Emerson EMC DX-202, DX-205, DX-318, DX-430, DX-450 User Manual

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EMERSON EMC

POSITIONING DRIVES & MOTORS

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Including IOM-1, PCM-1, PCM-5

T-16, Thumbwheels, and Parallel Programming

Other Manuals available, but bound separately:

T-21 Data Entry Panel

Information furnished by EMERSON EMC is believed to be accurate and reliable. However, no responsibility is assumed by MERSON EMC for its use. EMERSON EMC reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. EMERSON EMC also assumes no responsibility for any errors that may appear in this document. Information in this document is subject to change without notice.

P/N 400221-00 REV: A7

DATE: 6/24/92

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TABLE OF CONTENTS

INTRODUCTION....................................................................................................................................................... 6

OVERVIEW ............................................................................................................................................................. 6

YSTEM OVERVIEW ................................................................................................................................................... 7

NTRODUCTION TO THE BASIC POSITIONING DRIVE AMPLIFIER ................................................................................... 8

ERIPHERALS ............................................................................................................................................................. 9

PERATOR INTERFACE............................................................................................................................................. 10

T-21 D

ATA ENTRY TERMINAL ................................................................................................................................. 10

T-16 N

UMERIC DISPLAY.......................................................................................................................................... 10

TW-XXX T

POSITIONING DRIVE SPECIFICATIONS......................................................................................................... 12

DX-SERIES MOTORS AND AMPLIFIERS TYPICAL SPEED TORQUE CURVES ........................................ 15

INSTALLATION...................................................................................................................................................... 17

ASSEMBLY AND INSTALLATION CONSIDERATIONS ................................................................................ 17

TYPICAL 120 VAC LINE SIZING (SINGLE PHASE MODELS)....................................................................... 18

TYPICAL 230 VAC 3 PHASE MODELS.............................................................................................................. 19

AMPLIFIER MOUNTING INFORMATION ........................................................................................................ 27

AMPLIFER I/O LOCATIONS............................................................................................................................... 32

MOTOR MECHANICAL INFORMATION.......................................................................................................... 36

MOTOR WIRING .................................................................................................................................................. 43

MAIN/AUXILIARY AX

CABLE WIRING DIAGRAMS.............................................................................................................................. 48

HUMBWHEEL INTERFACE...................................................................................................................... 10

Wiring Considerations .......................................................................................................................................................20

Safety Considerations ........................................................................................................................................................21

Brake Option......................................................................................................................................................................21

Power Line......................................................................................................................................................................... 21

Grounding Considerations .................................................................................................................................................23

Electrical Noise..................................................................................................................................................................25

Magnetic Coil Noise ..........................................................................................................................................................25

Mechanical Consideration..................................................................................................................................................26

Load Coupling ...................................................................................................................................................................26

Selecting An Enclosure......................................................................................................................................................27

Amplifier Losses................................................................................................................................................................ 27

System Troubleshooting ....................................................................................................................................................27

POWER ......................................................................................................................... 46

TDS/TDL CABLE.............................................................................................................................................................48

TDT Cable .........................................................................................................................................................................48

Optional Bulkhead Connectors ..........................................................................................................................................49

OPERATING MODES............................................................................................................................................. 50

MODE SELECTION .............................................................................................................................................. 51

POSITIONING DRIVE CONFIGURATION AND PROGRAMMING ............................................................. 57

How To Start......................................................................................................................................................................58

PCX Program Revision...................................................................................................................................................... 58

Moving Through The Menus .............................................................................................................................................58

Changing Values In The Data Enter Screens .....................................................................................................................58

USING PCX DISK FILES...................................................................................................................................... 59

1. Data File........................................................................................................................................................................59

2. List File.........................................................................................................................................................................59

On-line Operations.............................................................................................................................................................60

ESTABLISHING COMMUNICATIONS .............................................................................................................. 62

DISK FILE OPERATIONS .................................................................................................................................... 63

DRIVE SETUP ....................................................................................................................................................... 64

LIMITS ................................................................................................................................................................... 68

INDEXING OPERATION MODE......................................................................................................................... 70

JOG ......................................................................................................................................................................... 75

HOME..................................................................................................................................................................... 76

OVERVIEW OF BASIC OPERATION MODES.................................................................................................. 84

Serial Mode........................................................................................................................................................................84

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Output Functions................................................................................................................................................................87

Input Functions ..................................................................................................................................................................88

DIAGNOSTICS......................................................................................................................................................... 98

F -POSITION ERROR FAULT............................................................................................................................ 100

FAULT INDICATOR CODES............................................................................................................................. 101

STABILIZATION OF HIGH INERTIA LOADS ................................................................................................ 106

INSTALLATION OF THE IOM-1 ....................................................................................................................... 107

INPUT/OUTPUT INTERFACE ........................................................................................................................... 108

Output Functions..............................................................................................................................................................110

Input Functions ................................................................................................................................................................111

EXAMPLES OF I/O CONNECTIONS TO THE IOM-1 ..................................................................................... 112

Detailed Description of Additional I/O Functions With the Addition of the IOM-1........................................................113

Input Functions ................................................................................................................................................................113

Output Function ...............................................................................................................................................................113

PARALLEL INTERFACE .................................................................................................................................... 114

CUSTOMER SUPPLIED THUMBWHEEL INTERFACE ................................................................................. 115

Thumbwheel Wiring........................................................................................................................................................116

PARALLEL PROGRAMMING INTERFACE ................................................................................................... 123

THUMBWHEEL AND PARALLEL PROGRAMMING SETUP AND OPERATION................................... 129

THUMBWHEEL AND PARALLEL PROGRAMMING INTERFACE ............................................................. 129

DATA FIELD NUMBER ................................................................................................................................................129

DATA FIELD PURPOSE................................................................................................................................................130

INDEX NUMBER ................................................................................................................................................ 131

T-16 SETUP AND OPERATION ........................................................................................................................ 136

INSTALLATION AND CONNECTIONS OF THE PCM-1 ............................................................................... 138

INPUT/OUTPUT INTERFACE (PCM-1)............................................................................................................ 139

OVERVIEW ......................................................................................................................................................... 139

UTPUT FUNCTIONS .............................................................................................................................................. 141

WHAT ARE PROGRAMS?................................................................................................................................. 147

DESCRIPTION OF PROGRAMMING FUNCTIONS ........................................................................................ 149

WAIT FOR INPUT..........................................................................................................................................................149

DWELL TIME.................................................................................................................................................................149

UPDATE OUTPUTS.......................................................................................................................................................149

EXECUTE INDEX..........................................................................................................................................................149

EXECUTE PROGRAM...................................................................................................................................................149

EXECUTE COMPOUND INDEX ..................................................................................................................................149

END .................................................................................................................................................................................149

HOW TO CREATE A PROGRAM...................................................................................................................... 151

PROGRAMMING CAPABILITIES .................................................................................................................... 154

SUSPEND/RESUME FUNCTIONS...................................................................................................................... 155

XTENDED SUSPEND/RESUME PROGRAMMING...................................................................................................... 156

INSTALLATION AND CONNECTIONS OF PCM-5........................................................................................ 158

SYNCHRONIZATION CABLE........................................................................................................................... 159

SCS-2 SYNC

ENCODER..................................................................................................................................... 161

BASIC OPERATION ........................................................................................................................................... 162

Some Application Examples............................................................................................................................................162

BI-POLAR SYNCHRONIZATION ..................................................................................................................... 168

ADDITIONAL PCM-5 PROGRAMMING .......................................................................................................... 177

PARAMETERS .................................................................................................................................................... 177

LEAD AXIS.......................................................................................................................................................... 177

SYNC RATIO....................................................................................................................................................... 177

SYNC VELOCITY SCALE FACTOR AND SYNC VELOCITY DECIMAL POINT ....................................... 178

BI-POLAR SYNC ENABLED............................................................................................................................. 179

INDEX, HOME .................................................................................................................................................... 179

PROGRAMS......................................................................................................................................................... 180

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SERIAL INTERFACE ........................................................................................................................................... 182

EXAMPLE OF A SERIAL MULTI-DROP CONNECTION............................................................................... 183

SERIAL SIGNAL FLOW DIAGRAMS............................................................................................................... 183

SETTING UP THE SERIAL INTERFACE SWITCHES AND PROTOCOL ..................................................... 184

LOCATIONS OF SWITCHES ............................................................................................................................. 184

SERIAL CABLES ................................................................................................................................................ 186

Wiring Diagrams From Computer to Drive .....................................................................................................................186

Wiring Diagram for DD-XXX Multi-Drop Cable............................................................................................................187

SERIAL INTERFACE CONTROL...................................................................................................................... 188

ASCII COMMANDS............................................................................................................................................ 189

SUMMARY OF SERIAL COMMANDS.............................................................................................................. 210

INDEX...................................................................................................................................................................... 216

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CUSTOMER SERVICE

Emerson EMC offers a wide range of services to support our customers’ needs. Listed below are some examples of these services.

SERVICE SUPPORT (612) 474-8833

Emerson Electronic Motion Control’s products are backed by a team of professionals who will service your installation wherever it may be. Our Customer Service Center in Minneapolis, Minnesota, is ready to help you solve these occasional problems over the telephone. It’s there, at the Center, that we are available 24 hours a day for emergency service to help speed any problem solving. Also, all hardware replacement parts, should they ever be needed, are available through our customer service organization. Need on-site help? Emerson provides on-site service, in most cases, the next day. Just call Emerson’s Customer Service Center when on-site service or maintenance is required.

TRAINING SERVICES (612) 474-1116

Emerson EMC maintains a highly trained staff of instructors to familiarize customers with Emerson Electronic Motion Controls and their applications. A number of courses are offered, many of which can be taught in your plant upon request.

APPLICATION ENGINEERING (612) 474-1117

An experienced staff of factory Application Engineers provides complete customer support for tough or complex applications. Our engineers offer you a broad base of experience and knowledge of electronic motion control applications.

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INTRODUCTION

OVERVIEW

The EMERSON EMC Positioning Drives are the first servo products specifically designed to offer high performance position control without the maze of boards, wires, connectors, pot adjustments and transformers normally associated with servo systems. The DX-Series drives support brushless motors and range in size from 2 in-lbs. To 400 in-lbs., continuous. Special care in motor selection has resulted in drives that have excellent torque to inertia ratios.

The drives consist of ruggedly constructed enclosures which contains all the required components for position and velocity control. The drives also provide connections for interfacing with external machine inputs and outputs, and logic control, along with a serial interface port that is used to program the drive.

Calibration

Calibration of the Positioning Drive is virtually eliminated because all user potentiometer adjustments have been eliminated. The potentiometer adjustments have been replaced by firmware. The software pre-sets the compensation values and continuously adjusts these values during motion. This allows the system to operate over a large inertial range without any manual adjustments or tuning required.

Installation

Installation and wiring is fast and easy because the Positioning Drive operates in most environments directly from an AC line source without requiring a separate isolation transformer. The unit is designed to be back mounted within a standard Nema enclosure typically found in a production facility. The size has also been minimized to allow users to reduce the space requirements for incorporating a servo control into their production machinery.

