Vo AT data for a 1 axis Power Mate APM 28 words of Vo AT data for 2 axis Power Mate APM Output Command Data Transferred from CPU to Power Mate Discrete Commands 32 bits of Q data Immediate Commands 6 words of AQ data GFK 0840D 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 Setup Data The bit num bers listed in the following table are offsets to this starting address Table 4 1 l Status Bits for the 1 Axis Power Mate IC693APU301 00 Ans Tabled 16 Front P
75. When a new Block Number becomes active AFTER a Conditional JUMP command Jump testing occurs one more time Motion Program Example Begin Program 1 CMOVE 1 20000 ABS LINEAR JUMP 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 Standard Mode User s Manual August 1996 GFK 0840D GFK 0840D 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 PMOWV
76. a CTL Block Number n a JUMP CTLO1 CTL12 1 65 535 Unconditional Dwell Axis Milliseconds 0 60 000 or n a n a DWELL 1 2 Parameter Number 0 255 Load Parameter n a Parameter Number 0 255 Parameter Value n a LOAD 32 bit maximum Null n a n a n a n a NULL Positioning Move Axis USER UNITS Positioning Mode Acceleration Mode PMOVE 1 2 8 388 608 8 388 607 or ABS INCR LINEAR SCURVE Parameter Number 0 255 Velocity Axis USER UNITS sec n a n a VELOC 1 2 1 8 388 607 or Parameter Number 0 255 Wait Axis CTL n a n a WAIT 1 2 CTLO1 CTL12 Absolute Moves ABS must specify a position within the End of Travel AND Count Limits or a stop error will occur when the move command is executed Parameters 246 255 are reserved special purpose parameters Load Parameter can load data into these parameters but the Power Mate APM may overwrite its own data into these 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 APM only 253 Stores Axis 1 Commanded Position user units when Follower Enable Triggeroccurs 254 Stores Axis 2 Strobe Positionvalue user units 2 Axis Power Mate APM only 255 Stores Axis 1 Strobe Positionvalue user units 1 8 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual Augus
77. a servo system Power Mate APM Motion Control This chapter provides practical ex amples illustrating how to program different types of moves jumps etc Error Codes Parameter Download Using COMM REO Specifications Wiring to SS 90 Drives Ordering Information LDT Interface Serial Encoders Related Publications GFK 0664 Series 90 30 Axis Positioning Module APM Programmer s Manual GFK 0781 Power Mate APM for Series 90 30 PLC Follower Mode User s Manual We Welcome Your Comments and Suggestions At GE Fanuc automation we strive to produce quality technical documentation After you have used this manual please take a few moments to complete and return the Reader s Comment Card located on the next page GFK 0840D iti Contents Chapter 1 INGOdUCHON is m 1 1 Features of the Power Mate 1 1 Firmware Compatibility Tables 1 2 Overview of Power Mate APM Operations 1 3 Overview of Motion Programmer 1 5 Motion Programmer Instruction Format 1 7 Chapter 2 Installing the Power Mate 2 1 Section 1 Description of the Power Mate APM 2 2 LED Indicators c ore vens E e eae eh 2 2 Serial COMM Connector 2 2 Multidrop Connection
78. ack ON No motion programs may be executed unless the Position Valid bit is ON GFK 0840D Chapter 6 Power Mate Motion Control 6 3 6 4 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 5 The axis is accelerated in the negative direction and moved at the configured Find Home Velocity until the Home Switch closes 6 The Power Mate APM continues negative motion at the configured Final Home Veloc ity until a marker pulse is sensed The marker establishes the Home reference posi tio
79. al August 1996 GFK 0840D Serial Communications Port Configuration Data The Power Mate APM can be programmed using the Motion Programmer software The computer running the Motion Programmer software connects to the Serial Communica tions 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 Communications Port Configuration Data are described in Table 3 2 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 DataBis Bits Number of data bits 7 Tas Tas ETC TT Modem turn around time 0 2550 in multiples of 10 milliseconds Maxmumiskideume 1 amp 0 SNP ID SNP ID 6 characters consisting of A F and A00001 n a 0 9 1st char must be A F GFK 0840D Chapter 3 Configuring the Power Mate APM 3 5 3 6 Axis Configuration Data Power Mate APM Axis Configuration Data consists of base values for configuration pa rameters used by one or more motion programs The values of these configuration pa rameters do not usually change therefore they are not included in the motion program The
80. am 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 executing a 2 axis program the program commands are scanned independently by each axis and only the data designated for that axis is executed Note that some commands do not specify an axis Block Jump Call and End and therefore will apply to both axes A 2 axis program can contain Sync Block commands to synchronize the 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 0840D Chapter 6 Power Mate Motion Control 6 7 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 Overtravel Limit Switches must be asserted if e
81. am Selected error 3B Status Only Move at Velocity while Home Cycle active error 3C StatusOnly Move at Velocity while Jog error 3D StatusOnly Move at Velocity while Abort All Moves bit is set error 3E StatusOnly Move at Velocity Data greater than 8 388 607 user units sec 3F StatusOnly Move at Velocity Data greater than 1 million cts secerror Jog Errors 40 StatusOnly Jog while Find Home error 41 StatusOnly Jog while Move at Velocity error 42 StatusOnly Jog while ForceD Aerror 43 StatusOnly Jog while Program Selected and not Feedholding error Status erroris reported command is not executed Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Table A 1 Status Word Error Codes Continued ErrorNumber Response Description Hexadecimal Force D A Errors 47 Status Only Force D A while Jog error 48 Status Only Force D A while Move at Velocity error 49 Status Only ForceD AwhileProgram Selected error Set Position Errors 50 Status Only Set Position while Program Selected error 51 Status Only Set Position Data overrange error 52 Status Only Set Position while not In Zone error 53 Attempt to initialize position before digital encoder passes reference point 54 Status Only Digital encoder position invalid must use Fin
82. am Zero Program Zero is a short default motion program 20 commands maximum which is defined in the configuration software and downloaded whenever the Power Mate APM is initialized by the PLC Program Zero is programmed by entering motion commands in an English language format similar to that of the Motion Programmer In a 2 axis module the Power Mate APM determines whether Program Zero is an axis 1 axis 2 or multi axis program according to which axis or axes are used in the program For example if all Program Zero commands contain Axis number 1 Program Zero will be classified as a Single Axis program for Axis 1 Therefore Program Zero will be allowed to execute concurrently with another Single Axis Program for Axis 2 The Program Zero commands are entered using the Function keys F1 F9 Paired with each command is a data field for entering either a signed integer or the number of an Power Mate APM parameter as appropriate for the configured command ra err Form gt y SERIES 98 38 MODULE IN RACK SLOT SOFTWARE CONFIGURATION Catalog IC693APU361 AXIS POSITIONING MODULE 1 AXIS PROGRAM PAGE 1 Command Data ACCEL 00000900300 VELOC B888884088 PMOVE AL 00000100900 VELOC 00000075060 PMOVE AL 00000000900 CNULL CNULL gt 9g00880008 lt lt More Config Data Exists PgDn for Next Page P
83. am reached the WAIT the second PMOVE would begin immediately when the first PMOVE finished Also if WAIT was used instead of DWELL in the previous example CMOVEs and PMOVEs would generate similar velocity profiles The WAIT will stop motion whether the previous move is a CMOVE or PMOVE Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D 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
84. an move forever ineither direction When a Count Limit is reached the reported position wraps around to the opposite limit where it can continue changing Thus if the Count Limits are set equal to or within the End of Travel Limits the End of Travel Limits will never be reached In 1 axis Power Mate APM release 1 xx firmware Count Limits are not used and MUST be set to zero in order to configure the Power Mate APM In Rotary mode Jogs or Incremental Moves can be used to cause continuous motion in either direction and the EOT limits will never be exceeded In EOT Mode Non Rotary Mode Jogs and Programmed Motions beyond either EOT limit are not allowed Rotary Mode selection is based on the relative values of Hi Lo Count Limits and the limits Power Mate APM will be in Rotary Mode if the Hi Count Limit is lt the Pos EOT limit AND the Lo Count limit is gt the Neg EOT limit The Power Mate APM will be in EOT Mode Non Rotary Mode if the Hi Count Limit is gt the Pos EOT limit OR if the Lo Count limit is lt the Neg EOT limit Rotary Mode is the DEFAULT operating mode for the Standard Control Loop because the default Count limits and EOT limits are 8 388 607 8 388 608 The Overtravel Limit Switches are external hardware switches The switch status is re turned in the CTL bits CTL05 CTL08 The Power Mate APM can be configured to use these CTL bits as Overtravel Limit Switches If the swit
85. ands 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 Power Mate APM Thus one command may be sent to each axis of the Power Mate APM every sweep The only exception is the Load Parameter Immediate command which is axis indepen dent This command may be sent using either or both sets of three words Thus two Load Parameter Immediate commands can be sent on the same sweep one in the first three AQ words and the other in the second three AQ words In a 1 axis Power Mate APM the only effective commands for the second set of AQ words are Force D A Output Analog Output 2 and Load Parameter Immediate 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 Table 4 7 The actual ad dresses of the Immediate Command Words depend on the starting address configured for the AQ references See Table 3 1 Module Setup 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 the Set Position command
86. anel Input CTLOI Status 1 Sate 06 Position Snobe Anis Panel Input CTLO7Staus E Confiuraion Compete foo esee E The bit numbers represent an offset to the starting address for I references 4 2 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Table 4 2 l Status Bits for the 2 Axis Power Mate APM IC693APU302 00 AxisEnabled Axis 16 Front Panel Input CTLO1 Status Strobe 1 State Front Panel Input CTLO2 Status Strobe 2 State Front Panel Input CTLO03 Status Home Switch 1 Front Panel Input CTL04 Status Home Switch 2 Front Panel Input CTLOS Status Overtravel 1 6 Postion robe Asi 22 Front Panel pot CTLOT Status Ovenravel2 0r 22 Axis Enabled Configuration Complete Poston Vaid 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 receive commands and control a servo An error condition which stops the servo will turn Axis Enabled OFE Position Valid The Position Valid status bit indicates that the value in the AI Actual Posi tion status word has been initialized by a Set Position command or successful completion of the Find Home cycle Position Valid must be ON in order to execute a motion program If the
87. ches are enabled whenever the drive is enabled and an Overtravel bit is OFF the Power Mate APM commands all mo tion on that axis to immediately cease If this happens the Jog and Clear Error Q bits can be turned on simultaneously to move the servo away from the Overtravel switch A Reversal Compensation feature onthe Power Mate APM allows accurate positioning on systems with backlash Backlash is exhibited by a servo that must move a small amount before the system begins moving when it switches directions For example consider a deadbolt door lock Imagine the servo controls the key in the lock and the feedback re ports movement of the bolt When the servo turns the key counter clockwise the bolt moves left However as the servo turns the key clockwise the bolt does not move until the key turns to a certain point The Reversal Compensation feature adds in the neces sary motion to move the servo to where motion will begin on the feedback device The Power Mate APM removes the compensation when a move in the negative direction is commanded and adds the compensation before a move in the positive direction The Servo Drive Disable Delay specifies how long the Power Mate APM will wait after a zero velocity is commanded before it turns OFF the Drive Enable output Because turning OFF the Drive Enable Relay stops the Power Mate APM from commanding the servo there are times when the relay should stay ON For example if the servo runs into an End of