Motor

Each Positioning Drive includes a high performance servo motor whose characteristics have been matched to the drive amplifier. Thus, the chance for a mismatch between the motor and the Positioning Drive is eliminated.

Programming and Troubleshooting

EMERSON EMC provides an easy to use software programming package with every drive that operates on an IBM PC/XT/AT or compatible computer with 512K bytes of RAM and a serial interface port. This software makes the Positioning Drive simple to program even for first time servo users. It is almost essential that the user of the positioning servo drive have access to a personal computer (PC). The PC can be used to change data, up and down load data and most importantly, help solve problems during operation and startup.

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System Overview

Following are the specific model numbers used in configuring the Positioning Drives.

Table I Positioning Drive Components

DX-202 (2 in-lbs.) DXA-202 Amplifier

DXM-202 Motor TDT-XX Cable

DX-205 (5 in-lbs.) DXA-205 Amplifier

DXM-202 Motor TDT-XX Cable

DX-308 (8 in-lbs.) DXA-308 Amplifier

DXM Motor TDL-XX Cable

DX-318 (18 in-lbs.) DXA-318 Amplifier

DXM Motor TDL-XX Cable

DX-430 (30 in-lbs.) DXA-430 Amplifer

DXM or DXE-430 Motor* TDL-XX Cable

DX-450 (50 in-lbs.) DXA-450 Amplififer

DXM or DXE-430 Motor* TDL-XX Cable

DX-480 (80 in-lbs.) DXA-480 Amplifier

DXM or DXE-480 Motor* TDL-XX Cable

DX-780 (80 in-lbs.) DXA-780 Amplifier

DXM-780 Motor TDL-XX Cable

DX-7120 (120 in-lbs.) DXA-7120 Amplifier

DXM-7120 Motor TDL-XX Cable

DX-6120 (120 in-lbs.) DXA-6120 Amplifier

DXM-6120 Motor RC-XX Cable

DX-6200 (300 in-lbs.) DXA-6200 Amplifier

DXM-6200 Motor RC-XX Cable

DX-6300 (300 in-lbs.) DXA-6300 Amplifier

DXM-6300 Motor RC-XX Cable

DX-8200 (200 in-lbs.) DXA-8200 Amplifier

DXM-8200 Motor

DX-8300 (300 in-lbs.)

DX-8400 (400 in-lbs.) DXA-8400 Amplifier

NOTE: The DX-8XXX series motor and Amplifiers are interconnected Via screw terminals so as to

allow for customer provided wiring Not to exceed 100ft.

NOTE: XX = CABLE LENGTH (FT)15

25 25 50 50

*NOTE: DX-430, DX-450 and DX-480 Drives can be provided with Motors that have either typical

English or metric flange and Shaft dimensions. The metric motor is designated with a DXM prefix and the English version is designated with a DXE prefix.

DXA-8300 Amplifier DXM-8300 Motor

DXM-8400 Motor

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Introduction to the basic positioning drive amplifier

The Positioning Drive amplifier is different from common analog amplifiers in that it includes a position feedback loop and the electronics to control motion functions. To accomplish this, the motor uses resolver feedback. The resolver converter electronics in the amplifier develops velocity and position feedback signals required for high performance and precise velocity and position control.

In addition the amplifier offers three standard modes of control providing a host of alternatives for implementing real time motion control.

In the ANALOG TORQUE or VELOCITY mode, the amplifier responds to a conventional +/10 volt signal. Most variable speed drives and servo amplifiers on the market today receive commands via analog input.

The true power and versatility of the Positioning Drive is best utilized in the additional positioning control modes. In most applications the user will use one of the following modes of operation.

In the PULSE mode, the drive responds to a serial pulse train representing externally generated incremental position change commands. These commands are normally in the form of CW or CCW directional pulses. This mode is commonly used to control DC stepper motors or numeric controlled (CNC) machinery.

The INDEXING mode allows up to thirty-two different indexes or positions to be preprogrammed and stored in a non-volatile memory. These indexes plus other commands such as STOP and JOG are selected easily by the drive’s parallel input/output (I/O) lines from devices such as PLCs or operator push buttons. Parallel I/O commands can be used for stand alone operation or, simultaneously in conjunction with any other two control modes.

Another powerful feature of the INDEXING mode allows ASCII commands through the standard RS423 serial interface. This interface port allows the user to down load new dimensional data e.g., position, distance, velocity, etc., and command an internally generated index using those parameters. These ASCII serial commands are well suited to operation from the RS232C serial interface on an IBM Personal Computer (PC) or Programmable Logic Controller (PLC) with ASCII or Basic Module.

For additional stand alone motion control capability, the drive is designed to accept a series of application oriented modules called “PCM” modules. The PCMs can be attached to any drive by simply plugging them onto the front. The PCM is designed to share the power supply inside of the drive and includes 12 additional optically isolated inputs/outputs (making a total of 24). When attached, the PCM module extends the operation of the Positioning Drive system.

The IOM-1, PCM-1, PCM-2 and PCM-5 modules are designed to be plug-on additions to EMERSON EMC’s line of Positioning Drives. Each module is intended to enhance a specific performance characteristic of the positioning drives.

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Peripherals

IOM-1 Input/Output Expander Module

The IOM Module mounts to the front of the basic drive to double the I/O capability for those applications where the number of inputs and outputs provided with the basic unit are not adequate for interfacing motion to the machine logic controllers. Each of these lines are optically isolated and can be connected in either a current sinking or current sourcing arrangement. In addition, the IOM-1 includes the parallel interface port required for connecting 1 or 2 thumbwheels and 1 remote display or parallel communications with a PLC.

PCM-1

The PCM-1 module converts the basic Positioning Drive from a “smart” servo drive system with indexing capabilities into a motion control system capable of executing numbered sequences of indexes called motion programs. Each motion program combines basic indexes to achieve complex motion profiles beyond what is possible with the basic drive. In addition, the PCM module greatly increases the non-volatile memory storage capability of the standard digital drive. This allows the user greater flexibility in both the size and the number of programs (and indexes) available. Another advantage of PCM-1 is that it increases the number of input lines from 8 to 16 and the number of output lines is increased from 4 to 8. All inputs and outputs are assignable from a standard list of I/O functions. Lastly, the PCM-1 allows the user to create compound indexes and includes the parallel interface port required for connecting 1 or 2 thumbwheels and 1 remote display or parallel communications with a PLC.

PCM-5

The PCM-5 has most of the capability of the PCM-1. The PCM-5 is able to do electronic synchronized line shafting and ratio control. This is accomplished by using an external encoder or drive representing a lead axis connected to the PCM-5. The drive with the PCM-5 can then be synchronized to the lead device. This mode of operation also allows for pulse counting of the lead device and indexing at velocities proportional to its speed. With this capability, flying shear/cutoff applications can easily be configured.

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Operator Interface

Emerson EMC can provide three different peripheral devices to enhance the operator friendliness of your drive. The T-21 Data Entry Terminal is ideally suited for providing machine operators with the ability to enter and/or alter and display machine motion parameters controlled by Emerson Digital Positioning Servo Drive. The T-16 displays position and velocity parameters using large sized LEDs that are visible from several feet away. Emerson EMC offers a simple thumbwheel interface called a TW-XXX that is offered in many different configurations. The TW-XXX is used to change data of a specific motion parameter or parameters. The thumbwheel option is ideal for applications needing minimum operator interface.

T-21 Data Entry Terminal

The T-21 communicates with any Emerson Positioning Drive using serial ASCII codes and allows the machine designer to access, display, or alter certain motion parameters such as index length. For frequently accessed motion parameters, the operator cam simply depress one of three user programmable function switches located on the front panel. By depressing the correct function key, the proper user created message is displayed. The message can be created to include information as to what setup parameter is being changed, on which axis, etc. If more than 3 operator altered setup parameters are required, a fourth F(x) key allows the user to store up to 95 additional operator alterable setup functions.

T-16 Numeric Display

The T-16 is used to display position or velocity of the drive. The T-16 has 7 large LEDs that are visible from several feet away. This allows the operator to view data shown on the display from different positions on a machine. The T-16 requires the use of the ION-1 or a PCM-1 module. The T-16 plugs into the parallel port on the module.

TW-XXX Thumbwheel Interface

The thumbwheel interface provides the user with a non-serial interface method for making changes to specific motion functions. The user can set up the thumbwheel to change velocities, distances/positions, dwell times, index counts, and acceleration and deceleration times. All the thumbwheels are mounted in a small, self contained enclosure. Cables can be ordered in specific lengths from 3 feet to 50 feet. The TW-XXX requires the user to have an IOM-1 or a PCM-1 module. The TW-XXX plugs into the parallel port on the module.

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FAMILY OF POSITIONING DRIVE PRODUCTS

Figure 1 Peripherals

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POSITIONING DRIVE SPECIFICATIONS

Specifications +/- 10% Table II Positioning Drive Specifications

DRIVE PERFORMANCE Drive Model#Motor

Model #

DX-202 DXM-202 2/4 .0000855 3000 7 AMP 2A(S.B.) 1.8 23 1.1/2.2 DX-205 DXM-205 5/10 .000253 3000 7 AMP 2A(S.B.) 1.8 23 3.0/6.0 DX-308 DXM-308 8/16 .0005 3000 7 AMP 2A(S.B.) 2.9 34 2.8/5.6 DX-318 DXM-318 18/36 .001 3000 10 AMP 5A(S.B.) 3.38 40 5.4/10.8 DX-430 DXM-430 30/60 .0026 3000 15 AMP 5A(S.B.) 3.38 40 8.9/17.8 DX-450 DXM-450 50/85 .0052 3000 25 AMP 5A(S.B.) 3.38 40 14.8/24.0 DX-480 DXM-480 80/160 .00772 3000 30 AMP 8A(S.B.) 3.36 42 24/48 DX-780 DXM-780 80/160 .013 3000 30 AMP 8A(S.B.) 3.38 40 24/48 DX-7120 DXM-7120 120/240 .021 2000 30 AMP 8A(S.B.) 5.57 66 24/48

DX-6120 DXM-6120 120/240 .0096 3000 15 AMP 7A 8 100 15/30 DX-6200 DXM-6200 200/400 .0192 3000 20 AMP 7A 8 100 25/50 DX-6300 DXM-6300 300/600 .0268 3000 30 AMP 10A 8 100 38/76

DX-8200 DXM-8200 200/300 .04 3000 20 AMP 7A 7.4 96 27/41 DX-8300 DXM-8300 300/450 .08 3000 30 AMP 10A 7.4 96 40/60 DX-8400 DXM-8400 400/600 .12 3000 40 AMP 10A 7.4 96 54/81

INPUT VOLTAGE: DX-202, DX-205, DX-308, DX-430, DX-450, DX-480, DX-780, DX-

INPUT VOLTAGE: DX-6120, DX-6200, DX-6300, DX-8200, DX-8300, DX-8400 = 196-

SWITCHING FREQUENCY: DX-202, DX-205, DX-308, DX-430 = 20 Khz

DEAD BAND: Zero VELOCITY SIGNAL INPUT: ±10 vdc typical (10 bit resolution speed selection ±10 volt) TORQUE SIGNAL INPUT: ± vdc typical (10 bit resolution speed selection ±10 volt) PULSE MODE INPUT: TTL compatible, 500 nsec minimum pulse width, 210 Khz max

ANGULAR ACCURACY: Cable Length 15FT

USER UNITS/REV: Programmable Range (200-25000) AMPLIFIER THERMAL SHUT DOWN AS DETECTED IN POWER STAGE:

All Drives: 80º - 90º C

MOTOR THERMAL SHUT DOWN AS DETECTED IN MOTOR (CASE TEMP):

All Motors: 100º - 115º C

Torque

Cont/Peak

IN/LBS

Rotor Interia IN/LBS/SEC

Max. RPM Bus Fuse Shunt Fuse KT

IN-LBS/AMPKEVolts/KRPM

7120 = 96-132 VAC, 50/60 Hz, single phase

264 VAC 3 PHASE 50/60 Hz

DX-450, DX-480, DX-780, DX-7120 = 15 Khz DX-6120, DX-6200 = 15 Khz DX-6300 = 12 Khz DX-8200, DX-8300, DX-8400 = 10 Khz

frequency

50FT 100FT

Minutes ±20 ±30 ±40

Amplifier

Current Ratings

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OPTIONAL FAIL-SAFE BRAKE: (Activated by the Positioning Drive)

Table III Fail Safe Brake

Model Holding Torque

IN-LBS

DX-308 12 DX-318 25 DX-430 45 DX-450 75 DX-480 120 DX-780 120 DX-7120 180

DX-6120 400 DX-6200 400 DX-6300 400

*DX-8200 300 *DX-8300 450 *DX-8400 600 *Special (consult factory)

COMMAND PULSE: 5-15 vdc

MODE INPUTS: 25-70 milliamps

ANALOG INPUTS: -10 vdc to +10 vdc operating range

-12 vdc to +12 vdc absolute maximum Different input greater than 9K ohms

SERIAL INTERFACE: RS423 signal compatible

Xmit, Rec, and GND

INPUTS AND OUTPUTS: Outputs: sink or source (2 terminals);

200 Ma max (external current limit required) each

Inputs: 10 to 30 vdc (internal current limit provided)

10, 12, 15 and 24 vdc typical

Table IV User Memory Capacity

User Memory Capacity

Drive

w/IOM-1

Jog 2 2 2 2 Home 1 1 1 1 Indexes 32 32 256 256 Programs 0 0 64 64

Drive

w/PCM-1

Drive

w/PCM-5

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Table V Number of User Programs

Number of Required

User Programs

1 1000 2 500 3 333 4 250 5 200

-62 16 63 15

Average Number of Available

Steps Per Program

Table VI Motor Load Specifications

Motor Radial and Axial Load Specifications

Motor Max Radial Load Max Axial Load

DXM-202 10 lbs 8 lbs DXM-205 10 lbs 8 lbs DXM-308 20 lbs 15 lbs DXM-318 20 lbs 15 lbs DX* -430 50 lbs 20 lbs DX* -450 50 lbs 20 lbs DX* -480 75 lbs 40 lbs DXM-780 150 lbs 50 lbs DXM-7120 150 lbs 50 lbs DXM-6120 150 lbs 50 lbs DXM-6200 150 lbs 50 lbs DXM-6300 150 lbs 50 lbs DXM-8200 150 lbs 50 lbs DXM-8300 150 lbs 50 lbs DXM-8400 150 lbs 50 lbs

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DX-SERIES MOTORS AND AMPLIFIERS TYPICAL SPEED TORQUE CURVES

DX-202, DX-308, DX-318, DX-430, DX-480, DX-780

Figure 2 Typical Speed Torque Curve

DX-7120

Figure 3 Typical Speed Torque Curve

DX-205

Figure 4 Typical Speed Torque Curve

∗ Continuous torque rating of the motors is measured using a 10” X 10” X 0.25” mounting plate that

acts as a heatsink.

∗ All specifications are ± 10%.

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DX-450

Figure 5 Typical Speed Torque Curve

DX-6120, DX-6200, DX-6300

Figure 6 Typical Speed Torque Curve

1) Peak operation is available for ≥1.0 seconds from 0 torque.

2) Speed torque curves are based on 144” sq. by ½” thick aluminum face plate.

3) Derate available torque by 1% per °C for operation above 30°C, to an ambient temperature of

45°C, for motor and amplifier.

DX-8200, DX-8300, DX-8400

Figure 7 Typical Speed Torque Curve

∗ Continuous torque rating of the motors is measured using a 10” X 10” X 0.25” mounting plate that

acts as a heatsink.

∗ All specifications are ± 10%.

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INSTALLATION

OVERVIEW

The Positioning Drives were designed with simple installation in mind. The Drive normally back-mounts into a standard NEMA enclosure. Because of its small footprint and no need for external transformers, boards and power supplies, the Positioning Drive saves significant panel space and cost over alternative servo positioning systems. Wiring and connecting the drive is equally simple. AC line power is connected via provided screw terminals. All 120 VAC models use single phase 50/60 Hz power. All 230 VAC models use 3 phase 50/60 Hz power.

Inputs and outputs for control and status are wired to a 12 position, detachable terminal strip (this also makes servicing easy). The RS423 serial interface used for setup, status and control can be connected with a 9 pin D-type connector. The motor connections for the 120 VAC single phase models are accomplished with factory supplied cable and mating connectors. The higher power 230 VAC 3 phase models are connected via screw terminals at the amplifier and motor. This allows the user to supply his own wire.

The larger drive motors also have NPT pipe thread holes for metallic raceways. It is a requirement that the stator wiring R, S, T be run in metallic raceways and 1-1/4” pipe conduit holes are provided. The feedback wiring must be done by using shielded cabling with 100% shielding via a foil shield and a braided shield.

ASSEMBLY AND INSTALLATION CONSIDERATIONS

The following procedures outline the methods necessary to assure reliable and trouble free installation of the EMERSON EMC Positioning Drive.

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TYPICAL 120 VAC LINE SIZING (SINGLE PHASE MODELS)

Figure 8 Typical 120 VAC Line Sizing

The approximate AC line source VA rating can be determined by multiplying the AC line sizing by 120 VAC.

Example: DX-780

Line sizing = 40 amp (40 amps) ∗ (120 VAC) = 4800 VA

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TYPICAL 230 VAC 3 PHASE MODELS

Figure 9 Typical 230 VAC 3 Phase Connections

The approximate AC line source VA rating can be determined by W = E•I 1.732

Example: DX-8200 = 20 Amps

Watts = 230 VAC • 20 Amps • 1.732 = 7,967

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The following table should be used as a guideline for minimum sizing the AC wiring.

Table VII Typical Line Ampacities & Wire Gauges

Drive Typical Line

Ampacities

DX-202 10 A 16 AWG DX-205 10 A 16 AWG DX-308 10 A 16 AWG DX-318 10 A 16 AWG DX-430 20 A 12 AWG DX-450 25 A 12 AWG* DX-480 40 A 10 AWG* DX-780 40 A 10 AWG* DX-7120 40 A 10 AWG* DX-6120 15 A 12 AWG* DX-6200 20 A 12 AWG* DX-6300 30 A 10 AWG* DX-8200 20 A 12 AWG* DX-8300 30 A 10 AWG* DX-8400 40 A 8 AWG*

Recommended

Minimum Wire Gauge

* AC power lines that are farther than 50 ft. from the power source, many require a larger gauge that

what is recommended above.

Wiring Considerations

If you are not sure of your grounding or signal wiring techniques, you should observe the recommended practices according to the IEEE Ground Book, ANSI Standard C1141 and the National Electric Code.

Wiring of any industrial equipment should be done with some consideration for future troubleshooting and repair. All wiring should be either color coded or tagged with industrial wire tabs.

All I/O wiring must be done with industrial grade insulated wire to withstand the environment of the application. 18 to 24 gauge wire must be used for I/O wiring. The use of larger gauge wire will cause the I/O terminals to prematurely fatigue. Each input and output to the control unit is designed to have high noise immunity. This does not mean that high voltage, noise emitting wiring on the rest of the application can be run adjacent to the control inputs. Precautions should be taken to eliminate any possible noise from reaching the drive.

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Safety Considerations

The user is responsible for emergency interlock switches. Any master interlock should be wired to shut down AC power to all parts of the system. Your system should be designed such that power is disconnected from the output loads any time the equipment is not running, or when the emergency stop is activated.

Brake Option

An additional safety and operational feature can be added by ordering the optional fail-safe brake. The brake allows the motor shaft to be held whenever power is removed from the brake coil (such as in a power failure). The user can control the on/off operation of the brake through either serial commands or an assigned input line. The power supply needed to operate the brake is provided internally in the drive.

Power Line

The lower power 120 VAC (DX-202 thru DX-7120) drives are designed to operate on a 50/60 Hz, single phase AC power line. The AC voltage of this power line must be within the specified range of 96-132 VAC and be free of voltage transients which exceed this range. If it is found that the AC power does not meet these specifications, further AC line conditioning may be required. Also, if there is sensitive electronic equipment (digital computer, test equipment, etc.) operating on the same AC power line as the Drive, additional EMI/RFI filtering may be required to reduce the effects of conducted AC line noise. Operation at 96 VAC will reduce the drive’s performance at high (max) speed.

The AC input lines are connected to the drive by means of the 3-position terminal strip located on the bottom plate of the drive. The AC line wires should be connected as shown below. Insufficient or incorrectly applied AC line power is a major cause of drive problems. Wiring sizing and transformer selection (if necessary) should be done carefully.

CAUTION: To insure proper operation after a power down the user should wait a minimum of

10 seconds before reapplication of power.

Figure 10 Typical 120 VAC Drives

• L2 is the AC neutral wire and must be grounded (see “Grounding Considerations”.)

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The high power 230 VAC (DX-6120, DX-6200, DX-6300, DX-8200, DX-8300, DX-8400) are designed to operate on 3 phase AC power. The AC voltage for these drives must be between 196 to 264 VAC.

The AC input lines are connected to the drive by means of the 4 terminals located on the bottom plate of the drive. The AC line wires should be connected as shown below. Insufficient AC line power from wire size and control transformers is a major cause of drive problems.

Figure 11 Typical 230 VAC Drives

The GND terminal is bonded to the chassis and must be connected to earth ground.

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Grounding Considerations

The GND terminal of the drive is internally bonded to the frame. The enclosure ground and the drive ground should be a common single point that ultimately is a continuous electrical path to earth ground. The following example illustrates the ideal grounding arrangement of the AC power.

Figure 12 Grounding Illustration

NOTE: These ground wires should not be shared with other equipment. Also note that the

neutral (L2) for the 120 VAC source for the low power positioning drive is grounded.

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The following two circuits are given as EMC recommended external disconnecting examples for the 120 VAC low power drives.