88. cond The velocity at which the ser vo 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 ms filter time delay between the final Home Switch transition and the Encoder Marker pulse Default 500 Find Home Vel Find Home Velocity User Units second The velocity at which the servo seeks the initial Home Switch transitions during the Find Home cycle If desired Find Home Velocity can be set to a high value to allow the servo to quickly locate the Home Switch Default 2000 Posn Offset Absolute Position Offset User Units This configuration item is only used with absolute feedback devices LINEAR Posn Offset is used to adjust the absolute position read from the feedback device and reported as actual position in the Power Mate AI data Default 0 Gradient Transducer Gradient nanoseconds inch LINEAR feedback type only Gradient should be set to the calibration value for the transducer actually used A typical transducer gradient is 9 050 microseconds inch 9050 nanoseconds inch Default 9050 Recircs LINEAR feedback type only The value chosen for Recircs represents a mul tiplier for transducer resolution and update time A high value for recircs allows high resolution but may slow the transducer update time enough to degrade system stability Default 4 GFK 0840D Chapter 3 Configuring the Power Mate APM 3 9 3 10 Progr
89. connectors are Marshall at 800 522 0084 Milgray at 800 MILGRAY and Vantage at 800 843 0707 If none of these distributors 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 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Appendix D Wiring to SS 90 Drives When the Power Mate APM is used with the SS 90 Servo Digital 100 Digital 200 use the con nection diagram below The pin numbers shown correspond to the 25 pin female connector of the IC693CBL311 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 GFK 0840D FOLLOWER MODE ONLY 245252 E USER DEFINED PINS IC693CBL311 ENCODER OUT PIN P3 SHLD ey 7 1 B LI am
90. culate the number of recirculations to specify when ordering a particular LDT GFK 0840D Appendix F LDT Interface F 3 1 Recirculations G F R Where Gradient approximately 9 05ns per inch for TEMPOSONICS II F Crystal frequency of the counter 16 896 MHz for Series 90 30 Power Mate APM APU301 802 R Resolution desired in inches 1 Example 0 654 round up to 1 9 05nsec in 16 896MH2z 0 01in Update Time Update time is defined as the time interval between maximum update refresh of the LDT output With the Series 90 30 Power Mate APM crystal frequency and resolution fixed the update time is proportional to the number of recirculations and the total length of the LDT The update time for the LDT is calculated using the formula below Update Time milliseconds DELLI Where DZ Dead Zone of the waveguide 2 5 inches for TEMPOSONICS II S Stroke Length N Null of the waveguide 2 0 inches for TEMPOSONICS II C Number of Recirculations G Gradient approximately 9 05ns per inch for TEMPOSONICS II 2 5i 24i 2in 9 05 i 1000 Counts per inch The actual counts per inch resolution of a given LDT be calculated with the formula Rt O G F Where Rt Resolution of the LDT in counts per inch Number of circulations specified Gradient of the sensor in nsec inch F Frequency of the counter in
91. d another JUMP command or a CALL 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 bit is 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
92. d Home or Set Position End of Travel and Count Limit Errors 56 Status Only Commanded Position gt Positive End of Travel or High Count Limit 57 Status Only Commanded Position lt Negative End of Travel or Low Count Limit 58 Absolute Position Position offset gt Positive End of Travel or High Count Limit 59 Status Only Absolute Position Position offset lt Negative End of travel or Low Count Limit Drive Disable Errors 5B Stop Normal Drive Disabled while Moving 5C Stop Normal Drive Disabled while Program Active Software Errors 5F Status Only Software Error Call G E Fanuc Field Service Program and Subroutine Errors 61 Stop Normal Subroutine not in list 62 Stop Normal Call Error subroutine already active 63 Stop Normal Subroutine End command found in Program 64 Stop Normal Program End command found in Subroutine Program Execution Errors 70 Status Only Request Program 0 with other programs active 71 Status Only Too many programs requested in same PLC sweep 72 Status Only Request Program 1 10 with multi axis program active 73 Status Only Request two programs on same sweep with program active 74 Status Only Request two programs for same axis lower number program executed 75 Status Only Empty or Invalid Program requested Program Execution Conditions Errors 80 Status Only Execute Program while Home Cycle active 81 Status Only Execute Program while Jog 82 Status Only Execute Program while Move at Velocity 83 Status Only
93. d may be a mechanical or mounting consideration Resolution The smallest increment of a stroke that can be detected and indicated on the output of the LDT The resolution is also limited to the smallest signal interval that Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D can accurately be detected by the Series 90 30 Power Mate APM The Series 90 30 Power Mate APM APU301 or APU302 will sample the LDT interface at a 16 896 MHz rate yielding a 59 186 nanosecond counter resolution Gradient The rate at which pulses propagate through the waveguide of the LDT this is approximately 9 05 microseconds per inch 0 356 microseconds per millimeter for TEMPOSONICS but will vary slightly from transducer to transducer The gradient for any particular transducer will be indicated on the label affixed to the transducer The nominal gradient for a Balluff LDT is 8 90 microseconds per inch Recirculations circulations A process that improves the resolution of a LDT system The on time of the LDT pulse duration signal differential TTL signal from the DPM is multiplied by a specified factor of 1 128 This provides more counting time for the Power Mate APM improving resolution The LDT response slows in direct proportion to the number of recirculations The recirculation value for the LDT is specified when ordering a particular LDT or may be adjustable within the LDT The following formula will allow you to cal
94. 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 sending a NULL com mand or changed as desired Move at Velocity will not function unless the servo drive is enabled Q Enable Drive and 91 Drive Enabled are set The listing of AQ immediate commands shows the words in reverse order to make understanding easier For example to command a velocity of 512 user units per second in 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 When the Power Mate APM is performing a Move at Velocity it ignores the Software End of Travel L
95. der Channel 1 12 5 Encoder Channel 1 B12 13 Cable Shield 25 no connection Fused Output an external source applied to this output could open the fuse 2 6 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D GFK 0840D Table 2 3 Cable Connections to Faceplate 1 0 Connector B 1 Axis Power Mate APM Module Terminal Connector B Block Description Pin Number Terminal Number Al 12 OV Bl 24 Analog Input A2 11 Analog Input B2 23 CTL12 Output A3 10 CTL11 Output B3 22 CTL10 Output A4 9 CTLO9 Output B4 15 Common for CTL04 07 08 Inputs AS 2 CTLO8 Input B5 14 CTLO07 Input A6 1 CTL 04 Input B6 16 Enable Relay 2 Output 7 3 Enable Relay 2 Output B7 17 Analog Output 2 Common 8 4 Analog Output 2 B8 21 OV A9 8 5 V Output B9 20 Reserved A10 7 Reserved B10 19 Reserved All 6 Reserved Bll 18 Reserved 12 5 Reserved B12 13 Cable Shield 25 no connection Fused Output an external source applied 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 Axis Power Mate APM Table 2 4 Cable Connections to Faceplate I O Connector A 2 Axis Power Mate
96. e 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 4 Swing the module down until the connectors mate and the lock lever on the bottom of the module snaps into place engaging the baseplate notch 5 Refer to Figures 2 4 through 2 7 and Tables 2 2 through 2 5 for wiring requirements 6 Power up the PLC rack The Status LED of the Power Mate APM will turn ON when the Power Mate APM has passed its power up diagnostics 7 Repeat this procedure for each Power Mate 8 Configure the Power Mate APM module s as explained in Chapter 3 GFK 0840D Chapter 2 Installing the Power Mate 2 15 Chapter Configuring the Power Mate APM 3 The Power Mate APM is configured using the Logicmaster 90 30 configuration software Configuring the Power Mate APM is a two part procedure consisting of m I O Rack Configuration m Module Configuration Rack Configuration The Power Mate APM is configured using Logicmaster 90 30 software in the same way as other Series 90 30 modules The software is used to define the type and location of all modules present in the PLC racks This is done by completing setup screens which rep resent the modules in a baseplate and saving the information to a configuration file which is then downloaded to the CPU Once a baseplate and slot location for the Power Mate APM is defined you can continue to the second pa
97. e tested by the Power Mate APM during execution of Wait or Conditional Jump commands Execute Motion Program 0 10 These commands are used to select stored programs for immediate execution Each command uses a one shot action thus a command bit must transi tion from OFF to ON each time a program is to be executed Programs may be temporarily interrupted by a Feedhold command When a program begins execution Rate Override is always set to 100 A Rate Override AQ immediate command can be sent on the same sweep as the Execute Program Q bit and will be effective as the program starts Only one Motion Program can be executed at a time per axis the Program Active 1 status 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 Clear Error When an error condition is reported this command is used to clear the Error status bit and its associated Status Code word Error conditions that are still present such as an End of Travel limit switch error will not be cleared and must be cleared by some other correc tive action Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D 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 Comm
98. eared and the transducer signal is restored When the Power Mate APM is configured for Linear Feedback the Home Cycle is disabled and the Q Find Home command bit has no effect After receiving a valid transducer signal the Power Mate APM attempts to set Actual Position to the transducer reading configured Position Offset If this value is outside the configured Hi Lo Count Limit range an error is reported Position Valid stays cleared and Actual Position is set to zero If this value is within the Hi Lo Count Limit range Actual Position is initialized and Position Valid is set Actual Position can be shifted by changing the Position Offset parameter with the Configuration software Once Actual Position is initialized the Power Mate APM continuously reads the linear transducer and updates Actual Position with any position changes The Set Position command can also be used to set Actual Position to a user specified value For additional details on specification and configuration of linear transducers see Appendix F LDT Interface Digital Serial Encoder The initial release of the Power Mate J supports only digital serial encoders used with the a Series or b Series digital servo Encoder resolution is fixed at 8192 encoder counts per motor shaft revolution Incremental or Absolute battery backed encoders may be con figured Refer to Appendix G for additional information about absolute encoder usage Non Programmed Motion The Powe
99. edrate Override 6 29 Final Home Velocity Find Home Q Discrete Command Find Home Cycle G3 Find Home Velocity 6 Firmware Compatability Tables 1 2 First Time Use Absolute Encoder Follower Mode ForceD A 6 6 Force D A Output AQ Immediate Com mand 4 13 Functional Connection Diagrams Index 3 Index Index 4 Functional Connection Diagrams for the 1 PM APM P 10 Functional Connection Diagrams for the 2 Axis PM APM 12 G Gradient 3 6 H Hi LoLimits 5 2 High Limit 3 6 Home Cycle Home Mode Home Offset 3 6 Home Position 3 6 Home Switch Mode 6 4 I O Cable and Terminal Block I O Cable Connections for the 1 Axis PM APM IC693APU301 p 6 I O Cable Connections for the 2 Axis PM APM IC693APU302 D 8 I O Connectors 2 5 I O Rack Configuration I OSpecifications C 2 Idle Time Immediate Commands Using the 6 Byte Format Important Configuration Considerations In Error Limit I Status Bit In Pos Zone B 6 In Position Zone AQ Immediate Com mand In Zone l Status Bit Incremental Encoder Mode Consider ations G 3 Incremental Positioning 6 9 Installing the 2 15 Installing the Power Mate APM Integrator Mode Integrator Time Constant B 6 J Jog Acceleration Jog Acceleration AQ Immediate Com mand 4 15 Jog Acceleration Mode 8 6 Jog Minus Q Discrete Command 4 10 Jog Plus Q Discrete Command