Figure 13 External Disconnect Examples (120 VAC Low Power)

The following examples are for the 230 VAC models. (DX-6XXX’s & DX-8XXX’s)

Figure 14 External Disconnect Examples (230 VAC High Power)

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Electrical Noise

Effects of electrical noise on the electronic equipment are greatly reduce when the techniques outlined below are closely followed.

1. Do not run low power control signals and high power wiring in the same raceway.

NOTE: If mixing wire cannot be avoided, then the low voltage control input and output wiring must be shielded. The shield for these wires should only be connected to ground only at the source end of the signals.

2. Never connect both ends of a shielded cable to ground. This may cause a ground loop

condition which could be very difficult to locate.

3. It is suggested that all the wires in the system be kept as short as possible.

Magnetic Coil Noise

In the case of DC relays, a diode is installed across the coil in a direction that will cause the voltage transient to be dissipated through the diode.

Figure 15 Magnetic Coil Noise (DC Line)

In the case of AC coils a capacitor and resistor are installed across the coil to supress the unwanted transient.

Figure 16 Magnetic Coil Noise (AC Line)

The specific values of resistance and capacitance may vary depending on the inductance of the coil. Consult the relay manufacturer for the proper values to use. These suppressor networks greatly extend the life of the contacts controlling the coil because the transient energy, which can easily reach 1000 volts, shunts through the suppressor’s rather than arcing across the controlling contacts as they open.

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Mechanical Consideration

To provide good mechanical alignment the mounting surface of the motor face plate is held perpendicular to the motor shaft to within 0.005 inches of the motor shaft. Projecting above the plane of the mounting surface is a close tolerance circular pilot boss, which, when matched with a pilot hole in the mounting structure, facilitates interchanging the motor, and minimizes the need for mechanical adjustments. The mounting surface is fitted with four holes, equally spaced on a bolt circle pattern.

The mounting panel must be stiff enough so it does not deflect significantly when radial loads are applied to the motor shaft. The mounting panel should also have good thermal conductivity, especially if peak performance is demanded of the motor.

Mechanical shock to the motor case or shaft (e.g., from striking or dropping) must be avoided to prevent damage to the motor. Possible results from striking or dropping include: Misalignment of the resolver; damage to armature bearings; cracking of the motor case; unbonding or demagnetization of the permanent magnets. Any of these would render the motor unserviceable.

Load Coupling

A flexible coupling must be used on the motor shaft to minimize mechanical stress due to radial loads, axial loads and/or misalignment. Radial and axial loading cannot exceed specified values.

Table VIII Load Coupling

Motor Max Radial Load Max Axial Load

DXM-202 10 lbs** 8 lbs DXM-205 10 lbs** 8 lbs DXM-308 20 lbs** 15 lbs DXM-318 20 lbs** 15 lbs DX* -430 50 lbs** 20 lbs DX* -450 50 lbs** 20 lbs DX* -480 75 lbs** 40 lbs DXM-780 150 lbs** 50 lbs DXM-7120 150 lbs** 50 lbs DXM-6120 150 lbs** 50 lbs DXM-6200 150 lbs** 50 lbs DXM-6300 150 lbs** 50 lbs DXM-8200 150 lbs** 50 lbs DXM-8300 150 lbs** 50 lbs DXM-8400 150 lbs** 50 lbs

* M-(XXX) = Metric E –(XXX) = English ** Maximum radial load is rated at 1 inch from the motor face

Gear Reduce Oil

It is strongly suggested that a synthetic oil is used in the gear reducer or rotary tables. This will reduce the amount of current it takes to drive the motor.

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Selecting An Enclosure

The EMERSON EMC Positioning Drive is designed for the industrial environment. However, no sophisticated electronic system can tolerate certain atmospheric contaminants such as moisture, oils, conductive dust and metallic particles. Therefore, if the drive is going to be subjected to this type of environment, we strongly urge you to mount your drive in a NEMA type 12 enclosure. Proper ventilation and filtering should also be provided. Amplifier losses should be considered for enclosure sizing and ventilation.

Amplifier Losses

The exact power losses in any application depend on the application. The following table losses would represent typical examples. The bridge power losses and shunt power losses can be derated based on any duty cycle for power demand.

The logic supply power consumption varies based on PCM modules. For all 120 VAC models, the logic power consumption is about 60 watts for the 230 VAC models. The consumption is about 100 watts.

The next consideration would be bridge power losses which vary by amplifier size. The table represents losses based on maximum continuous output current to the motor.

In applications where constant acceleration and deceleration occur, additional losses occur in the shunt regulator where energy stored in the rotating inertia is commutated to the drives BUS capacitors. This energy causes the BUS voltage to increase and once sensed, the excess voltage is shorted through a load resistor. These losses could easily equal the bridge power losses.

Table IX Amplifier Losses (By Model)

Model Logic Supply Bridge Losses Shunt Losses Total

DXA-202 60W 10W 10W 80W DXA-206 60W 25W 25W 110W DXA-308 60W 45W 45W 150W DXA-318 60W 100W 100W 260W DXA-430 60W 130W 130W 320W DXA-450 60W 200W 200W 460W DXA-480 60W 340W 340W 740W DXA-780 60W 340W 340W 740W DXA-7120 60W 340W 340W 740W DXA-6120 100W 400W 400W 900W DXA-6200 100W 700W 700W 1500W DXA-6300 100W 1000W 1000W 2100W DXA-8200 100W 700W 700W 1500W DXA-8300 100W 1000W 1000W 2100W DXA-8400 100W 1500W 1500W 3100W

System Troubleshooting

If you encounter a system problem, double check the installation instructions. These instructions eliminate most of the problems encountered. If you have a problem, call EMERSON EMC at (612) 474-8833 and ask for Customer Service Department.

AMPLIFIER MOUNTING INFORMATION

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DX-202, DX-205, DX-308

Figure 17 Amplifier Mounting Information (DX-202, DX-205, DX-308)

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DX-318, DX-430, DX-450

Figure 18 Amplifier Mounting Information (DX-318, DX-430, DX-450)

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DX-480, DX-780, DX-7120

Figure 19 Amplifier Mounting Information (DX-480, DX-780, DX-7120)

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DX-6120, DX-6200, DX-6300, DX-8200, DX-8300, DX-8400

Figure 20 Amplifier Mounting Information (DX-8XXX, DX-6XXX)

CAUTION: These amplifiers cannot be mounted on a combustible surface, as a 1000 watt

shunt resistor is located in the base of the chassis. A metal back panel or no back panel is preferred.

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AMPLIFER I/O LOCATIONS

DX-202, DX-205, DX-308

Figure 21 Amplifier I/O Locations (DX-202, DX-205, DX-308)

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DX-318, DX-430, DX-450

Figure 22 Amplifier I/O Locations (DX-318, DX-430, DX-450)

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DX-480, DX-780, DX-7120

Figure 23 Amplifier I/O Locations (DX-480, DX-780, DX-7120)

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DX-6120, DX-6200, DX-6300, DX-8200, DX-8300, DX-8400

Figure 24 Amplifier I/O Locations (DX-8XXX & DX-6XXX)

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MOTOR MECHANICAL INFORMATION

DXM-202, DXM-205

Figure 25 Motor Mechanical Information (DXM-202, DXM-205)

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DXM-308, DXM-318

Figure 26 Motor Mechanical Information (DXM-308, DXM-318)

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DXM-430, DXM-450, DXM-480

Figure 27 Motor Mechanical Information (DXM-430, DXM-450, DXM-480)

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DXE-430, DXE-450, DXE-480

Figure 28 Motor Mechanical Information (DXE-430, DXE-450)

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DXM-780, DXM-7120

Figure 29 Motor Mechanical Information (DXM-780, DXM-7120)

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DXM-6120, DXM-6200, DXM-6300

Figure 30 Motor Mechanical Information (DXM-6120, DXM-6200, DXM-6300)

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DXM-8200, DXM-8300, DXM-8400

Figure 31 Motor Mechanical Information (DXM-8200, DXM-8300, DXM-8400)

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MOTOR WIRING

DX* 308,318,430,450,480,780,7120

*English or metric motors.

The diagram below indicates how the motor, resolver, thermostat and optional brake are wired.

Figure 32 Motor Wiring (DX-308, DX-318, DX-430, DX-450, DX-480, DX-780, DX-7120)

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MOTOR WIRING – DXM 202, DXM-205

Figure 33 Motor Wiring (DXM-202, DXM-205)

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MOTOR WIRING – DXM 6120, DXM-6200, DXM-6300

Figure 34 Motor Wiring (DXM-6120, DXM-6200, DXM-6300)

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MAIN/AUXILIARY AC POWER

Figure 35 Motor/Amplifier Auxiliary Wiring

An external AC voltage of 220 VAC single phase can be connected to the AUX AX power input to the appropriate terminals (L1, L2 and GND). The main/auxiliary switch can be switched to the AUX position. Power for the logic supplies that power the computer is now separated from the high power circuits that create the motor +BUS voltage. The high current and voltage can now be removed from the three phase L1/L2/L3 and GND terminals, thus eliminating the DC BUS supply voltage source for the motor. Under these conditions, the position feedback from the resolver is in tact, yet high power voltage and current sources for R, S & T are removed. Motor power reduces to nothing as the BUS capacitors discharge after AC power is removed from the “MAIN AC POWER” input. An un-interruptible power supply of 220 VAC at 1 amp is adequate for power to the auxiliary input.

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FEEDBACK WIRING – DXM-8200, DXM-8300, DXM-8400

Figure 36 Feedback Wiring (DX-8XXX’s)

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CABLE WIRING DIAGRAMS

TDS/TDL CABLE

Shown below is a diagram on how the interconnect cable from the Drive to motor is assembled.

Figure 37 Cable Wiring Diagram (TDS/TDL)

The DX-308 and DX-318 use cable model TDS-XX. The DX-430, DX-450, DX780, and DX7120 use model TDL-XX.

WHERE XX DESIGNATES LENGTH XX = LENGTH (FT) 15 15 25 25 50 50

TDT Cable

Figure 38 Cable Wiring Diagram (TDT) The DX-202, and DX-205 use cable model number TDT-XX

WHERE XX DESIGNATES LENGTH XX = LENGTH (FT) 15 15 25 25 51 50

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Optional Bulkhead Connectors

Figure 39 Mounting Information, Bulkhead Connector, TDLB Cable

Figure 40 Mounting Information, Bulkhead Connector, TDTB Cable

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OPERATING MODES

OVERVIEW

The Positioning Drive is differentiated from common analog servo drives in that the amplifier includes a position feedback loop. As a result, the amplifier will provide both precise position and velocity control of the motor. The drive utilizes resolver feedback for both velocity and position feedback. Thus, a tachometer is no longer required.

The drives include three different control modes providing alternatives for implementing motion control. The modes are listed below.

Table X Motion Control Modes

MODE CONTROL INTERFACE COMMAND DEVICE

Analog Velocity Zero to +/- 10vdc Velocity Controller

Torque Zero to +/- 10vdc Torque Controller

Pulse Position

Increments

Position Increments CW & CCW Pulses Motion Generator,

Indexing Index, Home, Jog Inputs & Outputs 10 to

Index, Home, Job and Motion Programming

Pulse & Direction

+5 to +15V Logic

+30vdc, Optically Isolated (sink or source)

RS423/422/232C Serial Interface XMIT/REC ASCII

Motion Generator,

Indexer, CNC

Relay Logic, Operator Control Panel or a Programmable Logic Controller

Personal Computer, ASCII Unit on PLC, ASCII Terminal

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MODE SELECTION

There are basically three separate operating modes: ANALOG, PULSE FOLLOWER, and INDEXING. The DIP switches 3 and 4 are used to help configure the operating modes. Units are shipped with DIP switches 3 and 4 OFF.

Figure 41 Dipswitches/Mode Selection

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Analog Mode

In the Analog Torque or Velocity mode, the servo amplifier responds to a conventional ±10 volt DC signal. Most variable speed drives and servo amplifiers on the market today receive commands via this type of signal. If the DIP switches are set to enable this mode, the display character of the digital drive will be an (A). In this mode, a ±10 volt command signal is equated to ± velocity or peak torque as determined by the drives preprogrammed velocity (3000 RPM default) or peak torque based on drive size. ±10 = ± peak torque. The external and serial control modes are not ignored if an (A) is on the display. Sending an SC=1 to the drive would disable analog control and enable serial control with an (E) being on the display. If an (A) was on the display and an initiate index home or job from the I/O occurs, then the (A) will be replaced with an (E) and the requested motion occurs. At the end of motion, the display and mode revert to (A).

In either of the two analog modes of operation a (+)/(-) 10 VDC signal is equated to either (CW) or (CCW) maximum programmed velocity in the velocity mode or CW or CCW full peak rating in the torque mode. The mode of operation can be selected via the mode select switches on the front of the servo drive.

NOTE: CW rotation is defined while facing the shaft end of the motor.

Figure 42 Velocity/Torque Mode

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In either mode the ±10 VDC command signal is connected to the command input. The input circuit of the drive is a differential input amplifier with the following characteristics. Application of a + voltage to pin 7 with respect to pin 13 (GRD) will produce either a CW motion or torque in the CW direction as viewed from the shaft end of the motor.

Figure 43 Command Input Circuit IMPORTANT: Voltages on pins 6 or 7 must not exceed ±12 VDC with respect to analog

ground.

Figure 44 Command Connector To execute the Analog Mode, the mode select switches must be set correctly for either Analog Velocity or Analog Torque control and apply ±10 volts DC to the command connector on the amplifier.

REMINDER: Both the hardware and software position travel limits are active if they are set

up.

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Pulse Mode

In the Pulse mode, the Positioning Drive responds to a serial pulse train representing externally generated incremental position change commands. This mode is commonly used to control DC stepper motors or numeric controlled (CNC) machinery. The PULSE/PULSE or PULSE/DIRECTION operation are provided so that pulse inputs are converted to velocity and distance. The drive can be programmed to allow for pulses per revolution of 200 to 25,000. Once programmed, the total pulses received is converted to the equivalent distance in steps or pulses per revolution and the rate that pulses are received determines velocity. The base number system that the drive uses is binary with a resolution of 4096 per revolution. When using the pulse modes, there is no accumulative error. However, the positional accuracy is based on the lower of ±1 part in 4096 or ±1 of the programming resolution. At very low programming resolution such as 200 pulses per revolution, a dither of 360°/200 or 1.8° is typical. The maximum pulse rate input cannot exceed 204,800 Hz.

Figure 45 Pulse Mode

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Pulse/Pulse and Pulse/Direction Modes

Pulses on the CW pulse line make the motor rotate CW and pulses on the CCW pulse input line make the motor rotate CCW as viewed from the shaft end of the motor.

To set up the pulses per revolution, select the drive parameters screen using PCX and change the default setting of 4000 steps/revolution to your desired configuration. The mode select switches can be set to operate the drive in the pulse/direction mode. In this mode, the CW pulse input line becomes the pulse input and the CCW pulse line becomes the direction input. If there is no current flowing in the direction input, the pulse input line is interpreted as CCW direction.

In either pulse mode, once motion is initiated with these inputs, motion in the opposite directions can not be achieved until motion in the initiated direction has been stopped as a result of stopping the pulses. Attempts to defeat this may cause erroneous and unpredictable operation.

In a pulse train application, the pulse trains are fed into the CW and CCW inputs on the command connector. The inputs are optically isolated and can be used for sinking or sourcing current; this requires two connections per input. In either case (sinking or sourcing), the noise immunity is improved when the normal state of the input does not cause current to flow in the optical coupler. Current should only flow when a motion pulse is applied by the external pulse generator, and each pulse must be at least between 0.5 to 1.5 micro seconds and between +5 and +15 VDC to be accepted as a valid pulse.

Figure 46 Command Connector Circuit

NOTE: CW rotation of the motor is established with the operator facing the shaft end of the

motor.

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Figure 47 Example of Sinking/Sourcing Connections NOTE: Any connections between the customer supplied interface (stepper controller, etc.)

and the command connector should be made through a shielded cable. The shield of this cable should be connected to the customer interface ground (source end). If no shield connection is available at the source end, then the shield connection on the command connector may be used. Keep in mind that this shield connection is connected internally to chassis ground of the drive.

To execute one of the two Pulse Modes, simply select the desired mode of operation on the mode select dip switches and put pulses into the command connector on the amplifier.

Even though the Pulse Mode of operation is being used, the Indexing Operation Mode functions are active. This means the user could feed pulses into the amplifier and then initiate the Indexing Mode functions from the input terminals. The serial control mode also override the Pulse Mode in this same manner.

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POSITIONING DRIVE CONFIGURATION AND

PROGRAMMING

INTRODUCTION

NOTE: SEE MANUAL SUPPLEMENT P/N 400221-01 (PCX PROGRAMMING) FOR

PROGRAMMING INFORMATION.

EMERSON EMC’s PCX programming software provides a simple, menu-driven format for question/answer set up and programming of EMERSON EMC Positioning Drives. The minimum requirements to successfully run the PCX software are any IBM PC or compatible PC with 512K bytes of RAM, one floppy disk drive and an RS232 serial interface port. The DOS version required by PCX is 3.0 or greater. PCX allows the user to look at set up data found in the Positioning Drive and make changes if desired. Programming data can be uploaded (from the Positioning Drive to the PC) or downloaded (from the PC to the Positioning Drive).

In addition, PCX allows the user to control or monitor motion functions in the Positioning Drive. All commands sent from the PC by PCX are simple two or three character ASCII letters preceded by a single character axis identifier and followed by data if required. In most cases, PCX is used to set up and program a Positioning Drive or PCM controller from a personal computer. After programming, the PC is disconnected and the user program remains in the Positioning Drive’s non-volatile memory.

PCX provides descriptive question and answer formatting to assist the user. This allows minimum keystrokes to set up, program, monitor, or control, any Positioning Drive function without requiring an extensive user manual or knowledge of programming.

The PCX program also allows the user to edit files previously uploaded for multiple axes Positioning Drive systems at his desk and save them on a disk, without being connected to the Drive. These parameters can be saved under a file name (user’s choice) for later downloading and non-volatile storage into the Positioning Drive.

The PCX software referred to in the manual is 4.5 or greater. Versions with less than 4.5 may not allow for full operation. Contact the factory to obtain the most recent version.

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How To Start

The PCX software is supplied on a floppy diskette. The floppy diskette does not include the Disk Operating System (DOS). A backup copy of PCX should be made before starting. To initiate the PCX program, the user should type the letters “PCX” at the operating system prompt in the directory where PCX.EXE is located. Once the program has been loaded, the PCX diskette is no longer required to be in the disk drive. For certain file options, the user should ensure that a path is available to the COMMAND.COM file. This is accomplished by setting the DOS environment variable PATH or including the COMMAND.COM file in the current directory.

PCX Program Revision

Once the PCX program has been loaded and is executing, the initial screen showing the program revision is displayed.

Figure 48 PCX Version 4.10

The PCX program is subject to changes. To assure that files generated with earlier versions of PCX are compatible with the least version, the following procedure should be followed.

1. Using the old PCX, download the file to the positioning drive.

2. Using the new PCX, upload a file from the positioning drive.

The PCX program referred to in this manual is revision 4.10. Revisions with less than 4.10 may not allow for full operation. Contact the factory to obtain the most recent version.

Moving Through The Menus

PCX has a hierarchy system of menus. The top menu is the Main Menu. To proceed into more specific levels, position the cursor on top of the desired option then press the “ENTER” key. There are two methods available to position the cursor. Pressing the first letter of the desired option will cause the cursor to move to that option. Pressing the “UP” and “DOWN” arrow keys will cause the cursor to move accordingly. The user may always back out to the main menu by pressing the “ESC” key. However, the “ESC” key will not cause program termination.

Changing Values In The Data Enter Screens

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At the last level of the menu hierarchy, data entry screens are often presented. All data are validated and saved when the “ENTER” key is pressed. If they are out of range, the minimum or maximum acceptable value will be entered where applicable. Other data fields may require the use of the “LEFT” of “RIGHT” arrow keys to scroll through possible options. If data is not “ENTERED”, the previous data will remain unchanged. The “ESC” key will return the user to the previous menu.

USING PCX DISK FILES

PCX provides two types of disk files,

1. Data File

A data file contains all the data in the positioning drive’s memory in a transportable disk file. The upload, edit, create, and make options, all work with data files. Data files are always saved with the file extension of “.PCX” so it is not necessary for the user to specify one. Data files are stored in binary files and should only be edited by PCX.

2. List File

A list file contains the values found in the PCX setup screens in an ASCII character text file. It is created from a data file with Make, in the disk file operations. A list file can be used for printing, word processing, troubleshooting, or as documentation. List files are always saved with the file extension of “.LST” so it is not necessary for the user to specify one.

Files that are created require a user file name to save the data. If possible, it is recommended that files be saved in the current directory. When files need to be recalled, PCX displays a list of files that are found in the current directory. To save to the current directory, simply type in a file name of eight characters or less. The correct file extension will automatically be appended. Files can be saved to any directory of any disk drive by specifying a complete file path.

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Main Menu

When a key is pressed while viewing the introductory revision screen, the main menu will appear on the terminal screen.

Figure 49 Main Menu

From the main menu, the user may work directly with a drive or with a disk file. By selecting On-line Operations COM1 or COM2, PCX will automatically attempt serial communications with the drive. By selecting Disk File Operations, the user may setup a data file for a single axis without being hooked to the unit. Necessary values can be saved to a floppy disk for download at a latter time. The serial communications option may be used to manually establish communications with the drive. This option may be helpful at start-up time if communications are not established with the On-line Operations.

On-line Operations

When serial communications have been established with the drive, the On-line Operations menu will be presented on the screen.

Figure 50 On-line Operations

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Drive Setup

The setup options logically group together the necessary positioning drive values into data entry screens for editing. Everything necessary to prepare a drive for use can be accomplished in this option.