100. elocity Feedforward AQ Immediate Command Velocity FF Velocity Loop Gain AQ Immediate Command W Wait Command 6 16 WAIT Command Program Zero WAIT Motion Programmer Command Waveguide F 1 Wiring to 55 90 Drives Index 7
101. enhance tracking accuracy m High resolution of programming units Position 8 388 608 8 388 607 User Units Velocity 1 8 388 607 User Units sec Acceleration 1 134 217 727 User Units sec sec 00000000 00 Easy to Use 22119 Simple and powerful Motion Program instruction set m Simple 1 or 2 axis motion programs with synchronized block start Program support for a short motion program which can be created in Logicmaster 90 configuration software Succ o m Non volatile storage for 10 programs and 40 subroutines m Motion Programmer Status Screen for servo monitoring 1 1 m User scaling of programming units User Units m Generic programming using command parameters as operands for Acceleration Velocity Move and Dwell Commands m Configured with Logicmaster 90 software m Automatic Data Transfer between PLC tables and Power Mate APM without user programming m Ease of I O connection with factory cables and standard terminal blocks as well as a serial port for connecting programming devices Versatile 10 volt Velocity Command analog output m 12 bit plus sign analog input m Home and overtravel switch inputs Position Capture Strobe Input m User defined control inputs 8 and outputs 4 m A Quad B Encoder Feedback up to 175 kHz per channel
102. er Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D 5 Aninternal Set Position sets the Commanded and Actual Positions to the configured Home Position value the Power Mate APM sets the Position Valid I bit to indicate the Home Cycle is complete 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 can be performed when no other motion is commanded or while programmed motion is temporarily halted due to a Feedhold command 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 YI bit When an Overtravel Limit Switch is OFE Jog and Clear Error may be turned on simultaneously to move away from the open Limit Switch Thus a Jog Plus will not work while the Positive End of Travel Switch is open and Jog Minus will not work while the Negative End of Travel Switch is open Move at Velocity Command A Move at Velocity command is generated by placing the value 22h in the first word of AQ
103. eration There are two ways of generating a jump stop each described below A conditional JUMP triggered during a PMOVE will always generate a jump stop 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 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 Power Mate APM for Series 90 30 PLC Standard Mode User
104. even though the CTL bit may be ON before the block with the conditional JUMP and Type 3 command is executed axis motion will stop before program execution contin ues at the jump destination This stopping is NOT a Jump Stop which is described in Example 10 Example 8 Normal Stop before JUMP The following example contains a jump followed by a DWELL command The Power Mate 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 Standard Mode User s Manual August1996 GFK 0840D GFK 0840D 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 CTL03 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 Thi
105. f the Jump command is located ahead of the moves in the block If a jump occurs during a move the remainder of the move is aborted and the command at the destination location is immediately effective Jump destinations must be limited to the bounds of the program containing the Jump command Load Parameter LOAD This command initializes or changes a Power Mate APM pa rameter value The new value becomes effective immediately when encountered in the program Program Zero may load parameters 1 to 20 Pmove PMOVE Positioning Move this command is used when it is necessary for the axis to be within the configured In Position Zone before proceeding to the next com mand If no previous acceleration or velocity has been specified in a motion program the configured Jog Accelerationand or Jog Velocity will be used Velocity VELOC This command specifies the velocity of axis motion Once encoun tered this command will remain in effect until overridden by a later Velocity command Wait WAIT This command synchronizes the start of axis motion with an external in put or event reported in CTL 1 12 The start of motion is suspended until the bit being monitored is true GFK 0840D Chapter 3 Configuring the Power Mate APM 3 13 Essential Configuration Parameters To correctly configure the Power Mate APM several configuration parameters must be properly set This section explains how these parameters affect Power Mate APM opera tion and how
106. gUp for Previous Page gt gt OFFLINE NLM98NJUNK PRG JUNK REPLACE Figure 3 1 Example Program Zero Editor Screen Program Zero Programmer Instruction Format A Program Zero instruction consists of a command and associated data describing the command The command and data are entered into areas on the program editor screen called fields These fields are described below From left to right the fields are Command Name Field The English language designation for the command To enter a command position the cursor on a command name field then press the desired function key F1 F9 Most of the commands fall into groups such as CMOVE PMOVE VELOC ACCEL and so forth The variations of these commands can be displayed using the Tab key after pressing the function key for the particular group Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D For example to program a CMOVE IS P Continuous Move incremental s curve using a parameter first select a command field then press the CMOVE function key This causes CMOVE AL to be displayed in the command name field of the screen The variations of the command are cycled through by pressing the Tab key To program a JUMP command press F10 MORE and then press F1 JUMP GFK 0840D Chapter 3 Configuring the Power Mate APM 3 11 3 12 Operand Field Paired with each command is a data field In the data field enter either a signed integer or the
107. gen eral purpose inputs If ENABLED then 24 V dc must be applied to both of the inputs in order for the Power Mate APM to operate If not then whenever the drive is enabled a Limit Switch Input Error will occur The Jog and Clear Error Q bits may be used simultaneously to back away from the Limit Switch Default ENABLED Pos EOT Positive Software End of Travel limit User Units If the Power Mate APM is programmed to go to a position greater than the Positive EOT then an error will result and the Power Mate APM will not allow axis motion Default 8 388 607 Neg EOT Negative Software End of Travel limit User Units If the Power Mate APM is programmed to go to a position less than the Negative EOT then an error will result and the Power Mate APM will not allow axis motion Default 8 388 608 If Pos Neg EOT limits are both set to zero the Power Mate APM uses 8 388 607 8 388 608 instead Pos Err Lim Position Error Limit User Units The maximum Position Error Com manded Position Actual Position allowed when the 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 set to a value a
108. gured jog velocity With the Drive Enabled Q bit on and no servo motion commanded adjust the servo drive zero offset for zero position error Power Mate APM Commanded Position Power Mate APM Actual Position The Integrator should be disabled 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 necessary 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 ty
109. he 2 Axis PM APM 4 9 A Abort All Moves Q Discrete Command Absolute Encoder First Time Use Use After Loss of Encoder Battery Pow et Absolute Encoder Mode Hi LoLimits 2 Limitations on Total Travel G 2 Power Mate APM Power Up Restrictions when used with Rotary Mode with Rotary Mode Encoder Mode Considerations 3 Find Home Cycle Position Initialization Set Position Command Absolute Feedback Offset AQ Immedi ate Command 4 17 Absolute Position Offset Absolute Positioning ACCEL Command Program Zero iM Motion Programmer Command 1 8 Index 1 Index Index 2 Acceleration Mode Acceleration Linear Acceleration S Curve Actual Position AI Status Word Actual Velocity AI Status Word Analog Input AI Status Word 1 7 Appendix D Serial Encoders G 1 Automatic Data Transfers Axis Configuration Data Absolute Position Offset 8 6 Counts Disable Delay Final Home Velocity B 6 Find Home Velocity 8 6 Gradient 3 6 High Limit 8 6 Home Mode Home Offset B 6 Home Position In Pos Zone Integrator Mode Integrator Time Constant B 6 Jog Acceleration Jog Acceleration Mode Jog Velocity Low Limit Negative End Of Travel 3 6 Overtravel Limit Switch 8 6 Position Error Limit Position Loop Time Constant Positive End Of Travel B 6 Recircs B 6 Reversal ebd n User Units Velocity at 10 V B 6 Velocity FF B 6 Axis Enabled I Status Bit 4 3
110. he Abort All Moves Q bit turning ON or an error which would normally cause a stop error will end feedhold as well as terminate the program During feedhold jogging positive and negative is allowed but no other motion When feedhold is terminated and program execution resumes the Power Mate APM remembers and will move to its previous destination Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D s Example 16 Feedhold The following example illustrates a motion profile when feedhold is applied The linear move accelerates to the programmed velocity at the programmed rate Feedhold is ap plied at the dotted line so velocity decreases at the programmed acceleration to zero Then a Jog is performed using the Jog Minus Q bit This is evident because the Jog Ve locity is negative Note the acceleration used during the Jog is the current Jog Acceleration which is different than the programmed acceleration Note also the feedhold must be applied during the entire duration of the Jog After the jog motion has ceased the feed hold is ended and the program continues to completion ACCEL 1000 VELOC 2000 PMOVE 12000 INC LINEAR V 245269 A t Figure 6 17 Feedhold Feedrate Override GFK 0840D Some applications require small modifications to a programmed velocity to handle out side changes A Feedrate Override immediate command allows changes to a programmed velocity during program e
111. he Power Mate APM will report the Actual Position as the sum of the encoder position and the Absolute Feedback Offset established by the initial Find Home cycle or Set Position command Absolute Encoder Mode with Rotary Mode Some restrictions are necessary when Absolute Encoder mode is selected along with Rotary mode Absolute Encoder mode causes the Power Mate APM to automatically initialize Actual Position from the battery backed absolute encoder after a power cycle Absolute Encoder mode is selected by setting the Intgr Mode to CONTINU in the Configuration software Rotary mode allows the Power Mate APM to create continuous motion in one direction by the use of multiple CMOVE or PMOVE incremental commands As the axis moves Actual Position will reach a Hi or Low Count Limit then roll over to the other limit The distance between Actual Position rollovers is the Rotary Count Modulus Rotary Mode is selected by configuring the EOT Limit gt Hi Count Limit and Limit lt Low Count Limit The battery backed absolute encoder has a total absolute counting range of 8192 cts rev x 32767 revs 268 427 264 counts This is the maximum number of counts the encoder can move after a position reference operation Find Home or Set Position and still retain absolute position If the encoder rotates more than this number of counts after a position reference operation the absolute position is lost and the encoder starts a new counting cyc
112. imits Hardware Overtravel Limits must be ON if they are enabled A Move at Velocity can be stopped without causing an error in two ways a Move at Velocity command with a velocity of zero or turning the Abort All Moves Q bit ON for at least one PLC sweep GFK 0840D Chapter 6 Power Mate Motion Control 6 5 Force D A Command 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 3 200 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 Commands 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 p