Upload Data From Drive

When this option is selected, PCX will PCead the values that are stored in the drives memory. Next, PCX will attempt to save the data to a user specified disk file name. When completed, the newly created file may be used for downloading to another drive or in the off line options, editing and printing. Uploading may take a few minutes to complete depending on the system being read from.

Download Data From Drive

When this option is selected, PCX will attempt to list all files that have the extension of “.PCX” from the current directory. The user may select, from the list, a file to write to the drive. When selected, all values in the drive will be replaced by those from the file specified. If no files are found in the current directory, no downloading may take place. Downloading may take a few minutes to complete, depending on the system being written to.

Diagnostics

When this option is selected, PCX will monitor and display the status of the drive. This mode is useful when troubleshooting a system.

Shell

A DOS shell provides the user with a way to enter DOS commands without exiting PCX. In order for shell to work properly, the COMMAND.COM file must be accessible by PCX; This may be accomplished by using the DOS PATH or COPY command.

Terminal Mode

In this mode, the computer will operate as a dumb terminal. This means that the computer will send and receive ASCII serial commands. These commands can be used in place of the menus described in ON LINE SELECTION. However, this mode does not contain any help screens or instructions on how to program. The user must be cautious in this mode because whatever is typed is sent to the drive. Incorrect entries could be motion commands and if so, the drive would execute them.

NOTE: Programming should be done entirely with the PCX software or through the dumb

terminal ASCII serial commands – BUT NOT BOTH. If both programming methods are used, there is a chance that not all the parameters entered through the dumb terminal will be transferred to the PCX software. This may lead to unpredictable behavior of the drive.

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ESTABLISHING COMMUNICATIONS

The On-line Options in PCX require serial communications between the personal computer and the positioning drive. When selecting On-line Options the first time, PCX will attempt to communicate by transmitting a character and then receiving the echo. When the echo is the same as the character transmitted then communications have been established. PCX tries this procedure with all the possible baud rates. Once PCX has established communications, the program will continue by displaying the On-line Options. This procedure will not be called again unless communications are disrupted at a later time.

The following checklist should be addressed before attempting serial communications.

1. The serial cable must be connected to the personal computer serial port and the drive

serial A port.

2. On a multi-axis system, the serial cables must be connected as shown below.

Figure 51 Serial Cable Setup

3. On a multi-axis system, make sure that the baud rate setting on each drive is the same.

4. On a multi-axis system, make sure that each positioning drive has a unique axis identifier.

5. Power to all positioning drives must be on.

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DISK FILE OPERATIONS

When this operation is selected from the Main Menu, the Disk File Operations Menu will be presented on the screen.

Figure 52 Disk File Operation

Edit Existing Data File

PCX will attempt to list all files that have the extension of “.PCX” from the current directory. The user may select, from the list, a previously saved data file to be recalled. Editing a file is very similar to the On-line Setup options except it allows the user to change any drive values without being connected to the drive. After editing, the file may be saved, renamed, or left unchanged. Editing may only be done on data files that have previously been uploaded or created.

Create New Data File

PCX will allow the user to create a data file. The user must select the controller model and any optional PCM module for the file that is to be created. Once this has been done, the file may be edited and saved under a user file name for later use.

Make A List From A Data File

PCX will attempt to list all files that have the extension of “.PCX” from the current directory. The user may select a data file necessary to produce a list file. PCX will use the same file name but will append the extension “.LST” to the newly created list file. List files are ASCII character text files created from data files (see Using PCX Files).

Print List File

PCX will attempt to list all files that have the extension of “.LST” from the current directory. The user may select a list file to be printed. In order for printing to work properly, the PRINT.COM file must be accessible by PCX; This may be accomplished by using the DOS PATH or COPY command. The printer must also be available and on-line.

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Shell

DRIVE SETUP

When the Setup, Edit, or Create option is selection, the Drive Setup menu will be displayed on the screen.

Figure 53 Drive Setup

From the Drive Setup Menu, there are two areas that need to be setup. The Define Motion menu item is where motion related items are setup. Data entry screens for Jog, Home, Index and programs are programmed here. The second option, Drive Configuration, is where all other drive items are located. The drive setup, Input and Output Functions, Parameters, and Limits, are all programmed from this option.

Figure 54 Define Motion

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Figure 55 Drive Configuration

Jog, Index and Home

A drives basic motion functions are programmable by using these data entry screens. When on line with a drive, these options allow motion to be initiated and stopped by pressing the “SPACE BAR”. The bottom section provides helpful information such as the range of possible values, available types, valid units, and any other special instructions. These screens are explained in greater detail in the external operating modes. Additional capabilities are described in the IOM and PCM sections of the manual.

Inputs and Outputs

These two screens are used for assigning the input and output lines to a function. Line numbers correspond to those on the top of the drive and PCM modules. A function with a line number of zero designates that it is unused. Multiple functions can be assigned to a single line; it is common to assign all output faults to one output line. The left window allows the user to quickly determine what functions are assigned. The right window may be scrolled up and down to assign additional functions that are physically unable to fit on a screen. Refer to the input and output interface section for physical location and descriptions. Additional I/O capabilities for the IOM and PCM’s are in those sections.

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Input Polarity

Input functions that do not affect motion may be assigned as normally off (-, default) or normally on (+). When an input is assigned with “+” polarity, it is active while the input is not on. Input polarity is assigned by pressing the “+” or “-“ key on the input function indicated by the cursor.

Input Filtering

By pressing “ALT-F” on the input screen, PCX will pop-up the filtering data entry screen. Input filtering is a form of digital integration. It is not intended to reduce electrical noise or the effects of electrical noise in industrial environments. It is provided to digitally qualify that an input is on for a pre-determined time. The drive services inputs at a minimum rate of .002 seconds. Therefore, the input or input filtering is always subject to a delay of (.0005 to .0025) seconds. The .0005 delay caused by propagation delay of the hardware and .0025 is the sum of the propagation delay plus the service time. The PCX program will only allow for this time to be entered in increments of .002 as this is the minimum service rate. When “ESC” is pressed, PCX will return to the input setup screen.

Parameters

The Parameters screen allows the user to set up parameters for display purposes. These parameters include position units, distance decimal point, location, velocity units, velocity scale and velocity decimal point location. PCX and displays, such as EMERSON EMC’s T-21 Data Entry Terminal, use these parameters to display familiar user units. Some examples would be: IN/SEC; RPM; STEPS/REV; FT/MIN, etc.

Figure 56 Parameters

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Actuator Polarity

The default (+) of this feature provides for CW rotation of the actuator for positive (+) motion initiation. For example, a CW JOG input will cause CW rotation of the actuator as viewed from the shaft end of the actuator. To change this relationship, a (-) can be programmed. During the time this change occurs using PCX, the bridge is turned OFF and ON to accomplish a smooth transition.

Velocity Units, Velocity Scale Factor, Velocity Decimal Point Location

To make the display data meaningful, the user must set up a conversion between his units and the units that are used by the drive.

Example: The user has a system that direct couples to a lead screw and would like to program

velocity in IN/MIN and position inches. He has a pitch (5 REV/IN) LEAD SCREW. To determine the VELOCITY SCALE FACTOR he would have to calculate the following:

3000 (MAX MOTOR RPM) = 600 INCHES PER MINUTE

6 (PITCH)

Since in his system 600 IN/MIN = 3000 RPM, the VELOCITY SCALE FACTOR would be set = 600 or 600.0. If inches per second were desired then division by 60 would yield either 10.000 or 10.00. Once these decisions are made, the numeric value, decimal point and velocity units can be programmed. Velocity units would be either IPM (INCHES PER MINUTE) or IPS (INCHES PER SECOND). Any 3 ASCII characters are accepted.

Distance Decimal Point Location, User Steps Per Revolution

The user may also set up a distance conversion because he is working in inches and the drive works in steps. He can use the USER STEPS PER REV to create this conversion.

We have: 1 IN = 5 LEAD SCREW REVS Therefore: 1 IN = 5 MOTOR REVS

Now the user must decide how many steps per user rev. The drive will accept any number in a range of (200 to 25,000). The easiest way to do this is to divide the one inch by the 5 turns to find the number 0.2. This example yields three possible conversions; either 200, 2000 or 20,000. The number must be between 200 and 25,000.

If 2,000 is chosen, then 2,000 X 5 turns = 10,000 counts per inch. This would provide for a program resolution of .0001 inches. If 20,000 is chosen, then 20,000 X 5 turns = 100,000 counts per inch. This would provide for a program resolution of .00001 inches.

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Once a decision is reached, the value for steps for revolution, decimal point and units can be entered. Low resolutions, less than 1,000, are discouraged as dither is increased. For example, if 200 was selected, 360°/200 = 1.8° of dither. This could be objectionable.

Acell/Decell Shape

This option also allows the user to choose either linear ramps or mod-sine ramps for acceleration or deceleration. The difference is shown below.

Figure 57 Mod-Sine Ramps/Linear Ramps

Torque Output

The torque output controls the amount of available torque. 200% is the drives peak rating. 100% would be the amplifiers continuous rating. Peak torque is only available for short periods. Consult the MFR. Specs for the amplifier in use.

LIMITS

The Limits screen allows the user to set the maximum and minimum operating parameters.

Figure 58 Limits

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Maximum Velocity

MAXIMUM VELOCITY limits velocity entries to the value entered here.

Minimum Acceleration Rate and Minimum Deceleration Rate

Used to limit the minimum time it takes to accelerate and decelerate the motor and load from zero to 3,000 RPM or vice-versa. This time is greatly affected by load inertia and friction. Those factors should be considered when the time limits are set.

Distance Limit CW and Distance Limit CCW

Used to set the maximum distance that can be programmed in an index.

Position (Travel) Limit CW and Distance Limit CW

Used during absolute positioning applications. The limit positions are given with reference to the home position. Because of this, a home cycle must be executed before these travel limits are enabled.

Travel Limits/Fault Deceleration Rate

Used to set the deceleration rate after any fault occurs, or a travel limit (hardware or software) is tripped.

Stop Deceleration Rate

Used as the deceleration rate for a stop command (Serial or I/O).

Feed Limit Distance

Used for feed sensor index applications. The user can limit the distance that the motor will travel after it has been commanded to look for sensor input. This entry prevents excessive travel if a feed sensor or switch fails.

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INDEXING OPERATION MODE

In most applications the user will use the drive in this mode. The INDEXING mode of operation allows the user to execute up to 32 different indexes (distance or position moves) that can be stored in non-volatile memory. These 32 indexes, plus other motion functions such as Stop, Jog and Home, are easily programmed either by entering the proper ASCII commands or by using the PCX programming software supplied with the drive. The PCX software provides descriptive ‘prompts’ and ‘help’ menus to make programming easy. Programming through ASCII serial commands tends to be more difficult, but is available for the user who wishes to program without the help of the PCX software.

The INDEXING OPERATION MODE is the most commonly used mode and is accessible by having the mode select DIP switches set for either the PULSE/PULSE or PULSE/DIRECTION settings. Both the PULSE FOLLOWER, and INDEXING OPERATION MODES are operational.

The numeric display on the Positioning Drive will indicate an (E) if the external mode is selected. This is also the default mode of operation.

In the INDEXING OPERATION MODE the optically isolated inputs and outputs are the primary source of data to execute motion such as INDEX, JOG, and HOME. With a PCM-1, additional capability in the form of programs is available.

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Four types of indexes can be programmed into the drive as shown below.

INDEX TYPES

Incremental Index: Relative distance and direction from start.

Figure 59 Velocity Vs Time Profiles for 520

Figure 60 Screen Menu – Index/Incremental

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Absolute Index: End position is absolute coordinate regardless of start.

Figure 61 Velocity Vs Time Profiles (Absolute Index)

Figure 62 Screen Menu – Index/Absolute

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Registration Index

Run at the sensor velocity until the sensor or limit distance is achieved. Once either of these occurs, the parameters of the index are run. If the limit distance assignable output is programmed, it will com ON when the limit occurs.

Figure 63 Index/Registration

Figure 64 Registration Index Graph

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Feed-To-Sensor Index

Move an amount determined by the index parameters. Once achieved, move at a rate determined by the sensor velocity until either the sensor input or limit distance is achieved. If the limit distance assignable output is programmed, it will also com ON.

Figure 65 Index/Feed Sensor

Figure 66 Velocity Vs Time Profiles (Index Feed Sensor)

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JOG

The JOG function is provided to cause CW or CCW motion of the motor at controlled velocities. Initiation of JOG is usually accomplished by inputs connected to the optically isolated inputs although it can also be initiated through serial control and PCX. A FAST/SLOW input function can be programmed. Inputs can be programmed to have either a CW and CCW control or a JOG and a direction select. The default inputs provide for the CW and CCW inputs and JOG is assumed since the FAST/SLOW input isn’t assigned. In programming JOG, three velocities can be programmed; SERIAL VELOCITY, JOG FAST, and JOG SLOW. The acceleration time and deceleration times are also programmable, but are used for all velocities programmed.

Figure 67 Jog Function

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HOME

The drive is equipped with a capability for six different HOME types:

TYPE

0 OFFSET (HOME TO MARK+ OFFSET) 1 FEED ON (HOME TO SENSOR) 2 FEED ON/OFFSET (HOME TO SENSOR THEN MARK+ OFFSET) 3 FEED ON/OFF (HOME TO SENSOR THEN OFF SENSOR) 4 FEED ON/OFF/OFFSET (HOME TO SENSOR THEN OFF SENSOR

THENMARK+ OFFSET)

5 FEED ON/OFF/ON (HOME TO SENSOR THEN OFF SENSOR THEN ON

SENSOR)

Home cycles are used in applications that require a starting (HOME) position to locate tooling, fixtures, carriages, etc. that are required as a prerequisite to initiation of other cycles. Two separate inputs can be programmed to accomplish HOME cycles, HOME SENSOR and HOME INITIATE. The integration of motion relative to these inputs is what determines any specific HOME cycle. Any of the HOME cycles may be set up as you program the HOME function with PCX.

An example of a HOME cycle could be demonstrated with a ball screw or rack and pinion drive that converts rotary motion output into linear motion.

Figure 68 Example of Home Cycle

This particular application would utilize most of the programming features in the HOME setup. In this application, we want to position the carriage to the physical location of the external HOME sensor and then to an offset.

This is a type 4 HOME, FEED ON/OFF/OFFSET (HOME TO SENSOR THEN OFF SENSOR THEN OFFSET).

Notice that an additional feature in programming is the HOME lock ON/OFF. If the HOME lock is ON, then upon powering up, the only request for motion that will be accepted is one for a HOME cycle.

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Assuming the carriage is shown off the HOME sensor and that CCW (-) rotation of the motor causes motion toward the sensor, the following cycle would occur.

Figure 69 Home Sensor Graph

Figure 70 Screen Menu-Home Feed On/Off/Offset The (A) motion is the -1500 RPM to find the sensor.

The (B) motion is the +120 RPM to find the sensor “OFF”.

The (C) motion is the -30 RPM to move to the once per revolution offset.

Note that the last two questions in programming are:

1) MARK+ OFFSET--------------------

2) HOME POSITION-------------------

The offset is the amount of user steps within one revolution. The HOME position is the position for reference in programming that you want to assign to HOME. These two values are frequently zero. The 6 home types are explained as follows:

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HOME TYPE 0. OFFSET (HOME TO MARK+ OFFSET)

Figure 71 Home To Mark

Figure 72 HOME/OFFSET

(A) is the -30 RPM velocity to find the offset.

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HOME TYPE 1. FEED ON (HOME TO SENSOR)

Figure 73 Home To Sensor Graph

Figure 74 Home to Sensor (Feed On)

(A) is the -50 RPM velocity to find the sensor.

NOTE: THERE IS NO DECEL TIME ONCE THE SENSOR IS REACHED.

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HOME TYPE 2. FEED ON/OFFSET (HOME TO SENSOR THEN OFFSET)

Figure 75 Feed On/Offset Graph

Figure 76 Home Feed On/Offset

(A) is the -1500 RPM velocity to find the sensor.

(B) is the -30 RPM to find the offset.

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HOME TYPE 3. FEED ON/OFF (HOME TO SENSOR THEN OFF SENSOR)

Figure 77 Home Feed On/Off

Figure 78 Home Feed On/Off

(A) is the -1500 RPM velocity to find the sensor.

(B) is the +120 RPM velocity to move off the sensor.

NOTE: THERE IS NO DECEL AT THE FINAL OFF POSITION.

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HOME TYPE 4. FEED ON/OFF/OFFSET (HOME TO SENSOR THEN OFF SENSOR

THEN MARK+ OFFSET)

Figure 79 Feed On/Off/Offset

Figure 80 Home Feed On/Off/Offset

(A) is the -1500 RPM velocity to find the sensor.

(B) is the +120 RPM velocity to turn the sensor “OFF”.

NOTE: THERE IS NO DECEL AT THE FINAL POSITION.

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HOME TYPE 5. FEED ON/OFF/ON (HOME TO SENSOR THEN OFF SENSOR ON

SENSOR)

Figure 81 Home To Sensor Graph

Figure 82 Home Feed On/Off/On

(A) is the -1500 RPM velocity to find the sensor.

NOTE: THERE IS NO DECEL AT THE FINAL POSITION.

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OVERVIEW OF BASIC OPERATION MODES

The Indexing Operation Mode allows for different methods for executing the stored functions:

ASCII Serial Mode PCX Programming Mode Input/Output Mode

Serial Mode

The serial interface provides a capability that basically is an additional control mode beyond the three basic control modes (ANALOG, PULSE and INDEXING).

The Serial Control Mode can also be used to execute or program motion functions. The user can send the execution serial commands from his programming device through the serial interface to the drive. Common types of programming devices are programmable logic controllers (PLCs) equipped with BASIC or ASCII communication modules.

In Serial Control Mode, the numeric display indicates an (E.). This control mode is accessible via the serial connector “A” on the drive and the protocol is based on ASCII characters. To enter the Serial Control Mode, the digital drive must receive an SC=1 string preceded by an axis I.D. character if the appropriate DIP switches are set.

The serial interface is always accessible via serial ASCII commands. The difference, as far as the display is concerned, is that serial commands to initiate motion will be ignored unless the decimal point after the E is on (E.). If the decimal is on, meaning you are under Serial Control Mode, then motion initiation from the I/O is ignored. Stop commands from either serial or I/O are always accepted and additionally, both hardware or software travel limits are going to work if programmed in the (E) or (E.) modes.

Figure 83 Serial Control Mode

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Input/Output Interface

OVERVIEW

The Drive is equipped with 8 inputs and 4 outputs which are optically isolated for +10 to +30 vdc operation. Each input and output has 2 screw terminals associated with it to provide for either sinking or sourcing operation. The first 8 pairs of designated terminals are inputs and the last 4 pairs of terminals are outputs. The outputs are capable of sinking or sourcing 200 mA. It is the users responsibility to limit the output current to less than or equal to 200 mA.

These inputs and outputs allow for proper timing and coordination between the drive’s motion and other machine control functions. The inputs and outputs typically are connected to the machine’s programmable logic controller (PLC) or relay logic system. These inputs and outputs are also connected to limit switches, and/or switches and indicators on an operator’s control panel.

A large number of input/output control functions are provided. The functions used are assigned to any of the input/output lines. This is accomplished through either serial interface commands or by using the PCX software provided with the drive. Inputs may be programmed as normally off or normally on. In addition, more than one function may be assigned to the same input line. Each Drive comes from the factory with the inputs and outputs predefined for frequently used I/O configurations.

Using the I/O inputs, specific pre-programmed index functions are addressed by coding the 0-31 index number in binary. Receiving the proper binary code prior to an Index Initiate determines the required index. An output function can be programmed on one of the output lines to indicate when the move is completed. Other functions such as Jog and Home have discrete inputs assigned which, when activated, cause that function to execute. The input lines can be used to execute functions which can be activated by the user through switches, sensors, or possibly, a PLC’s output. This provides an interface between the drive and other parts of a machine or system.

Figure 84 I/O Mode

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An LED indicator is associated with each input and output. The input and output indicators are on if current is flowing in the associated line.

Figure 85 I/O Nomenclature

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Output Functions

Following is the list of output functions provided with the drive.

OUTPUT FUNCTION # BASIC

DRIVE ONLY

DRIVE WITH

IOM-1

DRIVE WITH

PCM-1

0 – READY X X X 1 – EXTERNAL MODE X X X 2 – IN MOTION X X X 3 – END OF INDEX X X X 4 – END OF HOME X X X 5 – END OF INDEX COUNT X X X 6 – HARDWARE FAULT X X X 7 – TRAVEL LIMIT FAULT X X X 8 – FOLLOWING ERROR FAULT X X X 9 – HOME COMPLETED X X X 10 – SENSOR LIMIT HIT X X X 11 – END OF SEQUENCE X 12 – PROGRAMMABLE OUTPUTS X 13 – END OF PROGRAM X 14 – END OR PROGRAM COUNT X 15 – IN SUSPEND X

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Input Functions

Following is the list of input functions are available for use in providing control through the standard I/O interface.

OUTPUT FUNCTION # BASIC

DRIVE ONLY

DRIVE WITH

IOM-1

DRIVE WITH

PCM-1

0 – INDEX INITIATE X X X 1 – HOME INITIATE X X X 2 – CLEAR TO INITIATE X X X 3 – HOLD INDEX/HOME MOTION X X X 4 – JOG X X X 5 – JOG CW X X X 6 – JOG CCW X X X 7 – JOG DIRECTION X X X 8 – SLOW JOG X X X 9 – CW TRAVEL LIMIT X X X 10 – CCW TRAVEL LIMIT X X X 11 – STOP MOTION X X X 12 – INHIBIT (DRIVE) X X X 13 – BRAKE OVERRIDE X X X 14 – INDEX SELECT X X X 15 – HOME SENSOR X X X 16 – FEED SENSOR X X X 17 – CLEAR END OF INDEX X X X 18 – CLEAR END OF HOME X X X 19 – CLEAR END OF INDEX COUNT X X X 20 – CLEAR SENSOR LIMIT X X X 21 – CLEAR FAULT X X X 22 – ZERO POSITION X X 23 – ZERO DISPLAY X X 24 – REMEMBER POSITION X 25 – RETURN TO POSITION X 26 – CLEAR END OF SEQUENCE X 27 – CLEAR PROGRAM OUTPUTS X 28 – EXTERNAL INPUT X 29 – PROGRAM INITIATE X 30 – PROGRAM SELECT X 31 – SUSPEND PROGRAM X 32 – RESUME PROGRAM X 33 – CLEAR SUSPEND X 34 – CLEAR END OF PROGRAM X 35 – CLEAR END PROGRAM COUNT X

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Input/Output Connections

Figure 86 I/O Connections

NOTE: 18 to 24 gauge wire must be used for I/O wiring. The use of larger gauge wire will

cause the I/O terminals to prematurely fatigue.