113. ing move Incremental Linear Use 0 255 1 data in Parameter PMOVE IS Positioning move Incremental S curve 8 388 608 8 388 607 1 PMOVE IS P Positioning move Incremental S curve 0 255 1 Use data in Parameter VELOC Set Velocity 1 8 388 607 2000 VELOC P Set Velocity to data in Parameter 0 255 1 ACCEL Set Acceleration 1 134 217 727 5000 ACCEL P Set Acceleration to data in Parameter 0 255 1 WAIT Wait for CTL XX bit to go high before 1 12 1 moving LOAD P01 Load Power Mate APM Parameter register 8 388 608 8 388 607 0 number LOAD P20 DWELL Wait for specified time in milliseconds 0 60 000 0 DWELL P Wait X milliseconds X is the value in 0 255 1 the Parameter JUMP UNCOND Continue program execution at given 1 65 535 1 block JUMP CTLO1 When the given CTL bit goes high during 1 65 535 1 4 the current block execution transfer JUMP CTL12 program execution to the given block Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Program Zero Motion Command Descriptions Each command is briefly described below For a comprehensive explanation of Motion Programming on the Power Mate APM refer to GFK 0664A The Series 90 Power Mate APM Programmer s Manual Acceleration ACCEL This command is used to specify the axis acceleration and de celeration rate for subsequent moves Once encountered the specified rate will remain in effect until overridden by a later Acceleration co
114. ision 11h not used Absolute Feedback Offset is the position offset that is used to initialize Actual Position when Absolute Encoder is used Actual Position Absolute Encoder Data Absolute Feedback Offset Controller and interface module Firmware Revisions should be interpreted as two separate words for major minor revision codes At least three PLC sweeps or 20 milliseconds whichever represents more time must elapse before the new Selected Return Data is available in the PLC Torque Limit TRLMT The Torque Limit Command provides a method of limiting the torque produced by a digital servo motor on each axis The controller module will set the torque limit TRLMT at the default 100 whenever a power cycle or reset occurs The PLC application logic must set any other value for desired TRLMT The valid range for TRLMT is 1 to 100 in units of 1 TRLMT can be changed during axis motion Refer to the appropriate servo motor manual for the actual motor torque curve to determine the actual value of torque output at a given velocity Configuration Modes This configuration command permits various configuration changes to the controller module by modifying the byte in the command string associated with the desired feature The values established by the Configuration Mode command are not saved through a power cycle or reset and must be re established on system startup Use of the Set Configuration Complete command is recommended with appropriate a
115. ith a User Unit value of 1 and a Counts value of 2 the decimal value of the ratio would be 0 5 The conversion constant multiplied by 0 5 yields the value 69910 for the Velocity at 10 v 1 2 139820 69910 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 Velocity Feedforward causes the servo to operate with faster response and reduced position er ror Optimum feedforward values are 80 90 The Vel at 10v value must be set cor rectly for proper operation of Velocity Feedforward Default 0 Intgr TC 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 to10 times greater than the Position Loop Time Constant to prevent instability and oscillation In Digital mode the position error integrator is not used and Intgr TC is used to config ure the digital servo Velocity Loop Gain Default 0 Intgr Mode Integrator Mode Operating mode for position error integrator OFF means the integrator is not used CONTINUOUS means the integrator runs continuous
116. le Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Restrictions when Absolute Encoder Mode is used with Rotary Mode 1 If the Rotary Count Modulus in counts is a power of 2 then no restrictions exist on rotary travel This means the distance defined as Hi Limit Low Limit 1 in counts must be a number which is a power of 2 such as 128 256 512 8192 16384 and so forth Under this condition the Power Mate APM will always initialize Actual Position to the correct rotary position after a power cycle 2 Ifthe power of 2 condition for Rotary Count Modulus is not met the rotary motion must be limited to a range of 268 427 264 counts after a Set Position or Find Home position reference operation This restriction can be handled in some systems by periodically performing a Set Position when the axis is stopped and holding a known rotary position Note Performing a Set Position or Find Home cycle in Absolute Encoder mode causes the Power Mate APM to recalculate the encoder Absolute Feedback Offset An Update Flash Memory command must always be sent to permanently save the new Absolute Feedback Offset The flash memory in the Power Mate APM has a limited number of update cycles 20 000 100 000 cycles This limitation should be considered if a system design required the Absolute Feedback Offset to be saved more than 10 times per day GFK 0840D Appendix G Serial Encoders G 5 GFK
117. lid l bit Appendix G Serial Encoders G 3 Set Position Command Absolute Encoder Mode The AQ Set Position command functions the same as in Incremental Encoder mode At the completion of the Set Position operation Actual Position is set to the Set Position value The Power Mate APM internally calculates the encoder Absolute Feedback Offset needed to produce the commanded Set Position value This Absolute Feedback Offset must be permanently saved in the Power Mate APM by sending AQ command 4Ah Update Flash Memory after the Set Position command Once the Absolute Feedback Offset is saved in Flash memory the Power Mate APM will automatically initialize Actual Position after a power cycle and set the Position Valid lI bit Absolute Encoder Mode Power Mate APM Power Up The battery pack attached to the servo subsystem will maintain power to the encoder counter logic Once the encoder has referenced through first time start up the actual position is automatically maintained by the encoder even if the axis is moved during servo power loss The encoder will monitor the status of the battery pack and report loss of battery power or low battery power to the Power Mate APM The Power Mate APM will complete a power on diagnostic and when configured for absolute encoder mode interrogate the referenced status of the serial encoder A valid referenced status from the encoder will signal the Power Mate APM to read the encoder absolute position T
118. m is selected The program commands can be categorized as follows Type 1 Commands m Call Subroutine m Jump Type 2 Commands m Block m Null Acceleration m Velocity Type 3 Commands m Positioning Move Continuous Move m Dwell m Wait 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 progr
119. mented Error This status bit is set when the Power Mate APM detects any error When set the 7o 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 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D 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 Setup Data The word numbers listed in the following table are offsets to this starting address Table 4 3 Status Words for the 1 Axis Power Mate APM IC693APU301 99 Position Error Axis 1 The word numbers represent an offset to the starting address for AI references Immediate Command Select Return Data 40h can be used to select Commanded Position or other data such as module firmwarerevision Tf Module configuration parameter AI Pos Err is DISABLED Analog Input Value will be reported instead of Position Error in AI word 012 This allows compatibility with APM release 1 00 and 1 10 firmware Table 4 4 Status Words for the 2 Axis Power Mate APM IC693APU302 P00 Commanded Positio
120. ming is critical Example 18 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 possible while avoiding the obstacle which prevents moving directly from A to C A simple way would be to move from point A to point B and then from point B to point C This sequence however wastes time A better way would begin the horizontal movement before reaching point B It has been determined that after axis 1 has moved to a position of 30 000 user units axis 2 could then start and still clear the obstacle The 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 45271
121. mmand Block BLOCK Block numbers are used to monitor and synchronize program execu tion terminate jump testing and as jump destinations Block number is an actual com mand in the Program Zero Editor Cmove CMOVE Continuous Move this command is used when it is not necessary for the axis to be within the configured In Position Zone before proceeding to the next command If no previous acceleration or velocity has been specified in a motion pro gram the configured Jog Accelerationand Jog Velocity will be used Dwell DWELL This command causes motion to cease for a specified time period in milliseconds before proceeding to the next command Jump JUMP This command is used to jump to another location in the program un der certain specified states of the Faceplate control inputs CTL 1 8 and Q control out puts CTL 9 12 The jump will occur when the condition tests true logic 1 An un conditional Jump can also be selected The jump may be forward or backward in the program The jump condition will be tested as soon as the move prior to the Jump com mand has completed A maximum of 220 jumps can exist for all programs and subrou tines Once the condition testing is allowed to start the test will occur once each millisecond every 2 milliseconds for 2 Axis Power Mate APM until a Block Number or another Jump command is encountered This will allow continued testing while a move or series of moves takes place i
122. move Linear 81h Abs Cmove Linear 90h Abs Pmove S 91h Abs Cmove S COh Inc Pmove Linear Clh Inc Cmove Linear DOh Inc Pmove S D1h Inc Cmove S Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D The Move command is executed as a single move motion program therefore all the restrictions that apply to motion program execution will also apply to it For example if a program is already active for axis 1 then an attempt to send this command for axis 1 will result in an error condition reported Jog Velocity user units sec This command sets the velocity used when a Jog Q bit is used to jog in the positive or negative direction Jog Acceleration user units sec sec 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 position loop time constant to be changed from the configured value The lower the value the faster the system response Values which are too low will cause system instability and oscillation For accurate tracking of the commanded velocity profile the Position Loop Time Constant should be 1 4 to 1 2 of the MINIMUM system deceleration time Velocity Feedforward This command sets the Velocity Feedforward gain percent It is the percentage of Commanded Velocity that is added to the Power Mate APM velocity command output Increasing Vel
123. mware revisions 2 50 and higher Default ENCODER Ctl Loop STANDARD selects the normal Power Mate APM motion control loop The STANDARD loop provides a velocity command proportional to position error with optional Velocity Feedforward and Integrator gain terms CCL1 and CCL2 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 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 2 50 and higher Default ANALOG Motor Type Selects the type of GE Fanuc Digital AC servo motor to be used with the Power Mate APM controller module and Digital Servo Interface module Power Mate J system Digital AC servos are only supported in Power Mate APM firmware versions 2 50 and higher A motor type of 0 for a particular axis disables digital servo control by the Interface module for that axis Default 0 a Series Servo Motor Motor Code Motor Model Motor Specification a0 5 3000 a1 3000 a2 2000 a2 3000 a3 3000 a6 2000 a6 3000 a12 2000 a12 3000 a22 1500 a22 2000 a22 3000 a30 1200 a 30 2000 a30 3000 a40 2000 a40 FAN
124. n 7 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 position 4 Theaxisis stopped at the configured Jog Acceleration rate and with the configured Jog Acceleration Mode Pow
125. n Axis 1 Commanded Position Axis 2 The word numbers represent an offset to the starting address for AI references Immediate Command Select Return Data 40h can be used to select Commanded Position or other data such as module firmwarerevision GFK 0840D Chapter 4 Automatic Data Transfers 4 5 4 6 Status Code Status Code indicates the current operating status of the module When the Error flag is set it contains an error code number which describes the condition causing the error For a list of Power Mate APM error codes refer to Appendix A Error Codes Command Block Number Command Block Number indicates the block number of the command that is presently being executed in the active Program or Subroutine It changes at the start of each new block as the program commands are executed and thus identifies the pres ent operating location within the program Commanded Position Commanded Position user units is where the axis is commanded to be at any instant in time The difference between Commanded Position and Actual Position is the Position Error value which produces the Velocity Command to drive the axis The rate at which the Commanded Position is changed determines the velocity of axis motion If Commanded Position moves past either of the count limits it will roll over to the other limit and continue in the direction of the axis motion Note The Select Return Data AQ Immediate Command can be
126. n Control 6 11 L5 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
127. nabled 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 The Abort All Moves Q bit turns ON The Enable Drive Q bit turns OFF An Overtravel Limit Switch turns OFF when OT Limits are configured to be enabled The next programmed move either PMOVE or CMOVE will pass a Software End of Travel Limit 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 8 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D 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 dista
128. nce 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 incremental 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 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 Asample 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 GFK 0840D Chapter 6 Power Mate Motion Control 6 9 V 245256 Figure 6 1 Sample Linear Motion S Curve Acceleration
129. nd can be used in two modes IN ZONE and CONTINUOUS The Integrator Time Constant is the amount of time in which 63 of the Position Error will be removed When using the IN ZONE mode at the end of a move when the Actual Position nears the Commanded Position and the servo is about to stop the axis may stop a little early if the servo cannot take out all of the error To increase precision the Integrator can then work to integrate out all error When using the CONTINUOUS mode the Integrator will always try to remove all Position Error even when moving Rapidly changing velocities can make the Integrator over or under compensate CONTINUOUS mode is not recommended for positioning applications The Integrator Time Constant must be five to ten times greater than the Position Loop Time Constant or oscillation might occur Software End of Travel Limits positive and negative are used to bound commanded mo tion The Power Mate APM will not execute any programmed motion which takes the Commanded Position to or past EOT Limit If the Position Valid I bit is ON a Jog will immediately be stopped at the EOT Limit Jogs with Position Valid OFF and Move at Veloc ity immediate commands ignore the EOT Limits This enables movement outside the EOTs while setting up a system Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D GFK 0840D High and Low Count Limits can be used for rotary type motion in which a servo c
130. nterface module is referred to as the Power Mate J system Refer to the Power Mate J User s manual GFK 1256 for additional information Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D Motion Programming Packages Motion programs are normally created using the Motion Programmer software package but a single short program Program Zero be created within the Logicmaster 90 30 configuration software Motion Programmer The Power Mate APM has a configurable SNP port to communi cate with the Motion Programmer The Motion Programmer operates much like the Lo gicmaster 90 software package It provides the capability of writing English language motion programs storing the programs on disks and downloading the programs to the Power Mate APM as desired A Status Screen supports servo system monitoring An overview of Motion Programmer functions is provided at the end of this chapter For detailed information on Motion Programmer refer to GFK 0664A the Series 90 Axis Posi tioning Module Programmer s Manual Program Zero The Logicmaster Configuration package contains an editor for creating a short 20 commands maximum program defined as Program Zero The commands are entered in an English language format similar to the Motion Programmer No ladder programming is needed Program Zero is discussed in detail in Chapter 3 Configuring the Power Mate APM Operator Interfaces Operator interfaces pro
131. nterrogation pulse response to return through the waveguide The effective length of the tube is either the end of the tube or the time required for the transmitted pulse to be reflected back to the electronics package A simple method of electronically making the tube length shorter is to surround the waveguide tube with a magnetic field of sufficient intensity magnetostrictive to reflect the transmitted pulse to the electronic detection circuitry Permanent magnets mounted to a moveable collar or slide are commonly used for this purpose As the magnet is moved along the length of the tube the transmitted pulse is reflected back to the electronics with a time delay proportional to the magnet position The LDT electronics can now accurately generate an output that is proportional to the absolute position of the magnet along the rod or waveguide tube GFK 0840D F 1 a47104 flange to tip stroke electronics package magnet dead null zone Figure F 1 Example of a Linear Displacement Magnetostrictive Transducer LDT LDTs have been used successfully in motion applications for more than fifteen years The LDT has many desirable characteristics absolute position sensing rugged sealed construction for use in harsh environments and non contact measurement These devices are typically used in linear motions of relatively short length Measuring hydraulic cylinder stroke length is one application where
132. ntgr Mode Integrator Mode to CONTINU Additionally proper operation of the Absolute mode requires an external battery pack that must be connected to the appropriate digital servo amplifier connector Refer to the appropriate amplifier manual for selection and installation of the battery pack Note The Position Error Integrator is not used when the Power Mate APM is used to control digital servos Therefore the Inter Mode Integrator Mode configuration is used for the alternate purpose of selecting Incremental or Absolute operating mode of the a Series pulse encoders Limitations on Total Travel for EOT Mode G 2 The maximum value that can be used for the EOT is 48 388 607 user units User units are configured as a ratio to the encoder count value and are bound to the range of 8 1 to 1 32 Additionally the feedback from a digital servo is fixed at 8192 counts per revolution Using a simple formula will determine the maximum number of motor shaft revolutions possible for axis travel when EOT non rotary mode is used Counts Maximum Hevolutions 1024 User Units Using the above calculation the maximum possible move is realized with the User Unit to Count ratio at the maximum 1 32 resulting in a maximum travel of 32 768 motor shaft revolutions Ihe maximum travel originates at the Actual Position zero and can move the number of maximum travel revolutions plus or minus of the zero position There is no restric
133. ntrol 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 0840D Chapter 5 Servo System Startup Procedures 5 3 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 Position Feedback Types m Non Programmed Motion m Programmed Motion Position Feedback Types Power Mate APM firmware revision 2 50 or higher supports three types of feedback devices m A Quad B Incremental Encoder m Linear Absolute Transducer m Digital Serial Encoder requires Digital Servo Interface module A Quad B Incremental Encoder A Quad B Encoders provide three output signals to the Power Mate APM Quad A Quad B and Marker The Quad A and Quad B signals transition as the encoder turns allowing the Power Mate APM to count the number of signal transitions and calculate the latest encoder position change and direction of rotation A Quad B Encoders are incremental feedback devices they do not provide a continuous indication of absolute shaft angle as the input shaft rotates For this reason the Power Mate APM Actual Position must be initialized with a known
134. o a Lower Velocity While 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 0840D Chapter 6 Power Mate Motion Control 6 27 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 6
135. ocity Feedforward causes the servo to operate with faster response and reduced position error Optimum Velocity Feedforward values 80 90 The Vel at 10 V value must be set correctly for proper operation of the Velocity Feedforward gain factor Integrator Time Constant milliseconds This command sets the Integrator Time Constant for the position error integrator This value specifies the length 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 oscillation Velocity Loop Gain VLGN The velocity control loop gain for an axis may be set with the Velocity Loop Gain command The VLGN value is used to match the load inertia to the motor inertia Jm VLGN is defined with a value of 16 representing an inertia ratio of 1 to 1 The VLGN value is calculated assuming that the load is rigidly applied to the motor Therefore in actual machine adjustment the set value may significantly differ from the calculated value due to rigidity friction backlash and other factors A PLC reset or power cycle returns this value to the configured data The user must set the velocity loop gain VLGN such that it satisfies the following equation JL VLGN 16 Where JL Load Inertia JM Motor Inertia VLGN Velocity Control Loop Gain 0 255 For example The rotor inertia Jm of a particular servo i
136. oder Battery Low c2 Serial Encoder Battery Failed C3 Servo Motor Over Temperature C4 Servo Motor Over Current C5 Serial Encoder Communications Alarm C6 SerialEncoder Alarm C7 Stop Fast Servo Unit Alarm Special Purpose Errors 0 Status Only Custom Loop Type Mismatch E1 Status Only Digital mode not supported by hardware EF Status Only Firmware HardwareAxisNumberMismatch 1 axixfirmware in 2 axis module or 2 axis firmware in 1 axis module Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Appendix Parameter Download Using COMM B This appendix describes an alternate method of loading Power Mate APM Parameter Memory from the PLC using a the COMM_REQ function block with command code E501h This function block can send up to 16 PM APM Parameter values at once The total data length of the COMM must be set to 68 bytes 34 words organized as shown below POP o Starting parameter number 0 255 Number of parameters to od 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 REFE
137. ogress to halt at the current Jog Acceleration rate Any pending programmed or immediate command is canceled and therefore not allowed to become effective The abort condition is in effect as long as this command is on If motion was in progress when the command was received the Moving status bit will remain set and the Jn Zone status bit will remain cleared until the commanded velocity reaches zero and the Jn Zone condition is achieved Feedhold On Transition This command causes any motion in progress to halt at the ac tive acceleration rate Once the motion is stopped the Moving status bit is cleared and the In Zone status bit is set when the In Zone condition is attained Jog commands are allowed when in the Feedhold condition After an ON transition program motion will stop even if the com mand bit transitions back OFF before motion stops Feedhold Off Transition This command causes any programmed motion interrupted by Feedhold to resume at the programmed acceleration and velocity rate Additional program moves will then be processed and normal program execution will continue If jogging occurred while Feedhold was ON the interrupted Move command will resume from where the axis was left after the jog The Move finishes at the correct programmed velocity and continues to the original programmed position as if no jog displacement occurred Enable Drive If the Error and Drive Enabled status bits are cleared this command will cause the
138. ommand The actual addresses of the Discrete Command bits depend on the starting address con figured for the Q references See Table 3 1 Module Setup Data The bit numbers 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 Abow AIMoves AST 16 Reset Strobe Flag Axsi 22 Execute Motion Program reserved LM Motion Program 09 reserved 1725 Execute Motion Program The bit numbers represent an offset to the starting address for Q references 4 8 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D GFK 0840D Table 4 6 Q Discrete Commands for the 2 Axis Power Mate APM IC693APU302 Abort AlTMoves Axis 16 09 Output Conta CTLIO Output Control CTLIT Output Control CTLIZ Output Control 06 ReserSuebe Fag Aus T 22 Execute Motion Program Abort ATEM Anis 4 Execute Moon Program 09 Feedhold A2 25 Execute Moon Program 2 2 Aus2 27 Execute Motion Prosen LogMims Axis 29 Execute Motion Program The bit numbers represent an offset to the starting address for Q references Jog Plus Axis 2 28 2 3 4 5 6 7 9 0 1 Abort All Moves This command command causes any motion in pr
139. once a subroutine has been called it must be completed before it can be called again for the same axis Thus recursion is not allowed Block Numbers and Jumps Block numbers are used as reference points within a motion program and to control jump testing A AI data word displays the current block number which 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 0840D Chapter 6 Power Mate Motion Control 6 17 L5 Conditional Jumps 6 18 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
140. oo small Immediate command ignored 12 StatusOnly Position Loop Time Constant computation overflow reduced to non overflow value 1E StatusOnly Immediate command Jog Velocity out of range command ignored 1F StatusOnly Immediate command Jog Acceleration out of range command ignored Program Errors 20 Status Only Program Accelerationoverrange defaultsto16 7millioncts sec sec 21 StatusOnly Program Accelerationtoosmall defaultedto32cts sec sec 22 Status Only Scaled Velocity greater than 1 millioncts sec 1 million cts secis used 23 StatusOnly Program Velocity is zero defaulted to 1 count sec used 24 Stop Normal Program Position too large 25 Stop Normal Unconditional Jump Destination not found 26 Stop Normal Jump Mask error 27 Stop Normal Wait Mask error 28 Stop Normal Parameter Position too large 29 Status Only Dwell time greater than 60 seconds 5 seconds used Position Increment Errors 2C Status Only Position Increment Overrange error increment ignored Find Home Errors 30 Status Only Find Home while Drive Not Enabled error 31 Status Only Find Home while Program Selected error 32 Status Only Find Homewhile D A forced error 33 Status Only Find Home while Jog error 34 Status Only Find Home while Move at Velocity error 36 Status Only Find Home while Abort bit set error Moveat Velocity Errors 39 Status Only Move at Velocity while Drive Not Enabled error 3A Status Only Move at Velocity while Progr
141. oop TC should be1 4to 1 2 of the MINIMUM system deceleration time For users familiar with servo bandwidth expressedinrad Bandwidth rad sec 1000 Position Loop Time Constant ms For users familiar with servo gain expressedinipm mil Gain ipm mil 60 Position Loop Time Constant ms Gain Bandwidth Position Loop Time ipm mil rad sec Constant ms 0 5 8 5 120 0 75 12 5 80 1 0 16 6 60 1 5 25 1 40 2 0 33 4 30 2 5 41 8 24 3 0 50 20 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Open Loop Mode For applications which do not require feedback or employ very crude positioning sys tems an Open Loop Mode exists Setting a zero Position Loop Time Constant which indicates that the positioning loop is disabled selects this mode Note that in Open Loop Mode the only way to generate motion is to program a non zero Velocity Feedfor ward The Position Error is no longer used to generate motion because Position Error is based on feedback and Open Loop Mode ignores all feedback User Units and Counts The Power Mate APM has a very powerful scaling feature A User Units to Counts ratio can be configured to allow programming in other than default counts In a simplified example suppose an encoder feedback application has an encoder which produces 1 000 counts per revolution 250 lines and is geared to a machine which produces one inch per revolu
142. osition 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 Increment 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 A Set Position command during non programmed motion will cause a status error m Turning OFF the Enable Drive bit while performing a Home Cycle or Move at Velocity will cause a stop error m The Feedhold bit has no effect on non programmed motion m The Rate Override command has no effect on non programmed motion Changing the Jog Velocity or Jog Acceleration will not affect non programmed moves in progress 6 6 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D s Programmed Motion The Power Mate APM executes program motion commands sequentially in a block by block fashion once a progra
143. ower Enable Triggeroccurs 254 Stores Axis 2 Strobe Positionvalue user units 2 Axis Power 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 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 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 32 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Appendix A GFK 0840D 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 W Programming errors which generate a Status Only warning message Programming errors that halt the servo Hardware errors encoder out of sync PLC Run switches off loss of programmer communications and so forth Note The Status LED on the faceplate of the module flashes slow 4 times second for Status Only errors and fast 8 times sec for errors
144. p G 4 Absolute Encoder Mode with Rotary Mode G 4 GFK 0840D Table of Contents vii Contents Figure 1 1 Figure 1 2 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 3 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 Figure 6 10 Figure 6 11 Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 Figure 6 16 Figure 6 17 Figure 6 18 Figure 6 19 Figure A 1 Figure C 1 Figure C 2 Figure C 3 Figure C 4 Figure C 5 Figure C 6 Figure C 7 Figure C 8 Figure D 1 Figure F 1 viii Hardware and Software Used to Configure Program and Operate an Power Mate APM Servo System Example Motion Programmer Editor Screen Connecting Power Mate APM Modules in a Multidrop Configuration Multidrop Cable for the Power Mate APM I O Cable and Terminal Block pre LR e RIDERE AMETS Functional Diagram for 1 Axis Power Mate APM I O Connector A Functional Diagram for 1 Axis Power Mate APMI O ConnectorB Functional Diagram for 2 AxisPower Mate Functional Diagram for 2 AxisPower Mate APM I O Connector B Connections for Linear Transducer
145. p information Features of the Program Editor m Insert Program Lines m Edit Program Lines m D elete Program Line m Check Program Syntax m Renumber Block Numbers m G OTO Function The figure below illustrates the editor screen with sample instructions 5 FILES SETUP _ FOLDER UTILTY PRINT TD curam NEN Bs Bicheck By soto rors Begin Program ACCEL 1 8888 Set accel to 888 Usr Un sec sec VELOC 1 4888 Set veloc to 4000 User lUn sec PMOVE 1 18888 ABS LINEAR Move to 18888 User Units VELOC 1 7500 Set veloc to 7500 User lUn sec PMOVE 1 8 ABS LINEAR Move to User Units End Program OFFLINEMAPM REV BAT JOBSNTEST1 APM PRG AXIS BYTES 48 BOE H REPLACE Figure 1 2 Example Motion Programmer Editor Screen Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Motion Programmer Instruction Format A program or subroutine instruction consists of a command and associated data describ ing the command The command and data are entered into areas on the program editor screen called fields These fields are described below From left to right the fields are Block Number Field This field is optional The Block Number field permits the entry of a number to designate the beginning of a block of program instructions It is used as a place for Jump commands to go to and for synchronizing
146. pically 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 Series 90 30 Power Mate APM requires PLC firmware release 3 52 or greater and LM90 software release 4 0 or greater The default Power Mate APM configuration for the Overtravel inputs is ENABLED Therefore 24 vdc must be applied to the Overtravel inputs or the Power Mate APM Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D will not operate If Overtravel inputs are not used the Power Mate APM configuration should be set to Overtravel inputs DISABLED 3 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 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 co
147. pplication logic to enable the PLC verification of desired modes MCON CTRL has the following possible values m MCON 00h Digital Servo Magnetic Contactor MCON NOT controlled by CTL Output Default m MCON 01h Digital Servo Magnetic Contactor MCON is controlled by CTL Output Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D With the default mode of operation the Q Enable Drive command On will energize the digital servo power relay MCON and enable servo power to the amplifier The Enable Drive Q Off will cause the MCON and digital servo power to be removed after the configured Servo Drive Disable Delay DisDly With MCON CTRL byte 4 set to 01h the Q Enable Drive ON OFF command Enables and Disables servo power to the motor The motor shaft will have no torque when the servo power is Off The MCON relay will remain energized This function is useful when the torque must be removed and reapplied repeatedly from the motor and will help avoid wear on the MCON relay With MCON CTL set to O1h a Q CTL output will control the ON OFF state of the magnetic contactor MCON CTL11 is the Axis 1 MCON control output CTL12 is the Axis 2 MCON control output for the two axis Power Mate J Absolute Feedback Offset This command updates the Absolute Feedback Offset counts used to initialize Actual Position from an AbsoluteDigital Encoder permanently save the encoder
148. pproxi 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 l erroneous feedback wiring 2 feedback device coupling slippage 3 servo drive failure In Pos Zone Position Zone User Units When the magnitude of servo position error is less than or equal to this value and neither Jog nor Move at Velocity is comman ded the In Zone status bit will be set In Position Zone also determines the position error at which Pmoves are considered to be comple
149. r 2 Installing the Power Mate 2 11 Functional Connection Diagrams for the 2 Axis Power Mate APM VO CONNECTOR 245313 VO TERM BLK CONN TERM DRIVE AXIS 1 m 2 VEL MOTOR VELCOM X cis A7 3 EC x ENABLE Zi B6 16 ov B12 13 SHIELD NOTE A FOR SINGLE ENDED B11 18 A1 Ale ENCODER DO NOT 12 5 1 XL 1 CONNECT 1 B1 Z1 B10 19 B1 Ld 1 11 6 B1 lt ua X B1 AXIS 1 21 71 ENCODER B9 20 A10 7 21 21 AQ 8 5V 5 AXIS BH Si ov Xix ov LOAD NEGATIVE POSITIVE OVERTRAVEL O OVERTRAVEL LIMIT SWITCH HOME SWITCH LIMIT SWITCH 2 OT CTLO6 1 TUE Yt B5 OT CTLO5 B4 15 INCOM1 i 24VDC BI i3 SHIELD B3 59 STROBE CTLOT feli 5V M 9 STROBE TCO X DRIVER A OY GENERAL PURPOSE 5V INPUTS B2 23 STROBE 2 CTLO2 he 5V 10 STROBE 2 02 X DRIVER J Figure 2 6 Functional Diagram for 2 Axis Power Mate APM I O Connector A 2 12 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D GFK 0840D CONNECTOR B 245255 Vo TERM BLK
150. r Mate APM can generate motion in an axis in one of five ways without the use of any motion programs m Find Home and Jog use the Q bits to command motion m Moce 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 FEEDHOLD uses the programmed acceleration and acceleration mode Power Mate APM Home Cycle 6 2 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 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D s 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 Home bit immediately turns OFF the Position Valid I bit until the end of the Home Cycle The Abort All Moves Q bit halts a Home Cycle but the Position Valid bit does not turn b
151. 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 Content of This Manual Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Appendix A Appendix Appendix C Appendix D Appendix E Appendix F Appendix G 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 Power Mate APM using the Logicmaster configuration package Automatic Data Transfers This chapter describes the 1 AI Q and data that is transferred between the PLC CPU and the Power Mate APM each sweep Servo System Startup Procedures This chapter explains the procedures for properly starting up
152. rete Command 10 Restrictions Absolute Encoder Mode with Rotary Mode Reversal Compensation Rotary Mode Restrictions G 5 S S Curve Acceleration SCURVE Jumps Select Return Data AQ Immediate Com mand Serial COMM Connector 2 Serial Communications Port Configura tion Data 3 5 Idle Time Modem Turn Around Time Parity B SNP ID 8 5 Stop Bits Serial Encoder Modes G 2 Serial Encoders Serial Encoders Models of G 1 Servo System Startup Procedures 5 1 Set Configuration Complete 76AQ Im mediate Command 4 17 Set Immediate Command 4 13 Set Position Command G 4 Setting the Configuration Parameters SNP ID 3 5 Specifications C 1 Standard Mode Startup Procedures Status Code AI Status Word 4 6 Status LED 2 2 Stop Bits 3 5 Strobe Position AI Status Word 4 6 Subroutines 6 17 Sync Out of B7 Synchronizing Block Indicator Field Mo tion Programmer System Troubleshooting Hints T TEMPOSONICS F 1 Torque Limit AQ Immediate Command kid GFK 0840D GFK 0840D Troubleshooting Hints System 2 Types of Acceleration Types of Positioning Reference U Unconditional Jumps Update Flash Memory AQ Immediate Command User Units 8 6 User Units and Counts 3 15 V VELOC Command Program Zero Motion Programmer Command 1 8 Index Velocity at 10 V Velocity at 10 volts B 14 V
153. rt 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 0840D 3 1 Setting the Configuration Parameters As with I O Rack Configuration Module Configuration is done by completing screens in the Logicmaster 90 30 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 Programmer Port Configuration Data m Axis Configuration Data m Program Zero 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 Table 3 1 Table 3 1 Module Configuration Data Configuration Description Values Defaults Units Parameter Start address for I ref type CPU Dependent 100001 or next higher n a 32 bits reference Start address for Q ref type CPU Dependent Q00001 or next higher n a 32 bits reference n a 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
154. s 0 10 Ib in s The load inertial JL in this application is 0 05 Ib in s2 VLGN 0 05 0 10 16 8 The default Velocity Loop Gain is set using the Integrator Time Constant setting in the Configuration Software Since the Integrator is unused by the controller module in Digital mode the Integrator Time Constant data is used to set the initial Velocity Loop Gain GFK 0840D Chapter 4 Automatic Data Transfers 4 15 Changing the VLGN value may cause an axis to be unstable and care should be used when making any change to the VLGN value 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 Parameter Register contents controller module s Firmware Revision and interface module s Firmware Revision The Select Return Data command uses a mode selection and an offset selection The mode selection byte offset 1 of the six byte command determines the Return Data type The offset selection byte offsets 2 3 of six byte command selects an individual data item for some modes Setting the mode to 00h causes the default Commanded Position to be reported The following Return Data selections are allowed Selected Return Data Data Mode Data Offset Commanded Position 00h not used Absolute Feedback Offset cts 07h not used Parameter Register 08h Parameter Number 0 255 APM Firmware Revision 10h not used DSI Firmware Rev
155. s a default If an ACCEL command 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 0840D Chapter 6 Power Mate Motio
156. s is the only way to sustain motion when a jump is performed Example 9 JUMP Without Stopping This is a simple example of a conditional jump from one CMOVE to another While jump testing the CTLO3 bit the first CMOVE accelerates to the programmed velocity Before the dotted line the CTLO3 bit is OFF 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 Chapter 6 Power Mate Motion Control 6 21 6 22 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 that is caused by a jump When a jump stop occurs the Jog Accel eration 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 beginning to decelerate See the scurve jump examples for more details The Jog Accel eration is used because a jump stop may indicate something is wrong The current Jog Acceleration which can be changed with an immediate command provides more versa tility than the programmed accel
157. t 1996 GFK 0840D Chapter Installing the Power Mate APM GFK 0840D 2 This chapter describes the 1 and 2 axis models of the Power Mate APM and how to install them on the Series 90 30 PLC baseplate The chapter is divided into the following sections m Section1 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 2 Axis Power Mate APM in stan dard mode LED Indicators There are 5 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 4 times sec for Status Only errors Flashes fast 8 times sec for errors which cause the servo to stop OK The Power Mate APM OK LED indicates the current status of the Power Mate APM board 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 OFF the Power Mate APM is not functioning This is the result of a hardware or software malfunction CFG It is ON when a valid module configuration has been received from the PLC Flashes slow 4 times sec during the Motion Program Store function Flashes fast 8 times sec during the Write User RAM to EEPROM operation EN1 When this LED is ON the servo drive for Axis 1 is enabled EN2
158. te Default 10 Chapter 3 Configuring the Power Mate APM 3 7 Pos Loop TC Position Loop Time Constant milliseconds The desired servo position loop time constant The lower the value the faster the system response Values which are too low will cause system instability and oscillation For accurate tracking of the commanded velocity profile Pos Loop TC should be 1 4 to 1 2 of the MINIMUM sys tem deceleration time Setting Position Loop Time Constant to 0 will place the Power Mate APM in open loop mode where only Velocity Feedforward is used to produce the analog velocity command output The Position Loop Time Constant will not be accu rate unless the Vel at 10v value is set correctly 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 APMs Force D A Out put AQ immediate command and the Actual Velocity AI status word can be used to determine the proper configuration value The allowed range for Velocity at 10 Volts which is affected by scaling is 400 user units counts lt Velocity at 10 Volts lt 1 000 000 user units counts For digital servos the Velocity at 10 v configuration field should be set to a conversion constant value of 139820 multiplied by the decimal value of the User Units to Counts ratio For example w
159. the feedrate override value frequent ly referred to as MFO value This new value will become effective immediately when re ceived by the Power Mate APM It is stored and will remain effective until overwritten by a different value A rate override has no effect on non programmed motion Feedrate is set to 100 whenever a program is initiated Position Increment Without Position Update user units This command offsets the axis motion from 128 to 127 user units without updating the Actual or Commanded Position The Power Mate APM will immediately move the axis by the increment commanded if the servo is enabled Move At Velocity user units sec This command is executed from the PLC to move the axis at a constant velocity The configured Jog Acceleration rate is used for Move at Velocity com mands Axis position data will roll over at the configured Hi or Lo Limit when reached during these moves Set Position user units This command changes the axis position register values without moving 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 desig nated and the Commanded Position will be set to the value Position Error Set Position can not be performed when the I Moving bit or the I Program Active bit is ON The position value must be within the End of Travel Limits and Count Limits or a status error will be re
160. the Power Mate APM s internal path generator Commanded Position the instantaneous position generated by the Power Mate APM s internal path generator Actual Velocity the velocity of the axis indicated by the feedback Actual Position the position of the axis indicated by the feedback Position Error the difference between the Commanded Position and the Actual Posi tion Position Loop Time Constant a configurable value determining the response time of the closed Position Loop GFK 0840D Chapter 1 Introduction 1 3 The Power Mate APM and the Series 90 30 PLC The Power Mate APM and Series 90 30 PLC operate together as one integrated motion control package The Power Mate APM communicates with the PLC through the back plane interface Every PLC sweep data such as Commanded Velocity and Actual Position within the Power Mate APM is transferred to the PLC in I and AI data Also every sweep Q and AQ data is transferred from the PLC to the Power Mate APM The Q and AQ data is used to control the Power Mate APM Q bits perform functions such as initiating motion aborting motion and clearing strobe flags AQ commands perform functions such as initializing position and loading parameter registers In addition to 1 AI and AQ reference data COMM REO function blocks may be used to send parameters to the Power Mate APM Details about parameter block downloading can be found in Chapter 6 Power Mate APM Motion Control
161. the next move Thus when the fourth move begins it is already at its programmed velocity 6 12 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D 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 0840D Chapter 6 Power Mate Motion Control 6 13 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
162. tion The default units would be one thousandth of an inch per count How ever you may want to write programs and use the Power Mate APM with metric units A ratio of 2540 User Units to 1000 Counts can be configured to allow this With this ratio one user unit would represent 01 millimeters 2540 user units would represent 25 4 millimeters one inch of travel The range for both User Units and Counts is 1 to 65 535 However the ratio of User Units to Counts must be between 8 1 and 1 32 A more detailed example is described below Example A machine has a motor with a 2000 line encoder connected through a 20 1 gear reduc tion to a 14 336 inch diameter spur gear The programmer wishes to program in 0 01 inch resolution The following is the given data 14 336 inch diameter spur gear 2000 line encoder 20 1 reduction gear 0 01 inch is the desired programming unit First determine the number of Encoder Counts per revolution of the spur gear 2000 lines per rev 4 20 160 000 Counts per rev The 4 results from A Quad B generating 4 counts per encoder line The 20 results from the reduction gear GFK 0840D Chapter 3 Configuring the Power Mate APM 3 15 Next determine the number of User Units per revolution using 0 01 inch resolution 14 336 inches 45 0378 inches per revolution 45 0378 inches per rev 0 01 inches per User Unit 4503 78 User Units per revolution This User Units to Counts ratio would be 4503 160 000 or 0 02815
163. tion on maximum travel for Rotary mode refer to Important Configuration Considerations in Chapter 2 for additional information on EOT Mode and Rotary Mode Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August1996 GFK 0840D Incremental Encoder Mode Considerations The digital serial encoder can be used as an incremental encoder returning 8192 counts per shaft revolution with no revolution counts retained through a power cycle The equivalent of a marker pulse will occur once each motor shaft revolution All Home modes Home Switch Move Move and Set Position reference the axis and set the Position Valid bit upon successful completion High count limits and Low Count limits are valid and the Actual Position as reported by the Power Mate APM module will wrap from high to low count or from low to high count values This is an excellent mode for rotary applications that will always operate via incremental moves in the same direction Home Offset and Home Position configuration items allow simple referencing to the desired location Incremental mode is selected by setting the Power Mate APM s Logicmaster 90 30 configuration field Intgr Mode Integrator Mode to OFF or to IN ZONE Absolute Encoder Mode Considerations The a Series serial pulse encoder can be used as an absolute type encoder by adding a battery pack to retain servo position while system power is off A Find Home cycle or Set position must be performed initiall
164. to axis 1 The first word word 0 contains the actual command number For the Set Position command the com mand number is 0023h The second and third words contain the data for the Set Position command which is a position The second word word 1 is the least significant word of the position and the third word word 2 is the most significant word 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 2 is the least sig nificant word The data to be sent to the Power 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 0840D Chapter 4 Automatic Data Transfers 4 11 4 12 Table 4 7 Immediate Commands Using the 6 Byte Format for both 1 and 2 Axis Power Mate APM Byte 4 Immediate Command Definition Rate Override RO 0 12096 Position Increment Without PositionUpdate Incr 128 127 User Units Move At Velocity Vel 8 388 608 8 388 607 User Units sec Position Set Position Pos 8 388 608 8 388 607 User Units D AOutput ForceD AOutput D A Output 32000 32000 Incr Position Increment With PositionUpdate Incr 128 127 User Units In Position Zone In Position Zone Range 0 2000 Data Move 27h MoveCommand T
165. tual position has caught up to the commanded position e g for Dwell Feedhold or Feedrate 0 GFK 0840D Chapter 4 Automatic Data Transfers 4 3 4 4 Position Strobe The Position Strobe status bit indicates that the Strobe Input at the I O connector has captured an axis position that is currently indicated by the Strobe Position AI status word The data will remain in the Strobe Position status word until the Position Strobe bit is cleared by the Reset Strobe Flag Q bit Once the Position Strobe bit is cleared new data may be captured by another Strobe Input Position data will be captured with in 1 millisecond from Strobe Input 2 milliseconds for 2 axis Power Mate APM In Error Limit The In Error Limit status bit is set when the absolute value of the posi tion error exceeds the configured Position Error Limit value When the In Error Limit sta tus bit is set commanded velocity and commanded position are frozen to allow the axis to catch up to the commanded position Faceplate Input Status CTL01 08 These inputs always indicate the state of the exter nal input devices connected to the Power Mate APM faceplate terminals CTL01 08 These inputs as well as CTLO9 CTL12 from the PLC Q table may be tested by the Power Mate APM during the execution of Wait and Conditional Jump commands Several inputs may serve alternate purposes CTLO1 Axis 1 Strobe input CTLO2 Axis 2 Strobe input CTLO3 1 Find Home switch input 04
166. um of 3 IC693APU modules per baseplate limited by power supply Model 341 PLC 141C693APU301 or IC693APU302 modules in CPU expansion and re motebaseplates Maximum of 2 IC693APU modules in CPU baseplate and 3 in each expansion remotebaseplate limitedbypowersupply Model351 352 PLC 23 IC693APU301 or IC693APU302 modules in CPU expansion and re motebaseplates Maximum of 2 IC693APU modules in CPU baseplate and 3 in each expansion remotebaseplate limitedbypowersupply Note that a Model 351 352 system can have up to 8 baseplates CPU baseplate and 7 expansion remotebaseplates NOTE Refer to GFK 0867B GE Fanuc Product Agency Approvals Standards General Specifications orlater version for product standards and general specifications GFK 0840D C 1 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 uV maximum wm Maximum Output 10 0 V 0 3 V m Minimum Load Resistance 2000 Q m Maximum allowable Voltage Between Analog Common and Ground 1 0 V 100 uH a47102 VOUT 1 VELCMD 1 100 uH VOUT 2 gt VELCMD2 125A FUSE ACOM OA Soe gt VEL CMD 1 COMMON 7 Mem 1125 0 On gt VEL CMD 2 COMMON 47 5 ov ov Figure C 1 Velocity
167. utomatic Data Transfers 4 17 Chapter Servo System Startup Procedures 5 Follow the procedures below to startup your servo system 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 or Linear Transducer to the Power Mate APM inputs Note If these connections 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 Overtravel Limit switches are used 24 Vdc wire them to the correct Power Mate APM inputs Otherwise the overtravel limits must be disabled using Configuration Software If a Home switch is used 24 Vdc wire it to the correct Power Mate APM inputs The Home switch must be wired so that it is ALWAYS ON closed when the axis is on the negative side of home and ALWAYS OFF open when the axis is on the positive side of home 4 Use the Configuration Software to set the desired user scaling factors and other 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 4 Home 05 7 Overtravel and CTL06 8 Overtravel and confirm that each bit responds to the correct switch 6 Tum on the
168. v AXIS LOAD NEGATIVE POSITIVE OVERTRAVEL OVERTRAVEL LIMIT SWITCH LIMIT SWITCH 4 OT 5 2 A6 12 Y 4 B5 14 OT INCOM B4 15 e 24VDC Figure 2 8 Connections for Linear Transducer When a linear transducer is used configured Feedback Type Linear the transducer differential 5V output must be connected as shown above Linear feedback does not require a Home switch so the Home switch input can be left unconnected or used as a general purpose 24V input Strobe and analog I O connections not shown above are unchanged from Figures 2 4 through 2 7 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D 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 Appendix C Module Specifi cations The configuration files created by Logicmaster 90 configuration software must match the physical configuration of the modules install the Power Mate APM on the baseplate follow these steps 1 Use the Logicmaster 90 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 2 Power down the Series 90 30 PLC system 3 Align th
169. vide 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 CIMPLICITY 90 ADS or a Programmable Coprocessor 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 Overview of Motion Programmer This section summarizes programming using the Motion Programmer For a compre hensive description of Power Mate APM programming refer to GFK 0664A The Series 90 Axis Positioning Module Programmer s Manual The Motion Programmer is a powerful English language programmer for the Power Mate APM It can be executed as a stand alone package or from the Logicmaster Startup Menu Programs and Subroutines are developed by selecting commands using function keys and then entering values into Operand fields to complete the instruction GFK 0840D Chapter 1 Introduction 1 5 1 6 Features of the Motion Programmer m Create and Edit Programs and Subroutines m Setup the Programmer Ports Load and Store Program files between the Motion Programmer and Power Mate APM m Print Motion Programs Subroutines and Setu
170. 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 Axis 1 2 Axis 2 Bits 12 15 Response Method high nibble 0 Status Only 1 Stop Normal 2 Stop Fast Figure A 1 Status Code Organization Response Methods 1 2 Status Only Errors Set the error flag and status code but do not affect motion 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 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 2 Table A 1 Status Word Error Codes ErrorNumber Response Description Hexadecimal 0 None No Error Configuration Errors StatusOnly Scaled data too big maximum value in range used Status Only Home Position gt Positive EOT Positive EOT used Status Only Home Position lt Negative EOT Negative EOT used Configuration Parameter Errors 10 StatusOnly Position Loop Time Constant too large Immediate command ignored 11 StatusOnly Position Loop Time Constant t
171. which is about 1 36 This ratio is greater than 1 32 so the resolution must be adjusted Assume the new pro gramming unit is 0 001 inch Determine the revised User Units per revolution using 0 001 inch resolution 14 336 inches x 45 0378 inches per revolution 45 0378 inches per rev 0 001 inches per User Unit 45 037 8 User Units per revolution This User Units to Counts ratio would be 45 037 160 000 or 0 2815 which is about 1 3 6 Thus values of 2815 for User Units and 10 000 for Counts could be used to obtain 0 001 inch resolution Acceleration Mode The Power Mate APM supports two types of acceleration Linear and Scurve Linear motion consists of constant linear acceleration and deceleration to specified velocities A profile of velocity versus time would show straight lines Scurve motion uses a variable acceleration An Scurve acceleration would begin slowly and increase up to the speci fied acceleration then decrease back to zero when the specified velocity was reached Scurve motions require twice the time and distance to change velocity compared to linear motions with the same acceleration CMOVE and PMOVE motion commands specify the acceleration mode for all pro grammed motion except the jump stop condition which is described in Chapter 6 Jog Find Home Abort and Move at Velocity use the configured Jog Acceleration Mode Important Configuration Considerations The Integrator will attempt to remove all Position Error a
172. xecution Whenever a program begins the override rate is initially set to 100 Thus changes to feedrate before the execute program bit is turned ON will be ignored but a feedrate commanded on the same sweep as an execute pro gram bit will be effective A percentage may be assigned to the feedrate from 0 to 120 When a Feedrate Over ride is commanded the Power Mate APM internally multiplies the feedrate percentage by programmed velocity to obtain a new velocity If the axis is moving the current move s Jog Acceleration Mode is used to change velocity to the new velocity All future move velocities will be affected by the feedrate change Note that when a feedrate of 0 is applied no motion will be generated until a new feedrate is commanded Also note the Moving I bit stays ON when the feedrate is 0 Feedrate Override has no effect on non programmed motion such as Jog Find Home or Move at Velocity Chapter 6 Power Mate Motion Control 6 29 Example 17 Feedrate Override During execution of this program feedrate changes of or 10 are commanded Dotted lines indicate 10 dashed lines indicate 10 ACCEL 1000 VELOC 6000 PMOVE 110000 INC LINEAR V a45270 Figure 6 18 Feedrate Override 6 30 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D s Multi Axis Programming Sync Blocks may be used in a multi axis program to synchronize the axis motion com mands at positions where ti
173. y or whenever encoder battery power is lost with the servo amplifier also in a powered down state Absolute Encoder mode must be configured in the Power Mate APM module to function properly Absolute mode is selected by setting the Power Mate APM s Logicmaster 90 30 configuration field Intgr Mode Integrator Mode to CONTINU Absolute Encoder Mode Position Initialization GFK 0840D When a system is first powered up in Absolute Encoder mode a position offset for the encoder must be established This can be done by using the Find Home cycle or the Set Position command Find Home Cycle Absolute Encoder Mode The Find Home cycle mode can be configured for Move Move or Home Switch operation Refer to Chapter 4 for additional details of Home Cycle operation The Home Offset and Home Position configuration items function the same as in Incremental Encoder mode At the completion of the Home Cycle Actual Position is set to the configured Home Position value The Power Mate APM internally calculates the encoder Absolute Feedback Offset needed to produce the configured Home Position at the completion of the Home Cycle This Absolute Feedback Offset must be permanently saved in the Power Mate APM by sending AQ command 4Ah Update Flash Memory after completion of the Home Cycle Once the Absolute Feedback Offset is saved in Flash memory the Power Mate APM will automatically initialize Actual Position after a power cycle and set the Position Va
174. ype Velocity 28h Velocity Vel 1 8 388 607 User Units sec Acceleration 29h Acceleration Acc 1 8 388 607 User Units sec sec Xx Xx Time Constant 2Ah Position Loop Time Constant Time Constant 0 5 10000 VFF 2Bh Velocity Feedforward VFF 0 100 Xx Xx Integrator 2Ch Integrator Time Constant Time Constant ITC 0 10 65 535 ms Xx Xx Xx VLGN 2Eh Velocity Loop Gain VLGN 0 255 Xx Xx Xx Torque 2Fh TorqueLimit Limit Range 1 100 Power Mate APM for Series 90 30 PLC Standard Mode User s Manual August 1996 GFK 0840D Table 4 8 Immediate Commands Using the 6 Byte Format for both 1 and 2 Axis Power Mate APM continued CARa Monte 400 elect Return Dag NN MCON ConfigurationModes CTRL xx ah ee CONDE Tm Pex os os o sat Upare ParameterData Par h 50h Load Parameterlmmediate Par 0 255 Parameter Data Range depends on parameter usage The word numbers represent an offset to the starting address for the references Only 00 or FFh are acceptable xx don tcare Null This is the default Immediate command Since the words are automatically transferred each PLC sweep the Null command should always be used to avoid inadvertent execution of another Immediate command Rate Override This command immediately changes

Power Mate for Series 90-30 PLC Standard Mode User`s Manual

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