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Detailed Descriptions of I/O Functions

Input Functions

FUNCTION # DESCRIPTION

0 INDEX INITIATE

Executes the selected index. If function #14 is not set up or there are no active I/O lines, INDEX 00 will initiate.

1 HOME INITIATE

Execute the home cycle.

2 CLEAR TO INITIATE

Informs the drive when it is OK to initiate another home, index or program. Program is for PCM only.

3 HOLD INDEX/HOME MOTION

Stops index or home motion when the switch is pressed and resumes index or home motion when the switch is released.

4JOG

Starts and stops a jog in the direction specified by the JOG DIRECTION input functions. Defaults to the programmed jog fast velocity.

5 JOG CW

Starts and stops a clockwise jog; motor rotation is defined while facing the shaft end of the motor. Defaults to the programmed jog fast velocity.

6 JOG CCW

Starts and stops a counterclockwise jog; motor rotation is defined while facing the shaft end of the motor. Defaults to the programmed jog fast velocity.

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FUNCTION # DESCRIPTION

7 JOG DIRECTION

Sets the direction for the JOG input function (active = CCW).

8SLOW JOB

Causes the jog slow velocity to be used when JOG, JOG CW, or JOG CCW are executed.

9 CW TRAVEL LIMIT

Forces clockwise velocity to zero and inhibits any further clockwise motion.

10 CCW TRAVEL LIMIT

Forces counterclockwise velocity to zero and inhibits any further counterclockwise motion.

11 STOP MOTION

Stops motion according to the programmed deceleration rate.

12 INHIBIT (DRIVE)

Prevents all motion by disabling the drive’s bridge transistors and engaging the fail-safe brake.

13 BRAKE OVERRIDE

Releases the fail-safe brake when INHIBIT is active. This allows the motor to be rotated by hand.

14 INDEX SELECT

Sets the starting input line number for a given number of index select lines. If, for example, you require 4 index select lines and want them assigned to input lines 5, 6, 7, and 8. You would assign INDEX SELECT to input line 5 and program (through PCX or serial commands) the total number of index select lines to be 4.

15 HOME SENSOR

Provides a sensor input for home types which require it.

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FUNCTION # DESCRIPTION

16 FEED SENSOR

Provides a sensor input for feed sensor type indexes.

17 CLEAR END OF INDEX OUTPUT

Clears the END OF HOME output. If not assigned, the END OF INDEX will automatically clear when the next motion occurs.

18 CLEAR END OF HOME

Clears the END OF HOME output. If not assigned, the END OF HOME will automatically clear when the next motion occurs.

19 CLEAR END OF INDEX COUNT OUTPUT

Clears the END OF INDEX output. If not assigned, the END OF INDEX COUNT will clear when the next motion occurs.

20 CLEAR SENSOR LIMIT DISTANCE HIT

Clears the SENSOR LIMIT HIT output. The sensor limit distance is programmed by PCX or serial commands.

21 CLEAR FAULT

Duplicates the function of the reset switch on the front of the digital drive. It will clear non-fatal drive faults.

22 ZERO POSITION

Sets the current position of the motor to zero. All absolute positions will be referenced to this set zero position.

23 ZERO DISPLAY

This zeroes all position query commands (FP and CP), they become zero and are referenced to this point. Absolute position is unaffected.

24 REMEMBER POSITION

Stores the current position of an absolute index.

25 RETURN TO POSITION

Returns to the position defined by REMEMBER POSITION.

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FUNCTION # DESCRIPTION

26 CLEAR END OF SEQUENCE OUTPUT

Clears the END OF SEQUENCE output. If not assigned, the END OF SEQUENCE output will automatically clear when the next motion occurs.

27 CLEAR PROGRAMMABLE OUTPUT

Clears a (PROGRAMMABLE OUTPUT). Each assigned PROGRAMMABLE OUTPUT will require a separate CLEAR PROGRAMMABLE OUTPUT.

28 EXTERNAL INPUT

Used with the WAIT FOR INPUT program function to stop program execution until the input line assigned with EXTERNAL INPUT is activated.

29 PROGRAM INITIATE

Executes the selected program.

30 PROGRAM SELECT LINES

Sets the starting input line number for a given number of program select lines. Then the number of program select lines is programmed through PCX or serial commands.

31 SUSPEND PROGRAM

Stops the execution of a program until the input line assigned with RESUME is activated. Also see I/O Suspend Resume Feature Section in the PCM-1 Section.

32 RESUME PROGRAM

Resumes the execution of a suspended program. Also see I/O Suspend Resume Feature Section in the PCM-1 Section.

33 CLEAR SUSPEND

Clears the IN SUSPEND output and returns the drive from a suspend cycle to normal operation without the need to “RESUME” and completion of the suspended program. Also see I/O Suspend Resume Feature Section in the PCM-1 Section.

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FUNCTION # DESCRIPTION

34 CLEAR END OF PROGRAM OUTPUT

Clears the END OR PROGRAM output. If not assigned, the END OF PROGRAM output will automatically clear when further motion is initiated.

35 CLEAR END OF PROGRAM COUNT

Clears the END OF PROGRAM output. If not assigned, the END OF PROGRAM output will automatically clear when the next motion occurs.

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Output Functions

FUNCTION # DESCRIPTION

0 READY

This output is ON continuously after power up if the microprocessor and its memory are operating correctly. It turns OFF when either A WATCHDOG TIMER FAULT or USER MEMORY FAULT occurs.

1 EXTERNAL MODE

This output is ON when the digital drive is operated from an external source. This output is OFF when the drive is in serial control such as when the drive is executing a HOME, INDEX, JOG or PROGRAM (PROGRAM is for PCM only).

2 IN MOTION

This output is ON whenever the commanded velocity is not zero.

3 END OF INDEX

This output comes ON after the completion of executed index. If this INDEX COUNT is greater than 1, this output will come ON after each index execution. It is turned OFF automatically with the next motion or when the CLEAR END OF INDEX is used.

4 END OF HOME

This output comes ON after the completion of a HOME cycle. It is turned OFF automatically with the next motion or when the CLEAR END OF HOME is used.

5 END OF INDEX COUNT

This output comes ON only after an index is executed the number of times specified by the INDEX COUNT. It is turned OFF automatically with the next motion or when the CLEAR END OF INDEX COUNT is used.

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FUNCTION # DESCRIPTION

6 HARDWARE FAULT

This output comes ON after the occurrence of a hardware drive fault. The hardware fault is indicated by a number between 0-7 on the diagnostics display. It is turned OFF when all hardware faults are cleared.

7 TRAVEL LIMIT FAULT

This output comes ON when either a hardware or software travel limit is hit and turned OFF when the fault is cleared.

8 FOLLOWING FAULT

This output comes ON when the maximum allowable following error is exceeded and turned OFF when the fault is cleared.

9 HOME COMPLETED

This output comes ON after the completion of a HOME cycle and stays ON continuously unless absolute position is lost.

10 SENSOR LIMIT DISTANCE HIT

This output comes ON during a feed sensor index if the SENSOR LIMIT DISTANCE is exceeded before a sensor signal is received. The only way to turn this output OFF is with the CLEAR SENSOR LIMIT input function.

11 END OF SEQUENCE

This output comes ON after the completion of a motion sequence. A motion sequence is completed when a HOME, INDEX, and/or PROGRAM or a combination thereof, is executed and no further motion commands are given. This output turns OFF automatically with the next motion or when the CLEAR END OF SEQUENCE is used.

12 PROGRAMMABLE OUTPUTS

The output lines assigned this function can be turned ON or OFF with the UPDATE OUTPUTS programming function.

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FUNCTION # DESCRIPTION

13 END OF PROGRAM

This output comes ON after each completion of a PROGRAM. It turns OFF automatically with the next motion or when the CLEAR END OF PROGRAM is used.

14 END OF PROGRAM COUNT

This output comes ON only after a program is executed the number of times specified by the PROGRAM COUNT. It is turned OFF automatically with the next motion or when the CLEAR END OF PROGRAM COUNT is used.

15 IN SUSPEND

This output is ON when the SUSPEND PROGRAM input function is active. Also see I/O Suspend Resume Feature Selection.

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DIAGNOSTICS

A single alphanumeric LED display on the front of the Positioning Drive provides status and fault information immediately available to the user. The display aids in quickly identifying problems so that corrective action can be taken and machine downtime can be minimized. In addition, the standard serial interface includes diagnostic status and fault reporting by simple ASCII serial commands. See the Serial Interface Section under Run Time Command section.

Figure 87 Diagnostic Display

Status Indicator Codes

Following is a list of different status diagnostic indicators.

(.) (Decimal point)

When the decimal point LED is on, this indicates the drive is in Serial Mode. In the Serial Mode, the parallel I/O lines that can initiate motion will not function. All other I/O lines will function.

(Ρ)INDEXING

When the Drive is executing an Index or Dwell after the programmed index, the “P” will be displayed on the status indicator.

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(H) HOMING

An “H” will appear on the status indicator when the drive is executing the Home function or dwelling in the Home function.

(J) JOGGING

When the Drive is executing the Jog function a “J” will be displayed on the status indicator.

(E) EXTERNAL MODE

The Drive is ready to accept pulses, initiate one of the I/O functions (only if decimal point is OFF) or initiate motion from the Serial Interface (only if decimal point is ON). The “E” will be displayed if you are putting pulses into the unit and the motor is rotating.

(A) ANALOG MODE

When the mode select switches are set to either the Analog, Torque or Velocity Modes, an “A” will appear.

When the Drive is in a simulated Calibrate Mode, the “C” will appear on the display.

(U) UNINITILIAZED MEMORY FAULT

This occurs when the non-volatile memory of the Drive changes and no longer matches the stored checksum of the non-volatile memory. The major reason for this “U” fault occurring is due to the fluctuating line voltage out of the range of 96-132 VAC. To clear this fault, reset the Drive and download the saved data on your PCX disk into the Drive.

(L) TRAVEL LIMIT

The “L” fault occurs when you hit either a hardware fault travel limit or a software fault travel limit. You must clear the fault before you can initiate motion by a serial, I/O or reset push button.

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Emerson EMC DX-202, DX-205, DX-318, DX-430, DX-450 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual