Impulse PCW-5181 User Manual

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Industrial Devices Corporation

The Only Microstepping Drive with:

Open Loop Stall Detect

Multi-Stepping Dynamic Smoothing Xtreme Smoothness

(OLSD™)

Motion Node

User’s Manual

P/N PCW-5181 Version 1.0

Revision History

Version: 1.0

April 2001

Industrial Devices Corporation (IDC) strives to maintain effective communication with all users and potential users of our products. If you have any questions or concerns regarding this technical manual or the product it covers, please contact:

Industrial Devices Corporation

3925 Cypress Dri ve

Petaluma, CA 94954

TEL: (800) 747-0064

FAX: (707) 789-0175

FROM OUTSIDE THE U.S. CALL (707) 789-1000

WEB SITE: www.idcmotion.com

EMAIL: info@idcmotion.com

Table of Contents

CHAPTER 1 - IMPULSE OVERVIEW ...............................................................................................1-1

CHAPTER 2 - SHIPPING CONTENTS .............................................................................................2-1

CHAPTER 3 - CONNECTING AND INSTALLING YOUR IMPULSE ...............................................3-1

ONNECTING A MOTOR TO THE IMPULSE

A. C B. S

ERIAL COMMUNICATION CONNECTIONS

.................................... ...... ....... ...... ....... ...... ....... ...... ...3-3

...................................................................................3-4

Making RS-232/RS-485 Connections ...................................................................................3-4

Daisy-Chaining Impulse Drives ............. ...... ....... ...................................................................3-5

Multi-Dropping with RS-485 ..................................................................................................3-5

Troubleshooting RS-232C Communication Problems ...........................................................3-6

ONNECTING AN

C. C

IDC K

EYPAD

..................................... .................................................... .........3-7

Using a Keypad with Impulse RS232C .................................................................................3-7

Using a Keypad with Impulse RS485 ....................................................................................3-7

ONNECTING

D. C E. LED DIAGNOSTIC F. CONNECTING

OUNTING THE IMPULSE DRIVE

G. M

OWER

AC P

NPUTS AND OUTPUTS

...................................... ................................................... ................3-8

NDICATIONS

................................................................................................. 3-8

.........................................................................................3-9

................................... .......................... .......................... ....... 3-10

Environmental and Installation Requirements .....................................................................3-10

Mounting Arrangements ......................................................................................................3-10

Impulse Dimensions ........................................... .................................................................3-11

Inserting and Removing Mounting Brackets from the Impulse ............................................3-12

Impulse DIN-Rail Mounting ................................ ...... ...........................................................3-13

CHAPTER 4 - CONFIGURING IMPULSE WITH APPLICATION DEVELOPER™ ..........................4-1

NSTALLING APPLICATION DEVELOPER ON WINDOWS

SING APPLICATION DEVELOPER

U F

INE-TUNING YOUR APPLICATION

XIS SETUP

OTOR

M M

ECHANICS

OMMAND

MOOTHNESS

X-S A

DVANCED

I/O S I/O D S

TORED MOVE SETUP

ILE MENU DIT MENU

E S

ETUP MENU

OMMUNICATIONS MENU UN MENU

R V

IEW MENU

PDATING YOUR IMPULSE OPERATING SYSTEM

...................................... ...... ....... ...... ....... ...... ...... ....... ...... ........................................4-10

.......................................................................................................................................4-11

...................................... ...................................... ....................................... ..............4-12

................................. ................................................................. .................................4-13

TREME SMOOTHING

DVANCED TUNING

ETUP

................................. ............................................. .............................................. .......4-18

ESCRIPTIONS

.................................. ................................ ................................. .................... 4-18

- E

..................................................................................................................................4-23

....................................... ...... ....... ...... ....... ...... ...... ....... ...... ........................................4-23

..............................................................................................................................4-23

.............................................................................................................4-24

....................................... ................................................... ........................................4-25

...................................... ................................ ................................ ...........................4-26

...................................................................................................4-2

...................................... .......................... .......................... ....... 4-10

™) ...................................................................................4-15

) ....................................... .................................................... .......4-17

DITING STORED MOVES

95/98/2000/ME/NT ................. ...... ....... ...... ...4-1

........................................................................4-21

: ................................... ........................................ 4-27

CHAPTER 5 - CONFIGURING IMPULSE WITH AN IDC KEYPAD .................................................5-1

Table of Contents

ECTION

S S

ECTION

NTRODUCTION TO THE

1 - I

ONFIGURING IMPULSE WITH AN

2 - C

FP100 I

MPULSE KEYPAD

EYPAD

IDC K

....................................... .................... 5-11

................................... ...... ....... ...... ...5-1

Configuring Impulse with the Keypad ..................................................................................5-12

Open a File ..........................................................................................................................5-12

Using the EDIT > SETUP Menus to Configure the Impulse ................................................5-12

MOTOR SETUP ..................................................................................................................5-12

COMMAND SETUP ............................................................................................................5-13

MECHANICAL SETUP ........................................................................................................5-15

MOTOR TUNING SETUP (X-Smoothness) ........................................................................5-16

ADVAN CED SE TUP ...................... ....... ...... ....... ...... ...... ....... ...... ....... ...... ....... ...... ....... .......5-17

I/O SETUP ..........................................................................................................................5-20

Move Menus - Using Stored Moves ......................... ...... ....... ..............................................5 -2 2

UNIT# ....................................... ............................................. ..............................................5-24

CHAPTER 6 - HARDWARE REFERENCE .......................................................................................6-1

MPULSE SPECIFICATIONS

EMOTE MOUNTING YOUR KEYPAD

XTENDING THE CABLE LENGTH TO YOUR KEYPAD EYPAD MOUNTING TEMPLATE

K I

MPULSE

PTIONAL ACCESSORIES FOR YOUR IMPULSE

MPULSE-APPLICABLE

I/O S

CHEMATICS

..............................................................................................................6-1

................................... ............. ............. ............. ............. .........6-2

...................................... ................... ................6-2

.................................... ............ ............. ............. ............. ............. ...6-3

.................................... .......................... .......................... ...................... 6-4

................................. ............. ............. ............. .........6-7

IDC M

OTORS

............................................................................................... 6-9

CHAPTER 7 - TROUBLESHOOTING THE IMPULSE ......................................................................7-1

ROUBLESHOOTING TABLE

IMITS TABLES

..............................................................................................................................7-3

................................... .......................... .......................... ...................... 7-1

CHAPTER 8 - PRODUCT SUPPORT ............................................................................................... 8-2

ARRANTY

& R

EPAIRS

.................................. ....................................................................... .........8-3

APPENDIX A: RECOMMENDED WIRING PRACTICES FOR IDC CONTROLS ............................ A-1

APPENDIX B - IMPULSE ADVANCED PROGRAMMING ..............................................................B-1

APPENDIX C - USING NON-IDC MOTORS WITH THE IMPULSE .................................................C-1

USTOM OR USER-DEFINED MOTORS

........................................................................................... C-2

INDEX........................................................................................................................END OF MANUAL

Chapter 1 - Impulse Overview

The Impulse is the latest microstepping drive from Industrial Devices Corporation and this innovative drive will move your appli cati ons with a combi nation of features previously unheard of in the motion control industry.

The Impulse is a self-contained microstepping drive designed to operate permanent-magnet linear and rotary hybrid step-motors. Its internal control hardware is based on a digital signal processor (DSP) operating a pair of IGBT power amplifiers. The Impulse is fully protected against shortcircuits and overheating.

Responding to users who demand the ultimate in value and reliability, the Impulse employs the following features and performance enhancements:

Feature Function

Open Loop Stall Detect Dynamic Smoothing Multi-Stepping Motion Node

Xtreme Smoothing

IDeal Performance Probe Automatic fine-tuning of the Impulse for optimum performance with the con-

I/O Capabilities 4 configurable inputs and one configurable output provide the user with

Configurable I/O Polarity I/O polarity can be set to Active High or Active Low ensuring compatibility

Diagnostic LED Green for power ON/ENABLED, flashing green for DISABLED, red for ON/

Ultra-Compact Packaging Top-notch performance, while consuming a minimal amount of space Resolution Up to 100,000 steps/rev FLASH Firmware Downloadable software facilitates quick upgrades over the internet Current Reduction Modes Enable Stop (current reduced to 75% of drive setting if no motion occurs

Anti-Resonance Provides optimum torque and nulls mid-range instability Integrate d C ooling Tunnel For maximum performance and multiple drive mounting capability Regenerative Circuit Dumps excessive power during deceleration

Allows a motor to run without an encoder and still be able to detect a stall Move profiles are smoothed to minimize jerk For full-stepping with the smoothness of microstepping 7 simple moves can be stored in the Impulse and activated via inputs or

serial port. This feature is optional. 6 component “gain” settings for low-speed smoothness, reduced vibration,

and more usable torque

figured motor

flexibility

with a wide range of controls

UNCONFIGURED, flashing red for FAULTS

during a user-programmed amount of time) Enable Idle (user-defined current reduction percentage if no motion occurs during a user-programmed amount of time)

Chapter 1 - Impulse Overview

This manual will enable you to 1) quickly setup and verify that your Impulse is operational, 2) configure and program the Impulse for your specific application, and 3) successfully troubleshoot possible performance problems.

1-1

Chapter 1 - Overview

This page intentionally left blank

1-2

Chapter 2 - Shipping Contents

Your Impulse will arrive equipped as listed in section #1. If any parts or accessories are missing, please call IDC Custome r Support at: (800) 747-0064. Sections 2 and 3 are provided as reference material.

- What You Will Receive if You Ordered the Following:

Chapter 2 - Shipping Contents

Impulse + FP100

(or FP220) Keypad

1. Impulse Microstepping Drive 1. Impulse Microstepping Drive 1. Impulse Microstepping Drive

2. AC power cord for Impulse 2. Motor Connector 2. AC power cord for Impulse

3. Motor Connector 3. AC power cord for Impulse 3. Motor Connector

4. FP100 (or FP220) Keypad 4. IDCMotion Software 4. FP100 (or FP220) -RS48 5 Keypad

5. Remote cable for Keypad 5. Impulse Quick Setup/Ref. Guide 5. Keypad Power Supply

6. Keypad mounting gasket 6. Impulse User’s Manual 6. Remote cable for Keypad

7. Keypad mounting template 7. Keypad mounting gasket

8. IDCMotion Software 8. Keypad mounting template

9. Impulse Quick Setup/Ref. Guide 9. IDCMotion Software

10.

Impulse User’s Manua

- Ordering and Identifying an Impulse

Using the tables below, fill in the boxes and you will be able to order or identify your Impulse:

IMPULSE Input Power Capability Drive Type Communication Accessories

Impulse Only

Impulse + FP100-RS485

(or FP220-RS485) Keypad

10. Impulse Quick Setup/Ref. Guide

11.

Impulse User’s Manua

IM L T4

Input Power Drive Type Accessories (order separately)

L Line Voltage 120 VAC T4 Stepper Drive, 4 A *FP_ _ _-_ _ Keypad Configuration

DB25BO 25 pin D-Shell Breakout Board

Capability Communication SS-IO 25 pin I/O Cable - 2 ft.

M Motion Node Version 2 RS232 SS-IO-6 25 pin I/O Cable - 6 ft. D Drive Version 4 RS485 SS-RS232 Serial Comm. Cable

PCS-5004 Keypad to PC Cable PCS-5110 Screw-Mounting Bracket PCS-5111 DIN Rail Mounting Bracket *FP100, FP220, FP100- R S485, or FP220-RS485

- Accessories Currently Available for the Impulse

SS-RS232 Impulse to PC Cable

DB25BO Screw Terminal Breakout Board

SS-IO (2ft. cable) SS-IO-6 (6ft. cable)

PCS-5004 Keypad to PC Cable

PCS-5110 Screw-Mount Bracket

PCS-5111 DIN Rail Mounting Bracket

2-1

Chapter 2 - Shipping Contents

This page intentionally left blank

2-2

Chapter 3 - Connecting and Installing Your Impulse

The purpose of this chapter is to provide information that will help you connect and install your Impulse drive in its intended application.

The Impulse drive easily interfaces with a PC, PLC, Step & Direction Motion Controller, or IDC keypad. Block diagrams of several Impulse-based applications are shown below.

Typical Impulse Applications

Keypad

PLC

I/O TX RX

RS232C

1 - 7 Stored Moves

961/962 Indexer

Single or Multi-Axis

Unit #1

RS232C

RS485

Digital Inputs (4)

Digital Output (1)

Fault Output

Step/Dir/Shutdown

Impulse

Unit #99

PLC

I/O

RS485

Unit #1

Unit #32

3-1

Chapter 3 - Connecting and Installing Your Impulse

Read This Page Bef ore Your Begin!

Always use cau ti on

• driven cylinders are capable of exerting trem endous force agai ns t an obstruction.

Always en sure that power to yo u r system is OFF

• mainten ance activity, or making any con nections or adjus t m ents.

Do not insert objects into the Impulse drive

• sonal injury, and equipment could be damaged beyond repair.

when working with mechanica l syste ms. Ge a rs an d s crew-

CAUTION!

before performing any

. High volt ages could cause per-

Do not open the Impulse drive.

• is opened.

The factory warranty will be voided if the drive

3-2

A. Connecting a Motor to the Impulse

Connecting an IDC Motor

The A+, A-, B+, and B- phase outputs power the motor windings.

Connect motor wires to the motor connector (supplied) and plug the wir ed con nector into the dr ive. Drawings below provide color codes for IDC motors.

GND is internally connected to the earth pin on the power connector. This provides a convenient terminal for grounding the motor frame and a motor cable shield. Note: If the motor is mounted on a machine that is grounded, do not connect the motor to GND.

The two INTLK pins must be jumpered together on the motor connector to allow power to the motor.

CAUTION! Do not remove the motor connector from the Impulse drive while power is applied. Removing the connector while power is applied could damage the connector pins.

Do not extend the interlock jumper wire to provide protection for anot her connector interface. The

interlock circuit is susceptible to trips caused by noise-pickup in cables (20 kHz switching).

Chapter 3 - Connecting and Installing Your Impulse

Note: This is a high-impedance safety-interlock circuit. If the interlock wire breaks, or the connector is removed, the current to the motor is immediately stopped, the drive faults (latches) and the LED on the front panel of the Impulse will flash five times (see LED Diagnostics on p. 3-8).

IDC Motor Wiring/Color Codes

Series Parallel Parallel

YELLOW

WHT/YEL

WHT/RED

RED

SHIELD

BLACK

WHT/BLK WHT/ORG

ORANGE

WHT/YEL

SHIELD

WHT/BLK

Connecting a Non-IDC Motor

YELLOW

WHT/RED

RED

BLACK

WHT/ORG

ORANGE

Motor Connector

GREEN/YEL

P31/32/33S12/21/23/32/33 P21/22, S21/23

YELLOW

WHT/RED

RED

WHT/YEL

BLACK

WHT/ORG

ORANGE

WHT/BLK

Quick Disconnect Cable Wire Color

A+ Red

A- Red/Yellow

*GND Green

B+ Red/White

B- Red/Black

*Gray-colored Quick Disc. cables are shielded - connect shield to GND.

One of the Impulse drive’s more advanced features, Open Loop Stall DetectTM, is guaranteed only when matched with one of IDC’s S or P-series motors.

IDC’ s S and P series motors have cust om windi ngs to pro vide optimu m dynami c performan ce with the Impulse. If you use another manufacturer’s motor, refer to Non-IDC Motors in Chapter 6, Hardware Reference, for more information.

3-3

Chapter 3 - Connecting and Installing Your Impulse

B. Serial Communication Connections

Making RS-232/RS-485 Connections

The standard Impulse drive uses a 3-wire implementation of RS-232C. The RX, TX, and COM lines are the serial signals supported. No hardware handshaking is required. Note that some RS-232C devices require handshaking, such as R TS and C TS. It is the respons ibility of the user to disable this handshaking via software or hard ware (see Troubleshooti ng RS -232C Com munica tion P roblems on page 3-6 for more information).

If you will be using RS-485 communication, the typical 5-wire interface connection to a “host” is shown below. See “Multi-Dropping Impulse Drives with RS-485” on the next page for information on using termination resi stors. Note: the maximum cable length for RS-485 communication is 4,000 feet.

Make your RS-232C connecti on as shown below . The PC Cable (IDC P/N SS-RS 232) shown below, is an ideal choice for making trouble-free RS-232C connections to the Impulse.

IDC P/N

SS-RS232

Comm Port Settings

RS-232C/RS-485 Baud Rate 19200 (fi xed) Stop Bits 1 Data Bits 8 Parity None XON/XOFF Yes

9-Pin

Connector

RS-485 Host

3 (TX) 2 (RX) 5 (COM)

TX-

TX+

RX-

RX+

COM

COM PORT

RS-232C

COM PORT

RS-485

3-4

Daisy-Chaining Impulse Drives

Your Impulse also supports daisy chaining. The unit address (range 1-99) can be set via the keypad or in Application Developer.

Rules for Daisy Chain Operation

1. Units on a daisy chain must be “d evice add ressed ’ (nu mber ed) in o rder for commu nications to work properly. A unit’s address should increment upward as you move down the daisy chain from the PC (see illustration below).

2. Do not duplicate unit addresses.

3. Any loose RS-232C connections or miswiring along the daisy chain will cause communications to fail. Please double check wiring if communication problems arise.

4. Please call IDC if you need to daisy chain more than 99 drives.

5. The hardware diagram below shows how to connect the daisy chain.

Chapter 3 - Connecting and Installing Your Impulse

PC/Host

RS-232C

Device

COM

Multi-Dropping with RS-485

If you will be “multi-dropping” Impulse drives with RS485, add 120-ohm termination resistors across RX and TX connections of the last unit as shown below:

RS-485

Host

Impulse

Unit 1

RX TX COM

Impulse

Unit 2

RX TX COM

Impulse

Unit 3

RX TX COM

Add resistors as shown here:

3-5

Chapter 3 - Connecting and Installing Your Impulse

Troubleshooting RS-232C Communication Problems

If communications between computer and Impulse are unsuccessful, one or more of the following procedures will usually solve the problem:

1. Host transmit (TX) must be con nected to receive (RX) of the dr ive unit, and receive ( RX) of the host must be connected to transmit (TX) of the drive. If communication fails, try switching connections on either the host or the drive.

2. Some serial ports may require handshaking. Jumper R TS to C TS, and DSR to DTR (s ee tab le).

3. Check your ground connections. The COM

Jumpers 9 pin D 25 pin D

RTS to CTS 7 to 8 4 to 5

DSR to DTR 4 to 6 6 to 20

terminal should be isolated from earth gro und. Use DC common or signal ground as your reference - do not use earth ground or shield.

4. Voltage between TX and COM should be -8.0 to -12.0 VDC. Voltage between RX and COM should be 0 to -0.5 VDC. Consult factory if measured voltages are outside these ranges.

5. For RS-232C only: If any cable is more than 50 ft. long, you should use a line driver, optical coupler, or shield. Shields must be connected to earth ground at one end only.

6. Reminder for PDA Users: Prog rams such as Palm’s Hotsync Manager take over a comm. port. Be sure to close/exit these types of programs if you are using serial communication with your Impulse.

7. Important Application Note Regarding PC Com Port: PC FIFO (First In First Out) Buffers should be used and adjusted t o the highe st settings f or fastest pe rformance. This applies to bot h Receive and Transmit Buffers.

• In your Windows operating system, go to Start > Settings > Control Panel > System >

Device Manager > Ports (Com 1, Com 2) > Port Settings > Advanced > Buffer.

3-6

• Select Use FIFO Buffers, and ensure both Buffers (Receive and Transmit) are adjusted to

the High setting for best performance.

C. Connecting an IDC Keypad

Two versions of IDC keypads can be used with the Impulse drive. The FP100 works only with the Impulse, while the FP220 can be used with the Impulse as well as IDC’s Smart Drives (see keypad-specific information below).

Chapter 3 - Connecting and Installing Your Impulse

COM PORT

The COM PORT on the front panel of the Impulse is used for connecting either version of keypad.

Power is applied to either version of keypad when power is connected to the Impulse.

Using a Keypad with Impulse RS232C

FP100 Keypad

Connect the FP100 Keypad to the Impulse with the cable supplied with the keypad.

FP220 Keypad (Version 3.0 or higher)

Only FP220 Keypad ver sions 3.0 an d higher will wo rk with the Impulse drive.

T o use an FP220 keypad with your Impulse, y ou mu st set DIP-switch #3 to the ON position and switch #s 1, 2, and 4 to OF F.

The FP220 uses the same keypad cable as the FP100.

I/O

Keypad with Impulse RS232C

Keypad

Using a Keypad with Impulse RS485

Impulse RS485 requires either the FP100-RS485 or FP220-RS485 keypad.

On the FP220-RS485 keypad only, set DIP switches as described above. Both FP100-RS485 and FP220RS485 keypad are connected as follows:

1. Connect the keypad cable to the keypad and to the Impulse.

2. Connect the keypad power supply cable to the keypad as shown in the illustration.

3. Plug in the AC adapter.

Keypad with Impulse RS485

Keypad

3-7

Chapter 3 - Connecting and Installing Your Impulse

D. Connecting AC Power

There is no ON/OFF switch on the Impulse. AC power is applied by plugging the *power cord (included) into the connector on top of the Impulse.

Input voltage must be in the range of 120 VAC ± 10%, single phase, 50/60 Hz, 500 VA max @ 4 Amps. Operation outside these specifications will result in reduced performance, drive faults, and may damage the drive.

When power is applied, the LED on front of the drive should briefly turn red, then steady green. If a red light is present, see Section E of this chapter for more information on fault detection codes.

*Note: If the AC power cord requires replacement, the replacement must be rated for Hard Usage or Extra Hard Usage.

To AC Power Supply

E. LED Diagnostic Indications

The Impulse drive detects and resolves fault conditions (see table below). Faults are signaled by either a steady red or a flashing red LED on the front panel. A solid green LED indicates normal operation. A slowly flashing green LED indicates a shutdown (disabled), while a rapidly flashing green LED signals a regen dump. Faults are cleared by either 1) cycling power, 2) sending a RESET command via the serial port or configurable logic input, or 3) probing the motor if the LED is steady red.

For more detailed explanation of faults refer to Chapter 7, Troubleshooting the Impulse.

Diagnostic LED Indications

LED Signal Indication

Green (steady) Normal Operation

Slow Flashing Green Shutdown

Quick Flashing Green Regen Dump

Red (steady) Motor Not Probed

1 Flash Red Stalled 2 Flashes Red Undervoltage Fault 3 Flashes Red Overvoltage Fault 4 Flashes Red Overcurrent Fault 5 Flashes Red Interlock Fault 6 Flashes Red Overtemperature Fault 7 Flashes Red EEPROM Checksum Fault

LED

3-8

F. Connecting Inputs and Outputs

Connect your inputs and outputs to IDC’s 961/962 Indexer according to the information below. Schematics for Impulse I/O circuits can be found in Chapter 6, Hardware Reference

Application Notes

1. On 961/2, ensure that Step/D irection and Dif ferential Jumpers are installed (see 961/2 manu al).

2. If using IDC P/N SS-I/O or SS-I/O-6 cable, cut one end of the cable if necessary (see table below for SS-I/O cable color-code). If making your own cable, or using a non-IDC indexer, refer to the Impulse I/O Schematics (Chap. 6) and the 25-pin Connector drawing below.

3. Use a shielded cable, and connect the shield only at the Impulse. Connect shield to pin 9.

4. IDC offers a 25-pin screw-terminal breakout board (shown below) to add convenience and flexibility to your application. Terminals on the breakout board match the pins of the 25-pin connector on the Impulse.

5. When wiring TTL signals to other manufacturer’s indexers, the Step TTL command signals from the controller should be wired to Step +, the Direction signal to Dir + , and the Shut down signal to SD + (Step -, Dir -, and SD - should not be connected). Remember, th e drive common must be connected to the controller common.

Chapter 3 - Connecting and Installing Your Impulse

6. Activating the Shutdown input disables the drive amplifier and de-energizes the motor. Wh en this input is OFF the drive is enabled and the motor is energized. The polarity of this input is configurable.

7. The open-collector Fault Output turns ON (Active High) when any one of the LED- indicated conditions occur (see Section E, LED Diagnostic Indicators). The output stays ON while the LED flashes.

IDC Indexer

(962 Dual-Axis Shown)

Breakout

Board

P/N DB25BO

IDC Cable P/N: SS-IO/SS-IO-6

Pin Impulse Signal Wire Color Pin Impulse Signal Wire C ol o r Pin Impulse Signal Wire Color

1 STEP + Brown 10 COM Gray 19 COM Black/White 2 STEP - Red 11 COM White 20 Reserved Red/Black 3 DIR + Orange 12 Reserved Black 21 Reserved Orange/Black 4 DIR - Pink 13 Reserved Brown/White 22 COM Yellow/Black 5 SD + Yellow 14 INPUT 1 Red/White 23 Output 1 Green/Black 6 SD - Green 15 INPUT 2 Orange/White 24 Reserved Gray/Black 7 FAULT + Light Green 16 INPUT 3 Green/White 25 Reserved Pink/Black 8 FAULT - Blue 17 INPUT 4 Blue/White

S T U P T U

COM COM

S T U P N

2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

Note: Cable SHIELD is internally connected to the

DB25 metal housing.9 Drain Violet 18 COM Violet/White

SHLD FLT-

FLT+

E V

SD-

I R

SD+

DIR-

DIR+

STEPSTEP+ SHLD COM +5 ZZ+ BB+ AA+

3-9

Chapter 3 - Connecting and Installing Your Impulse

G. Mounting the Impulse Drive

This section includes installation requirements, Impulse dimensions, installing and removing mounting brackets, and mounting the Impulse on a DIN rail.

Environmental and Installation Requirements

• Operating Ambient Temperature: Max. 50º C (122º F) @ 4 Amps

• Storage Temperature: Max. 65º C (149º F)

• Not intended for use in humidity above 95% (non-condensing), or at altitudes greater than 3,048 meters [10,000 ft.]

• Heat Dissipation @ 4 A (typical): 32 Watts

• Leave 6 inches above and below drives for airflow and wiring.

• Leave 0.1 inch between drives for easier mounting.

• Air supplied to the Impulse must be uncontaminated.

Mounting Arrangements

The illustration on the right shows an example of an acceptable mounting arrangement.

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

6.0 in.

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

3-10

Impulse Dimensions

Impulse with DIN-rail Mounting Bracket (P/N PCS-5111

Chapter 3 - Connecting and Installing Your Impulse

TS 35 DIN RAIL

5.599

1.779

6.365

Impulse with Screw-type Mounting Bracket (P/N PCS-5110)

1.779

6.365

5.599

10-32 screw with .305'' head ∅

6.000

1.779

3-11

Chapter 3 - Connecting and Installing Your Impulse

Inserting and Removing Mounting Brackets from the Impulse

Both Impulse mounting brackets are interchangeable and each is inserted or removed according to the following procedures. No tools are required to insert a bracket, however a flat-bladed screwdriver is required for removal. If additional brackets are required, see Chapter 2, Shipping Contents, for part numbers.

Installation of Bracket

1. Insert the bracket into the bracket housing from the top side of the Impulse as show n in the drawing on the right.

2. Slide bracket downward until a single click is felt (detent position). The bracket will be seated in the position shown at righ t. Note: If you push the bracket beyond the detent position (second click), it will be necessary to push the bracket back to the detent position.

Do not attempt to remove the bracket by pulling it from the bottom of the bracket housing. Both brack et and bracket housing coul d be per manent ly damaged.

(DIN Rail Bracket Shown)

Installation

Slide Bracket into Position as Shown Here

Insert

Bracket

Removal of Bracket

(DIN Rail Bracket Shown)

1. Insert the tip of a flat-bladed screwdriver between the bracket-release arms as shown in the drawing at right.

2. Gently twist the tip of the screwdriver until the arms are spread apart enough to clear the detent mechanism on the housing. Maintain this position.

3. While holding the arms apart with the screwdriver, push the bracket toward the top of the bracket housing as shown in the drawing.

Do not attempt to remove the bracket by pulling it from the bottom of the bracket housing. Both brack et and bracket housing coul d be per manent ly damaged.

Removal

Insert screwdriver blade perpendicular to bracket (profile of blade shown in spread position)

Twist until arms are spread apart - hold in position

Push bracket free of

arms and out the bracket housing

3-12

Impulse DIN-Rail Mounting

The DIN-rail mounting system is a combination of 1) a removable mounting bracket, which locks the drive onto the DIN-rai l (ins tallation on pr evious p age), plus 2) the DIN-r ail hang er on t he upper rear part of the housing that suspends the weight of the drive on the rail.

Chapter 3 - Connecting and Installing Your Impulse

Mounting the Impulse on the DIN-Rail

1. Hook the top of the DIN-rail hanger over the top of the DIN-rail.

2. Rotate the Impulse drive downward until it locks into place on the rail.

3. Pull back slightly on the drive to ensure it is securely fastened to the rail.

Removal of Impulse from the DIN-Rail

Mounting

Impulse Securely Mounted on DIN-Rail

1. Ensure power to the drive is OFF.

2. Remove the motor connector.

3. Insert tip of flat-bladed screwdriver into slot provided on the bottom of the mounting bracket (see drawings on the right).

4. Gently pry down ward unti l the brack et disconnects from the rail. Note: The bracket will fall approximately 1 inch, but will still be retained by the Impulse housing. Do not attempt to remove the bracket by pulling it from the housing.

5. The bracket can be reset to the detent position by pushing upward until a click is felt (see “Installation of Bracket” on the previous page).

Removal

Insert screwdriver blade and pull downward

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Chapter 3 - Connecting and Installing Your Impulse

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3-14

Chapter 4 - Configuring Impulse with Applic ation Developer

Chapter 4 - Configuring Impulse with Application Developer™

This chapter covers the installation and use of IDC’s Application Developer software to configure your Impulse drive.

Installing Application Developer on Windows 95/98/2000/ME/NT

1. Place the IDC CD in your CD-ROM drive and click on the Start button.

2. Click on Run.

3. Type the following in the Command Line box that appears (replace “x” with your CD drive letter if different): x:\App_Dev\Setupex.exe

4. Click OK and follow the onscreen instructions.

5. Restart Windows (recommended).

There are no known installation problems with Application Developer, but please call the IDC Applications Department at (800) 747-0064 or (707) 789-1000 (from outside U.S.) if you need assistance installing this software.

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Chapter 4 - Configuring Impulse with Application Developer

Using Application Developer

Application Developer’s graphic user interface allows you to configure and program your Impulse using an appropriately equipped computer. Upon starting Application Developer you will be given four options for beginning the configuration of your application (see window below).

1 2 3

page 4-5

Select from one of the following options to begin configuring your Impulse:

1. Upload Project. If your drive has already been configured, this option allows you to upload a project file from the drive for editing (modification), troubleshooting, etc. See Upload Project on the next page for more information on using this option. The Project Wizard is the best method for initial drive configuration and building a new project file.

2. Launch Now - Allows you to go directly to the main menu or tool bar buttons to quickly configure or change project parameters. See Launch Now on page 4-4 for more information.

3. Project Wizard - Clickin g on the Project Wizard button will take you through the quickest, most accurate method of configuring the initial setup parameters for your project file (see page 4-5 for details).

4. Open an Existing Project. To bypass the Project W izard and select a stored file from the Open File window, click on the Open an Existing Project button (see page 4-4).

4-2

Upload Project

1. Begin by clicking the Upload Project button on the Application Developer Startup window. Yo u will see the Control Type Selection menu (shown right).

2. Configuration begins by selecting your Impulse from the list of Steppers. Click OK.

3. Select the Port you will use to connect the Impulse.

Chapter 4 - Configuring Impulse with Applic ation Developer

Comm Port Settings

(for reference only)

RS-232C/RS-485

Baud Rate 19200 (fixed) Stop Bits 1 Data Bits 8 Parity None XON/XOFF Yes

4. Select the Unit Number (from 1 - 99) of the Impulse being configured.

5. To test communication u sing the current setup, click on Test Connection. Click OK.

6. Skip the section on Using the Project Wizard and go to Fine Tuning Your Application.

Note: Echo and Mode are not available; they have no effect on the Impulse drive.

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Chapter 4 - Configuring Impulse with Application Developer

Launch Now

This method of begi nning Application Develo per is typically used by more experienced users o f IDC products. Select your Impu l se vers ion and press OK. You can now go directly to the Main Menu or tool bar buttons to configure the Impulse (see Fine-Tuning Your Application).

Open an Existing Project

If you want to open a project file which has been st ored on disk (not in the Impu lse), select Open an Existing Project. Select the desired file and click on the Open button. After opening an existing

project file, it is still possible to use the Project W izard at any time by simply clicking on the W izard toolbar button. See Fine-Tuning Your Application if you do not wish to use the Project Wizard.

4-4

Using the Project Wizard

1. Click the Project Wizard button on the Application Developer Startup window.

• Select the product you are configuring, Impulse in this case, and click on Next.

• The Wizard Navigator (left side of window) allows you to quickly locate your current posi-

tion in the setup process. The column of boxes represents the parameter being configured. A box’s color r epresents its configuration status, i.e. gray indicates a parameter not yet configured, yellow indicates the parameter currently being configured, and black indicates completed configuration of the parameter.

Wizard Navigator

Chapter 4 - Configuring Impulse with Applic ation Developer

2. Click on the Next button and the Motor setup window will appear . The configuration pro cedure in Motor Setup differs slightly depending upon whether you are using IDC or Custom (userdefined) motor (see A ppendix C t o configur e a custom mo tor). IDC -supplied motors hav e been precisely characterized in motor files which reside in an Application Developer directory . These files cannot be altered or deleted. User-defined (custom) motor files must be created by the user.

If you want to change the operational characteristics of an IDC m otor, you can do so b y selecting an IDC motor from the scrollable list and saving it under a new file name in the Motor Editor (the original motor file remains unchanged under its original file name).

• From the pull down menu, s elect the IDC mot or you will be us ing, or click on Add Custom

Motor and see Appendix C for information on configuring a custom motor file.

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Chapter 4 - Configuring Impulse with Application Developer

3. Click Next and the first of three possible Mechanics setup windows will appear. The Mechanics window that appears depends on the selection made in the Select an IDC

Mechanical System list.

Mechanics window A (shown below) appears when a Motor Only is being configured. This

window shows the IDC motor or user-defined file name in the Part # text input box, and the Motor Rotor Inertia (in kg-cm

• Select Motor Only.

• Load Inertia - Enter Load Inertia in the text input box.

• Move Unit - Choose your move unit from the pulldown menu.

) of the motor being configured.

Mechanics window B (below) will appear if an IDC Mechanical System (other than Motor Only) is selected. This window allows you to select an IDC Mechanical System, the Part # of the system, and the Stroke Length, Travel, Gear Ratio, or Table Diameter of the system.

• Select the category of IDC Mechanical System you are using.

• Select the Part # of the system.

• Select the Stroke Length (cylinders), Travel (tables), Gear Ratio (gearmotors), or Table

Diameter (rotary tables).

• Enter the Load Ma ss (cylinders and ta bles), o r Load Inertia (gearmo tors and rotary tables).

• Select the Move Unit for the system.

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Chapter 4 - Configuring Impulse with Applic ation Developer

Mechanics window C will appear if you select Non-I DC Mechanics from the “system” list.

• Enter your Total System Inertia (Load + Mechanics + Motor).

• Select your Move Unit (steps, revs, mm, or inches) from the pulldown menu.

• Enter you r Distance Ratio (only if in ches or mm a re the selected Move Un its ). You cannot

enter Distance Ratio if either steps or revs has been selected.

4. Click Next and the Resolution setup window will appear

• Select your Step Resolution from the pulldown menu, or enter a step resolution in increments of 200.

5. Click on Next and the I/O (Input/Output) setup wi ndow will appear . Using the pull down menus,

select configurations for up to fou r (4) Discrete Inputs and one (1) Discrete Output. The buttons to the right of the inputs and outputs are provided for toggling between Active High (A.H.) and Active Low (A.L.).

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Chapter 4 - Configuring Impulse with Application Developer

Discrete Inputs (see pulldown menu)

Discrete Outputs (see pulldown menu)

6. When all parameters h ave been configured, click Next and the Accept window will appear . This

display allows you to review the se ttings made earlie r, or gives you an opportunit y to return (Back button) to any parameter you may want to chan ge.

• When satisfied with the setup of your system, click on Accept. The Wizard Navigator

should now indicate that all setup parameters have been configured. Use the scroll.bar/buttons to review the project file.

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Chapter 4 - Configuring Impulse with Applic ation Developer

7. Your basic project file has now been configu red b ut the f our “Finish” step s must b e comp leted in order to send the project file to the drive and probe the motor.

• Click on Config. Comm Port (#1) and select the Port to which you are connecting the

Impulse. Next, select a Unit Number (from 1 - 99) f or the Impuls e being configu red. To test communication using the current setup, click on Test Connection. Click OK.

• Click on Send All (#2) to send the project setup parameters to the drive.

• Click on Probe Motor (#3). Pressing this button tells the drive to execute an electronic

probe of the motor to determine a host of proprietary, internal settings for use in the antiresonance/stall detect features. Any time the drive is connected to a different type of motor, or if a new motor file is selected, the motor must be re-probed. When the drive is probing the attached motor, a 1 kHz tone will be heard emanating from the motor. Depending on motor type, this tone may persist for up to 15 seconds. Motor probe is not required each time the Impulse is powered on. .

• Click on Set Tuning Values (#4) and enter the values from your IDC motor label.

• The project fi le has been sent to the drive and your appli cation can n ow be fine-tun ed using

the Axis Setup menu (starting on the next page).

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Chapter 4 - Configuring Impulse with Application Developer

Fine-Tuning Your Application

Your basic system setup parameters have been configured by the Project Wizard, and though the system is functional, your application will probably require further configuration and fine-tuning.

The remainder of this chapter provides information on configuring your Impulse with Application Developer’s setup and I/O menus. In addition to the parameters configured by the Project Wizard, these menus provide additional features for more control of your system and greater capacity for applications. Also covered in this chapter is the Motion Node or Stored Move option.

The Project Wizard remains available at any time by clicking on the Project Wizard button. The Toolbar Buttons provide access to the setup parameters and other features that will be covered in the remainder of this chapter.

Toolbar Buttons

The Application Developer toolbar buttons allow quick access to most of the menu s available on the menu bar. The toolbar buttons shown below are available when configuring an Impulse drive. If a button or item on the menu bar is grayed-out, that function is not available to Impulse users.

Axis Setup

•The Axis Setup menus consists of five configurable sub-menus. Click on the Axis Setup but-

• The first menu to appear will be the Motor menu tab (begins on the following page).

• Important! After making changes in the Axis Setup menu, remember to perfor m

New Project

Open Project

Save Project

Project Wizard

Axis Setup

I/O Setup

Edit Stored Moves

View Configuration

Send All

Receive All

ton or go to File > Axis Setup on the main menu bar.

a Send All command (Send All button or Communications > Send All) to send newly configured parameters to the drive.

Reset Impulse

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Motor

Chapter 4 - Configuring Impulse with Applic ation Developer

• Motor Name - Select your motor from the list, or click on the Edit Motor button to create a custom motor file or edit an existing IDC motor file.

• Electrical - These text input boxes display the electrical characteristics of the selected motor. If a text input box displays a zero (0), that particular electrical characteristic has not been configured as part of the motor file. To create or change a motor file, see Edit Motor.

• Mechanical - These text input boxes display the mechanical characteristics of the selected motor. If a text input box displays a zero (0), that particular mechanical characteristic has not been configured as part of the motor file. To create or change a motor file, see Edit Motor.

• Edit Motor - See Appendix C for information on using this feature. The “Advanced” tuning feature is also covered in Appendix C.

See Appendix C to Edit a Motor

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Chapter 4 - Configuring Impulse with Application Developer

Mechanics

Move Unit and Total Inertia (kg-cm

) are displayed on this tab, but they are not editable

parameters. Click on the Change Mechanical System/Units button to edit your mechanical parameters.

• Change Mechanical System/Units - The text input-box parameters (in each available Setup

Mechanical System window) are dependent upon the selection you make from the Select Mechanical System list. Examples of different mechanical parameters are shown below.

Windows for Configuring IDC Mechanical System Parameters

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Parameters for non-IDC Mechanics

Notes:

• Motor Rotor Inertia is pr ov id e d fo r

reference only.

• Enter your Total System Inertia

(Load + Mechanics + Motor).

• Ensure all units have been con-

verted to kg-cm

Command

Chapter 4 - Configuring Impulse with Applic ation Developer

The Command Tab allows you to configure the Command Signal and Jog I nput parameters, and to select the level of Numeric Precision that Application Developer will use to build the project file.

Command Signal Configuration

• Drive Resolution - Enter the operating step resolution in integer multiples of four times the

tooth count of the motor (50 tooth count x 4 = 200), or select a resolution from the scrollable list. Note: the default resolution is 25,000 and the valid range is 200 to 100,000.

• Stop Rate - Enter the deceleration rate of the motor when a STOP or EOT input is acti-

vated (see Limits Tables in Ch. 9, Troubleshooting the Impulse). Notes: (1) The Stop Rate units are user-defined (selected). (2) The Stop Rate should be a value that ensures enough torque to control deceleration while not allowing the motor to stall.

• Direction - Sets motor direction. Toggle the Direction button to select Direction + (CW) or

Direction - (CCW).

• Shutdown Polarity - Toggle the Shutdown Polarity button to select Shutdown Active

Low or Shutdown Active High.

Jog Input Configuration

This option allows you to modify the jog parameters (Jog Accel, Jog Low, Jog High) to be used by the Jog Inputs (JOG+, JOG-, JOG SPEED). These values will be in displayed in units selected in the Project Wizard (Mechanical Setup Move Units) or in Axis Setup > Mechanics > Change Mechanical Sytem/Units.

Note: Numeric entries made in the Jog Input Configuration section of the Command tab are applied using the user-defined units shown. If the units are changed (Setup > Axis > Mechanical > Change Mechanical System/Units), the user must edit the Jog Input Configuration values to obtain the intended velocities and acceleration in terms of the new units. Application Developer does not automatically translate the numeric values when the units are changed.

Enter Jog values directly in the text input boxes or use default values (shown below).

• Jog Accel (Jog Accel/Decel) - Default = 20.00 (user-defined units)

• Jog Low (Jog Low Speed) - Default = 0.50 (user-defined units)

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Chapter 4 - Configuring Impulse with Application Developer

• Jog High (Jog High Speed) - Default = 2.00 (user-defined units)

Numeric Precision

• Select Standard to limit the decimal precision of accelerations, decelerations, velocities,

and distances to the following:

Accels and Decels: #.x (One decimal place) Velocities: #.xx (Two decimal places) Distances: #.xxx (Three decimal places)

The Standard decimal precision is sufficient for most applications. Standard is the default setting.

Note: The keypad (FP100 or FP220) only supports Standard decimal precision, therefore project files intended to be used in conjunction with the keypad must be created using the Standard setting. Attempting to load a project file into the keypad without Standard decimal precision will result in an error.

• Select Extended to limit the decimal precision of accelerations, decelerations, velocities

and distances to the following:

Accels and Decels: #.xxx (Three decimal places) Velocities: #.xxxxx (Five decimal places) Distances: #.xxxxx (Five decimal places)

Project files created with Extended decimal precision may be edited only in Application Developer.

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X-Smoothness (Xtreme Smoothing™)

The X-Smoothness tab is the most advanced low-speed tuning feature currently available on any microstepping drive. The benefits of low-speed smoothness are 1) reduced vibration, and 2) an increase in torque, which was typically lost to vibration before the arrival of the Impulse drive.

Achieving this revolutionary smoothness is easily and quickly accomplished by following the simple procedure below. Note: the motor must be disconnected from its load while performing Xtreme Smoothing™.

Chapter 4 - Configuring Impulse with Applic ation Developer

• X-Smoothness Sliders - Click and drag the indicator to change a value.

• Test Speed - This text input box displays the Recommended T est Speed and may be edited

if necessary.

• Recommended Test Speed - This value has been either 1) pre-configured for IDC motors,

or 2) calculated when a custom motor file was created in the Advanced Mo tor Editor. V erify that this value has been entered in the Test Speed display.

• Run Test/Stop Test Button - Toggles between Run Test and Stop Test.

•Restore - Restores each X-Smoothness to the previous values.

Adjusting X-Smoothness #1, #2, #3

Important: Whether using an IDC motor or a non-IDC (custom) motor, all six X-Smoothness values (L1, L2, M1, M2, H1, H2) must be adjusted in the order described in the following procedure. Note: Slider bars L1 and L2 are interactive, as are M1 and M2, and these interactive sliders should be alternately adjusted until the deepest null setting is achieved.

X-Smoothness #1

Recommended values for L1 and L2 have been pre-configured for IDC motors, but we recommend that these settings be verified and adjusted if necessary by the following procedure. If you are using a custom motor file, these values wer e calculated in the Advanced Motor Editor .

1. Press the Run Test button.

2. Move slider L1 left and right until the smoothest running condition is reached.

3. Move slider L2 left and right until the smoothest running condition is reached.

4. Press Stop Test.

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Chapter 4 - Configuring Impulse with Application Developer

X-Smoothness #2

Recommended values for M1 and M2 have been pre-configured for IDC motors, but we recommend that these settings be verified and adjusted if necessary by the following procedure.

5. Press the Run Test button.

6. Move slider M1 to approximately 8,000.

7. Move slider M2 left and right until the smoothest running condition is reached.

8. Move slide M1 left and right until the smoothest running condition is reached.

9. Press Stop Test.

X-Smoothness #3

10. Press the Run Test button.

11. Move slider H1 left and right until the smoothest running condition is reached.

12. Move slider H2 left and right until the smoothest running condition is reached.

13. Press Stop Test.

14. Click OK.

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Advanced (Advanced Tuning)

The Advanced tab allows you to enable/disable and modify various advanced perfor mance features of the Impulse drive.

Anti-Resonance

Chapter 4 - Configuring Impulse with Applic ation Developer

Note: Observe decrease in Gain when Multi-Stepping is Enabled.

• Enable this feature by selecting the Enabled check box. Ensure that both Damping Gains

are configured if Anti-Resonance is enabled.

Current Reduction Mode

•Select Stop to enable the stop mode current reduction time-out period. Stop Mode reduces

current by 25%. This time-out period is directly entered in milliseconds. The valid range is 6 to 19,656 ms.

•Select Idle to set the idle mode current reduction time-out period. This time-out period is

directly entered in seconds. The valid range is 0 to 3600 seconds (0 = disabled).

•In the % box, enter the percentage that current will be reduced after the idle mode time-

out has expired. The valid range is 0 to 100%.

Profiling

•Select Dynamic Smoothing Enabled by clicking on the check box and entering the recom-

mended gain in the input b ox. D ynamic Sm oothin g™ is an IDC pro prietary method o f auto matically reducing “jerk” (sudden change of acceleration) which is often inherent in move sequences generated by indexers. Dynamic Smoothing™ is similar in effect to so-called Scurve profiles. The softening of accel/decel transients sharply reduces ringing in the motor and various attached structures.

•Select Multi-Stepping En abled for more aggressive dynamic smoothing. Gain will be

1/10 of the recommended gain when Dynamic Smoothing is enabled. Multi-Stepping™ is an IDC proprietary method of obtaining very smooth motion from step motors when using low resolution indexers, i.e. 200, 400, 1000 steps/rev. The Multi-Stepping™ feature, when enabled, executes coarse stepping regimens by using microsteps to fill-in between the widely-spaced, low-resolution steps. This is a form of interpolation that produces smooth motion in an otherwise coarse and noisy stepping system.

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Chapter 4 - Configuring Impulse with Application Developer

Stall Detection

• Select Stall Detection to enable the Open Loop Stall Detect™ encoderless stall detection

feature.

• Stall detection becomes active at velocities of 0.5 RPS and greater.

Remember to perform a “Send All” command to send the modified project file to the drive.

I/O Setup

After configuring the Axis Setup parameters, the discrete inputs (4 ea.) and output (1 ea.) will need to be configured for your application. See I/O Descriptions below for details.

• Click on the I/O Setup tool bar button.

• Select up to four Discrete Inputs and one Discrete Output from the pulldown menus.

• Use the toggle button s to right of the inputs to select between Active Low (A.L.) and Active High (A.H.).

I/O Descriptions

Input Descriptions

EOT (End of Travel): Activation of an End of Travel input during any motion (external steps or internal move engine) will terminate motion at the rate specified by the Stop Rate parameter, and latch the direction. Motion is only allowed in the direction opposite of the latched EOT direction until a negative edge (activation on to activation off) is made. This guards against the switch activator becoming “trapped” if the Stop Rate was insufficient to stop motion in the activation region. The EOT input is also required in the execution of Home type moves. See Stored Move

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Chapter 4 - Configuring Impulse with Applic ation Developer

Setup - Editing Stored Moves later in this chapter for more information on Home moves.

Jog +: Activation of a Jog+ input will jog the motor at the acceleration rate specified by the Jog

Accel parameter and the velocity specified by the current state of a Jog Speed input in the positive direction. If a Jog Speed input has not been configured, the motor is jogged at the velocity specified by the Jog-Low parameter.

Jog -: Activation of a Jog- input will jog the motor at the acceleration rate specified by the Jog Accel parameter and the velocity specified by the current state of a Jog Speed input in the negative direction. If a Jog Speed input has not been configured, the motor is jogged at the velocity specified by the Jog-Low parameter.

Jog Speed: The Jog Speed input toggles between the low and high velocities for the Jog+ and Jog- inputs as specified by the Jog-Low and Jog-High parameters. If the state of Jog Speed input is changed while a Jog+ or a Jog- input is asserted, the motor will accel or decel at the Jog Accel r ate to the high or low velocity respectively.

Kill: Activation of a Kill input terminates any motion (external steps or internal move engine) instantly without a deceleration ramp.

Move Select: The Move Select input is used to trig ger on e of the 7 poss i ble stor ed moves (Mot ion Node option only). Each configured Move Select input serves as a bit in a 3-bit binary number therefore allowing the binary representation of numbers 0-7. The Move Select configuration option is only available on inputs #1-#3 with input #1 being the least significant bit (LSB) and input #3 being the most significant bit (MSB). Note that the bit places are fixed with respect to the input numbers. For example, if input #1 were configured as an EOT and input #2 were configured as a

Move Select, asserting input #2 would run stored move #2 not stored move #1. Below is a Move Select assertion table:

Move Select Inputs

Input #3 State Input #2 State Input #1 State Result

Inactive Inactive Inactive Idle Inactive Inactive Active Run Stored Move #1 Inactive Active Inactive Run Stored Move #2 Inactive Active Active Run Stored Move #3

Active Inactive Inactive Run Stored Move #4 Active Inactive Active Run St ored Move #5 Active Active Inactive Run Stored Move #6 Active Active Active Run Stored Move #7

T o guard against inadvertently selecting moves during input transitions, all Move Select inputs must be stable for the time specified by the Mov e Select Input Scan T ime. See the “Editing Stored Moves” section for more information on setting the Move Select Input Scan Time.

Stop: Activation of a Stop input terminates any motion (external steps or intern al move engine) at the rate specified by the Stop Rate parameter.

Warm Boot: Activation of a Warm Boot input resets the drive and clears any latched fault condition. To g uard against a Warm Boot input being inadvertently held asserted, the Warm Boot input is negative edge triggered (activation on to activation off). To insure the negative edge is latched, the Warm Boot input must be held asserted for at least 500µs before releasing.

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Chapter 4 - Configuring Impulse with Application Developer

Output Descriptions

Brake: The Brake output is activated on any fault condition. This provides a control signal to engage a brake when the Impulse loses torque due to a fault. The Brake output also provides a polarity-configurable fault output since the ded icated fault output is fixed as an active high, si nking output. Note: The Brake output is not intended nor designed as a power source for a mechanical brake.

In Motion: The In Motion output is activated upo n receiving incoming step pulses or when a stored move (Motion Node option) is running. The minimum step frequency that the internal velocity tachometer can render is 156.25 Hz (156.25 / Step Resolution in RPS). Input step freq uencies below

156.25 Hz will not activate the In Motion output.

Stall: The Stall output is activated when OLSD™ (Open Loop Stall Detect) detects a motor stall.

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Chapter 4 - Configuring Impulse with Applic ation Developer

Stored Move Setup - Editing Stored Moves

If your Impulse is equipped with the Motion Node option you will be able to access the Stored Move Setup menu shown below. The Impulse will store seven (7) moves which can be invoked

through binary inputs, by serial commands (see Appendix B), or via the Run > Stored Move window . Moves are edited in the Stored Move Setup window via Edi t > Stored Move or the Edit Stored Moves tool bar button.

• Click on the Edit Stored Moves button.

• Use the information provided below to configure your Stored Moves in the St ored Move Setup menu.

Stored Moves are defined by the parameters Accel (acceleration rate), Decel (deceleration rate), Velocity, Position/Distance, and Move Type. Distance Units pertaining to the four dynamic parameters are selected in the Project Wizard or the Axis Setup tab (Setup > Axis > Mechanics > Change Mechanical System/Units). The three move types are Incremental, Absolute, and Home, each selectable by a radio button.

Incremental moves are indexed to the commanded position from the current position. Absolute moves are indexed to the commanded distance. Home moves function as follows:

1. The drive moves at the specified velocity (direction selected by velocity sign) until it sees an EOT input go active.

2. On the active going transition, the drive decelerates according to the specified Stop Rate parameter.

3. The drive reverses direction and moves at 1/16 of the specified Velocity until it sees an activeto-inactive transition on the EOT input. This locates the inside edge of the EOT sensor precisely .

4. The drive stops the slow mov e and executes an incremental move defined by the Distance entry . This final move is always in the opposite direction to the initial search direction specified by the sign of the V elocity parameter . This move constitutes an offset from the edge of the EOT sensor.

5. After the final position is reached, the drive zeros its position counter. All subsequent “absolute” moves will be relative to this Home position.

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Chapter 4 - Configuring Impulse with Application Developer

Note: Homing is predicated on the assumption that the system is positioned somewhere between the EOT switches when the home move is invoked. If the system is initially outside the interval between the EOT switches, the homing routine will fail in one of two ways: (1) carriage will be driven against mechanical end-stop. (2) carriage will end up “homed” outside the interval between the EOT switches.

Digital inputs are configurable as EOT (Active High/Active Low) on the Setup > I/O menu. More than one Home move can be specified and stored simultaneously if it serves a purpose.

Input Scan Time - This is the time the drive requires the binary input selection to be stable prior to triggering a move. Its primary purpose i s for debou nci ng input s. Scan time can be conf igured from 0 to 19,656 milliseconds.

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File Menu

Edit Menu

Chapter 4 - Configuring Impulse with Applic ation Developer

• Selecting New Project will take you to the Project Wizard.

• The default file suffix is *.idc.

• Project files may be stored on disk as DOS files.

• All other selections under the File menu are generic to all Windows applications.

• Stored Move and Motor File Editor s , both discussed previously, can also be accessed from

Setup Menu

• I/O, Axis, and Project Wizard, accessible from toolbar buttons, have been discussed previ-

• Select Controller Type as the first step in starting a new project file. You must select a con-

the menu bar.

oulsy.

troller before you can build a new project file.

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Chapter 4 - Configuring Impulse with Application Developer

Communications Menu

•Use Send All to download a project file to the drive. A Send All toolbar button is also avail-

able.

•Use Retrieve All to upload a project file from the drive for modification.

• Project Update allows you to accelerate the configuration of multiple drives when all drives

have the same setup configuration. After configuring your first drive with the Project Wizard, select Project Update and follow the onscreen prompts for each additional drive.

• Change Unit Num ber is used to set the unit address of each

drive to be used on a daisy chain. Each drive must have its own unique software address. The unit nu mber must b e set before the units are connected in the daisy chain.

Press Query Address if the address is unknown. This feature can only be used with a single drive connected to the computer. An attempt to Query Address of a unit on a daisy chain will result in an error message.

• Setup Comm Port is us ed to s elect a C omm Port when you r PC

has multiple serial ports. This dialog box also contains a Comm Port test utility to verify proper RS-232/485 operation.

• Select Test Connection to command an instant communication test (also available in Setup

Comm Port).

• For information on Load Flash Memory, see Updating Your Impulse Operating System at

the end of this chapter.

4-24

Run Menu

Chapter 4 - Configuring Impulse with Applic ation Developer

•The Run > Stored Move menu is available only on drives equipped with the Motion Node option and can only be accessed from the menu bar. This menu allows you to view all stored move profiles and to run and stop each stored move.

• No editing of moves is available on this menu. During the execution of any stored m ove, the Impulse ignores the step and direction inputs. Any activity on those inputs is completely lost. In other words, stored moves are not added in with incoming step commands. Typically, it is not a useful control stratagem to trigger a stored move while engaged in motion commanded via the step and direction inputs.

• Binary inputs (digital inputs 1, 2, and 3) may be configured as Move Inputs (Active High/ Active Low) for triggering stored moves (Setup > I/O).

• Serial Commands - A host system may trigger moves over the serial RS-232/485 connection. This procedure involves the transmission of Unit Addressing, Parameter Indexes, Data and Checksum. The advanced topic of serial communications protocol is covered separately in Appendix B.

•Click on Probe Motor to probe th e motor at any time. Probe th e motor when a st eady re d LED is present.

• Select Jog Motor to access the jog utility shown below. Jog Low and Jog High may be changed for immediate effect but the configured input speeds (set in the Axis Setup > Command menu) will not be changed. The center button toggles between High and Low speeds, and the arrow buttons change motor direction.

•Click on Reset Impulse to clear a fault. Reset is a warm boot.

4-25

Chapter 4 - Configuring Impulse with Application Developer

View Menu

• Select Configuration Text File to see your system

configuration status. All configuration parameters are listed and may be viewed by scrolling the list.

• Select Control Status for a quick look at current I/O configuration, motor position and veloc-

ity, fault history, and basic internal drive information (i.e. firmware version, etc.).

4-26

• Click Drive Info for a look at hardware and firmware versions. In the unlikely event that the Impulse sustains an EEPROM Fault (7 red LED flashes) the Restore Factory Settings button is used to clear the current memory contents and restore the factory default configuration of the Impulse.

• Click Fault History to look at the eight most recent drive faults, accumulated hours of operation, and the number of power cycles.

• Click Refresh to get a quick snapshot of the Drive Status.

•Press the Poll button to continuously check drive status. Stop Polling turns polling off and restores the Refresh button.

Chapter 4 - Configuring Impu lse with Application Developer

Updating Your Impulse Operating System:

Your Impulse drive contains FLASH memory technology allowing the flexibili ty and convenience of upgrading the operating system using Application Developer and a PC RS232 or RS485 serial connection. The latest released Impulse operating system version is available for download at our web site http://www.idcmotion.com

WARNING:

the factory. The potential for FLASH corruption exists if the operating system upgrade is interrupted while in progress. If the FLASH memory becomes corrupted, it will need to be reprogrammed at the factory.

NOTE:

sure to save the drive setup as a .idc file or in a keypad before upgrading the ope rating system.

Upgrading the operating system should only be performed when instructed by

Upgrading the operating system will reset the drive setup to factory default settings. Be

Loading the Operating System

WARNING: DO NOT

RS485 bus. Attempting to load multiple units simultaneously will result in a FLASH corruption of all units.

1. Obta in th e n ew op erating system file fro m http://www.idcmotion.com or directly from the factory.

2. With a from Application Developer.

3. Use the Open File dialog box to select the desired .hex operating system file.

4. Applic ation Deve loper wil l est ablish a FL ASH memory conne ction and begi n the trans fer. The warning and progress screens (shown below) will appear when the FLASH transfer begins.

Impulse drive connected, select

single

attempt to load the operating system over an RS232 daisy chain or

Communications > Load FLASH Memory

4-27

Chapter 4 - Configuring Impulse with Application Developer

This page intentionally left blank

4-28

Chapter 5 - Configuring Impulse with an IDC Keypad

Section 1 of this chapter is intended primarily to familiarize new IDC keypad users with the FP100 Impulse Keypad, and we recommend th is section be reviewed by those expe rienced with the FP220 keypad as well. If you are u sing an FP220 keypad (vers ion 3.00 and above) t o configure the Impulse, it is imperative that the keypad DIP-switches be set as shown on the next page.

Section 2 provides step-by-step procedures for configuring the Impulse with either the FP100 or FP220 keypad.

Section 1 - Introduction to the FP100 Impulse Keypad

The FP100 version of the IDC keypad was developed solely for the Impulse drive, while the FP220 (version 3.00 and higher ) can also be u sed with the Impu lse and with IDC’ s extensive line of Smart Drives. The FP100-RS485 and FP220-RS485 keypads may be used with an Impulse and RS-485 communication.

The keypad was designed to provide operators with a convenient way to configure an application, and though it functions primarily as an operator interface, it is also effective as a troubleshooting tool.

Application Note: If a project file was created in Application Developer using the Extended level of Numeric Precision (Axis Setup > Command > Numeric Precision > Extended), you will receive a pr ecision err or message when the file is loaded into a keypad. Only the Standard level of numeric precision (Axis Setup > Command > Numeric Precision > Standard) is compatible with the precision level of the keypad. See Chapter 4, Configuring Impulse with Application Developer.

Keypad Features

• Easy-to-r e ad, two-line, 40-character, back-lit display

• Can be sealed to IP65 (NEMA 4) washdown environ me nt

• Large, scratch-proof keys with audible and tactile feedback

• Connects to the Impulse with a remote cable

• Allows project files to be copied to and from a PC.

5-1

Chapter 5 - Configuring Impulse with an IDC Keypad

Keypad Hardware Features

Adjusting Contrast

On the back of the keypad there is a plastic potentiometer, adjustable with a flathead screwdriver. This is used to adjust the contrast on the LCD display. If the Impulse drive and keypad were purchased together, this adjustment has been made by IDC. Some adjustment may still be necessary to accommodate a variety of lighting conditions or viewing angles.

Remote-Mounting the Keypad

The keypad can easily be mounted and sealed to NEMA 4 specifications by using the included mounting gasket and 6-foot communication cable. See Chapter 6, Hardware Reference, for important information on mounting the keypad and extending cable length.

DIP Switch Settings

DIP-switch settings on the back of the FP100 keypad have no effect on either the keypad or the Impulse drive.

NOTE: If you are using an FP220 keypad with your Impul se, you must set DIP-swi tch #3 to the ON position and switch #s 1, 2, and 4 to OFF. Settin g switch #3 to ON does not apply when using the FP220 with other IDC drives or controls. See appropriate user’s manual or call IDC Applications Engineering for information on keypad applicability.

Back of Keypad

DIP Switch

1234

Keypad Connector Pins

FP220 Settings (#3 ON)

Contrast

+5VDCRXGND TXN/C

12345

5-2

Chapter 5 - Configuring Impulse with an IDC Keypad

Functions of the FP100 Keypad Keys

F Keys (F1-F2-F3)

Used as menu or sub-menu item selectors.

RUN

an axis, or accesses Test/ Debug functions.

probe and jog the motor, warm-boot the drive, and enable/disable software

EDIT

shutdown.

ters and programs, lists pro- grams, & resets position

EDIT

counter.

the setup and stored move parameters. Select, edit,

HELP

and load project files.

keys, menus, and command syntax.

HELP

firmware, and hardware ver-

COPY

sions. Shows drive and I/O

to another within a control.

status, and fault history.

DEL

COPY

the editor or deletes entire

to and from a drive.

programs from memory.

Menu Keys

- Runs a program, jogs

- Run stored moves,

- Edits Setup parame-

- Configure and tune

- Provides help on

- Displays keypad,

- Copies one program

- Deletes characters in

- Copies project files

0-9 Keys

Enters numbers directly, and letters when preceded by the ALPHA key.

←↑→ ↓

For scrolling through menu options, setup choices, and files in the ed i tor. Moves motor in JOG mode.

COMMA

May be used in file names.

DEL

- Deletes project files or characters in a text-entry editor.

ESC

Saves an entry and moves back one menu level.

Serves as a minus or hyphen key on the FFP100 keypad. The + symbol is not available on the FP100.

ALPHA

ALPHA plus a numeric key

selects alphabet characters.

selects alphabet charac-

Pressing:

ters, for example:

ALPHA >1 enters “A”

ALPHA +1 selects A,

ALPHA >1>1>1>1 enters “a”

ALPHA +1+1 selects B

ALPHA

DECIMAL POINT

Used to enter fixed-point

numbers when the textentry editor allow it.

numbers.

ENTER

Selects project files and saves edits to project files in the File Options menu.

5-3

Chapter 5 - Configuring Impulse with an IDC Keypad

Keypad Menu Structure

Most operations using the key pad are menu-driven. A menu consists of a t itle bar on the top dis play line and as many as three options (or sub-menus) at a time on the bottom display line. Each option is displayed above one of the function keys, F1, F2, or F3. Press a function key to select the corresponding option.

If a menu has more than three options, arrows will appear on both sides of the display to indicate that more options are available. Press the appropriate arrow key to scroll, one display at a time, through all options in that menu. To exit a menu witho ut mak ing a selection, or to back up one menu level, press ESC.

The following table shows the Menus which are accessible from the Main Display by pressing the RUN, EDIT, HELP, COPY and DEL keys:

FP100 Main Menu and Sub-Menus

Menu Options

MOVE (F1)

Run a stored move

PROBE (F2)

Probe the motor for internal characteristics

JOG (F3)

Jog motor at LOW (F1) or HIGH (F2) speeds

WMBOOT (F1)

Reset the drive without cycling power

SHTDWN (F2)

Enable/disable software shutdown

FILE (F1)

Open, Save, or Rename a Project File

SETUP (F2)

Configure system components and operating limits

MOVE (F3)

Optional Feature Configure and edit stored moves.

UNIT#

Configure Impulse unit number for use in a daisy chain

START (F1)

N/A on FP100

VERSN (F2)

Provides Operating System, Hardware, and Keypad Version numbers

STATUS (F3)

Provides I/O, Drive Status, and Operating History of the Impulse

TO PAD (F1)

Send project file to the drive

FROM PAD (F3)

Retrieve project file from the drive

Delete a project file or a character in the EDIT > FILE submenus

5-4

Apply Power to the Keypad

Power is supplied to th e FP100 keyp ad thro ugh its con nection t o the Impul se COM P ORT. Note: If you are using an FP100-RS485, see Chapter 3, Section C for connection procedure.

Chapter 5 - Configuring Impulse with an IDC Keypad

When power is first applied to the keypad (prior to any menu being selected) you should observe the display shown on the right. The top line of the display sh ows the device your keypad is connected to (Impulse or PC), while the bottom line shows the open project file name and status. Note: If your Impulse is equipped with the optional Motion Node, the top line of the display will read: CONNECT: Impulse MN

File status is indicated by an asterisk (*). If and asterisk appears next to the file name, this indicates that the data in the open file has not been sent to the drive. The asterisk disappears when a COPY > TO PAD or a COPY > FRM PAD is performed. The asterisk reappears when a new project file is opened or when changes have been made to the currently open project file. See Using the EDIT Menus in this chapter for opening, saving, and naming files

General Rules for Using the Keypad

Entering Characters with the ALPHA key

The ALPHA key allows you to enter alphabet characters into a project file from the keypad. The ALPHA key acts as a toggle button between the alphabet characters and the number on a key

• Any letter located above a number on a numeric key may be inserted into a file name, i.e. the A, B, or C on the top part of the #1 key.

CONNECT: Impulse FILE: untitled *

• You must pres s ALPHA prior to each letter you wish to enter. Y ou must press ALPHA again if you want to enter a number immediately following the letter, hence .

• Press a key 1, 2, and 3 times to enter the upper case letters.

• Press a key 4, 5, and 6 times to enter the lower case letters.

•Press the ← or → arrow keys to move the cursor to the next space.

ESC Key

Use the ESC key to save an entry or selection and move back one screen on the display.

ENTER Key

Use the ENTER key to select or save a file in the FILE OPTIONS MENU.

Sending the Factory Default Configuration to the Impulse

In the unlikely event that the Impulse sustains an EEPROM Fault (7 red LED flashes), this fault can be cleared by restoring the factory default configuration. To restore the default configuration:

1. Press the decimal key.

2. Press the right arrow key.

3. Press the DEL key.

5-5

Chapter 5 - Configuring Impulse with an IDC Keypad

RUN

Using the RUN Menus

Press the RUN key to display the MOVE, PROBE, JOG, WMBOOT, and SHTDWN menus.

Run Stored Move (MOVE)

Note: The MOVE feature is available only if you purchased the optional Motion Node version of the Impulse

RUN > MOVE allows you to select and run one of the seven stored moves in the drive. Once a move is selected, the move will run until completion, or the move can be stopped at any time by pressing the ESC key. See Move Menus - Using St ored M oves, later in this chapter, to configure stored moves.

Probe the Motor (PROBE)

RUN > PROBE allows a quick motor probe when a steady red light is present on the LED diagnostic indicator.

−−−−−−↑

MOVE PROBE JOG

−−−−−−↑

WMBOOT SHTDWN

−−−↑

Probing Motor...............

↑ RUN ↓−−−−−

↑ ↑

↑ RUN ↓−−−−−

↑ ↑

↑ RUN MOVE ↓−−

↑ ↑

1 2 3

↓−−−−−

↓−−−−−↓−−−−−

↓−−−−−

↓−−−−−↓−−−−−

↓−−

↓−−↓−−

Jog Motor (JOG)

RUN > JOG allows you to jog a properly configured motor . The distance is displayed in the units selected under EDIT > SETUP > MECH > UNITS, and the default velocity is HIGH.

The jog velocities and jog acceleration are defined u nder EDIT > SETUP > COMAND > JOG. The motor is jogged by pressing and holdin g the direction-respective arrow key. The motor is stop ped by releasing the arrow key.

Warm Boot System (WMBOOT)

RUN > WMBOOT will reset the drive without recycling power.

Disable Amplifier (SHTDWN)

RUN > SHUTDWN allows you to override the hardware SHUTDOWN input for disabling the dri ve only . If the hardware input has asserted an amplifier shutdown, this feature will not override the input to enable the drive.

JOG: 0.0 Revs LOW <HIGH>

Warm Booting.............

−− Software Shutdwn −− ↑

↑ ENABLED ↓↓↓↓

↑ ↑

−−

−−−−

5-6

Chapter 5 - Configuring Impulse with an IDC Keypad

EDIT

Using the EDIT Menus

Press the EDIT key to display the FILE, SETUP, MOVE, and UNIT# menus.

File Menu (FILE OPTIONS)

The FILE menu allows you to select, save, and name or rename your project files.

EDIT

Opening a Project File

This option allows you to select one of eight (8) stored project files. All eight project files are initialized to the default configuration and are named “untitled”. The project files are selected by scrolling the names up or down using the arrow keys.

> FILE

−−−−−−↑

↑ EDIT ↓−−−−−

↑ ↑

↓−−−−−

↓−−−−−↓−−−−−

FILE SETUP MOVE

−−−−−−↑

↑ EDIT ↓−−−−−

↑ ↑

↓−−−−−

↓−−−−−↓−−−−−

UNIT#

−−−

−−− FILE OPTIONS −−−

−−− −−−

−−−

−−−−−−

OPEN SAVE RENAME

−−−↑

−−−↑ Select File ↓−−−

EDIT

> FILE > OPEN

−−−↑ −−−↑

1: untitled

Saving a Project File

This option allows you to save a project f ile. If a cus tom pro j ect file has n ot b een s elected si nce the keypad was powered-up, you will be prompted to select a project file location (file #) to overwrite. A project file location is selected by scrolling the filenames using the up or down arrow keys and pressing the ENTER key. Once a project file is selected, you will be prompted to enter a new name for the file.

−−−↑

−−−↑ Select File ↓−−−

EDIT

> FILE > SAVE

Project file names may consist of a combination o f numeric digits and alphabet letters and are limited to 10 characters. Alphabet characters are accessed by pressing the ALPHA key and repeatedly pressing the numeric key until the desired letter is displayed on the screen. Use the right and left arrow keys to move the cursor.

If a custom project file is currently open, you will be prompted to overwrite the currently open project file. If YES is selected, the open project file will be overwritten with the data currently in the keypad. If NO is selected, you will be prompted again to select a project file location to overwrite and rename if desired.

−−−↑ −−−↑

1: untitled

↓−−−

↓−−−↓−−−

↓−−−

↓−−−↓−−−

5-7

Chapter 5 - Configuring Impulse with an IDC Keypad

Renaming an Open Project File

This option allows you to rename (or name) the currently-open project file. Project file names are entered using a combination of the ALPHA and numeri c keys. Project file name s consist of numeri c digits and alphabet letters and are limited to 10 characters. Alphabet characters are accessed by pressing the ALPHA key and repeatedly pressing the numeric key until the desired letter is displayed on the screen. Use the right and left arrow keys to move the cursor.

If RENAME is selected and a project file is not open, an error message will be displayed.

EDIT

> FILE > RENAME

Using the SETUP Sub-Menus for Configuring Your System

The following table shows the structure within the EDIT > SETUP sub-menu. For more detailed descriptions of setup parameters, see Chapter 5 - Configuring Impulse with the FP100 or FP220 Keypad.

Sub-Menu Setup Parameter Description of Setup Parameter

COMMAND

MOTOR

MECHANICS

TUNING ADVANCED

I/O

Direction Positive or negative motor direction Shutdown Active Low or Active High polarity Drive Resolution Operating step resolution Stop Rate Deceleration rate Jog Acceleration/Deceleration, and High/Low Jog speeds Probe the Motor Probes for motor characteristics and sends 1 kHz tone Motor Type IDC motor type Motor Current Operating current User Units Choose inches or millimeters, or toggle between revolutions

and steps Units Gear Ratio Units scaling ratio for distance, velocity, and acceleration X-SM1, X-S M2, X-SM3 Empirical fine tuning of the X-Smoothness Anti-Resonance Anti-resonance gain settings Profiling Enabling Multi-Stepping and Dynamic Smoothing Stop Reduction Timeout Set the stop mode current reduction timeout period Idle Mode Reduction Set the idle mode current reduction timeout period Stall Detection Enables Open Loop Stall Detect Input Configure 4 inputs Output Configure 1 output Polarity Select Active High or Active Low polarity

Requires Open File

5-8

Chapter 5 - Configuring Impulse with an IDC Keypad

HELP

Using the HELP Menu

Versions

•Press the HELP > VERSN (F2) for access to Operating

System, Hardware, and Keypad versions (see examples on the right).

• Press F1, F2, or F3 for respective version displays.

•Press the ESC key to exit the HELP menu.

−−−−−−

−−−−−− HELP −−−−−−

−−−−−− −−−−−−

ST ART

VERSN STATUS

−−−−−−

−−−−−−−−−−−−

VERSIONS

OPSYS HDRWAR KPAD

OpSystem Version

vXXX

Hardware Version

AMP: E0 I/O F0

Keypad Version

vXXX

Status

•Press HELP > STATUS for I/O configurations, current

drive status, and the operating history of the drive.

•Press I/O to check t he con figu rat ion of four discrete inputs

and one output.

•Press DRIVE for current drive status. The example shows

no fault condition.

•Press HISTRY for the following operating histories: num-

ber of hours in oper at ion, number of power cycles, and last eight drive faults.

•Press HR_OP for the total number of hours the Impulse

has been in operation.

•Press PWR_CY for the number of times power has been

cycled.

•Press FAULT to look scroll through the last eight (8) drive faults. Stored Fault #1 is the most recent fault.

STATUS

I/O DRIVE HISTRY

In1 In2 In3 In4 Out1

OFF OFF OFF OFF OFF

System is Enabled FAULT: ✻✻✻✻

OPERATING HISTRY

HR _OP PWR_CY FAULT

Hours Operation

XXX.XX

Num Power Cycles

XXX

↑↑↑↑ Stored Fault #1 ↓↓↓↓

Overcurrent

(example)

5-9

Chapter 5 - Configuring Impulse with an IDC Keypad

COPY

FROM PAD

TO PAD

Using the COPY Menu

Downloading project files between keypads and Impulse or between keypad and PC can save a significant amount of time when configuring your drive with an FP100 keypad.

Press COPY for the following two options:

TO PAD FRM PAD

This option allows you to send the currently open project file to the drive. Answering YES to the send prompt will send the open project file and overwrite the current setup in the drive.

Allows you to retrieve the current setup from the drive. Answering YES to the retrieve prompt will extract the project file from the drive and make it the “open” file in the keypad. The extracted file is not saved to non-vola tile memory and must be saved u nder EDIT > FILE > SAVE if the data is to be stored.

Application Note: Keypads do not provide the same decimal-level precision as IDC’s Application Developer software. A project file created at higher precision will cause a “precision error message” when loaded into a keypad.

Send Current Setup?

YES NO

Retreve Drive Setup?

YES NO

COPY

DEL

Using the DEL (Delete) menu

To Delete a Project File

1. Press DEL.

2. Using the up a nd down arrow k eys, select the pro ject file to be deleted by scrolling through the list of eight (8) existing files.

3. Press ENTER to select the file to be deleted. Confirm deletion by pressing YES or NO.

- - ↑↑↑↑ Select File ↓↓↓↓ - -

1: untitled

Delete File? YES NO

To Delete a Single Entry in the EDIT > FILE > RENAME File Editor:

1. Move the cursor over the entry you wish to delete (move with ← or →).

2. Press DEL.

5-10

Chapter 5 - Configuring Impulse with an IDC Keypad

Section 2 - Configuring Impulse with an IDC Keypad

This chapter contains information and steps for developing an Impulse project file with the FP100 keypad. Configuring all parameters in the EDIT menu will ensure that your project file is setup correctly.

The task of configuring your Impuls e for a specific applicatio n consists of custo mizing a number of software parameters to match the mechanics of the system. These parameters include motor setup, I/O, jog, stored move profiles, and advanced tuning.

The configuration procedures in this section will follow the format of the example below:

Parameter Being Configured (example: Motor Type)

pad

1. Press EDIT, then SETUP, then MOTOR, then TYPE

EDIT

> SETUP > MOTOR > TYPE

3. Default configuration, if any, will be shown on the bottom line of the display

2. You will see this display on the keypad

−−−↑

−−−↑ Motor Type ↓−−−

−−−↑−−−↑

None

1. Using ↑ ↓ arrow keys, scroll the list of motors and stop when the you r motor appears.

2. Press ESC.

4. Follow these steps to configure this parameter

↓−−−

↓−−−↓−−−

5-11

Chapter 5 - Configuring Impulse with an IDC Keypad

Configuring Impulse with the Keypad

Open a File

Using the EDIT > FILE menu, open a project file.

Using the EDIT > SETUP Menus to Configure the Impulse

The EDIT > SETUP menus allow you to configure your motor, mechanical units, I/O, operating characteristics, and perform advanced tuning of your system for optimum performance.

MOTOR SETUP

Configuring Motor Type

This menu allows you to select a preconfigured IDC motor type. In addition to IDC motor types, the keypad can store one custom motor type. The keypad does not contain a motor editor, so custom motor types must be created using the Application Developer *motor editor, then loaded into the keypad via a project file.

*See Application Developer > Axis Setup > Motor Tab > Edit Motor

EDIT

1. Using ↑↓ arrow keys, scroll the list of motors until the desired motor appears on the bottom line.

2. Press ESC to save your motor selection.

> SETUP > MOTOR

−−−−−↑

−−−−−↑ SETUP ↓−−−−−

−−−−−↑−−−−−↑

COMAND MOTOR MECH

−−−−−↑

−−−−−↑ SETUP ↓−−−−−

−−−−−↑−−−−−↑

TUNING ADVNCE I/O

−−−↑

−−−↑ Motor Type ↓ −−−

−−−↑ −−−↑

−−−

−−− None −−−

−−− −−−

↓−−−−−

↓−−−−−↓−−−−−

↓−−−−−

↓−−−−−↓−−−−−

↓ −−−

↓ −−−↓ −−−

−−−

−−−−−−

5-12

Probing the Motor

A new drive setup must be instructed to probe itself after you have selected motor type on the keypad (procedure on next page). The in ternal setup p arameters obtained d uring the m otor probe are s tored in nonvolatile memory so that the process need not be repeated every time the power is cycled.

Each time a different type of motor is connected to the drive, the motor must be probed. The drive should always be reconfigured for a new motor to avoid degrading the anti resonance feature and OLSD™. When the drive is probing the attached motor , a short 1 kHz tone wi ll be heard emanating from the motor. Depending on motor type, this tone may persist for an ywhere from several seconds to half a minute.

The motor probe may be initiated (1) immediately after configuring motor type, or (2) after all parameters in the EDIT menus have been configured. In either case, the following procedure applies:

Chapter 5 - Configuring Impulse with an IDC Keypad

To Probe the Motor:

1. Return to the initial keypad display (no menu selected).

2. Press RUN > PROBE (F2). At the end of the 1 kHz tone, the

motor has been probed.

3. Press ESC.

4. Continue configuring the EDIT Menu parameters if they have not been completely configured, or go to step 5.

5. Press COPY > FRM PAD (F3) to send the project file to the drive. Your project file now contains parameters vital to the advanced performance features of the Impulse.

COMMAND SETUP

The following five parameters are configured in the COMMAND sub-menu:

DIR Motor Direction (POSITIVE=CW or NEGATIVE=CCW) SHDWN Shutdown Polarity (ACTIVE LOW or ACTIVE HIGH) D-RES Drive Resolution (steps/rev)

STPRTE Stop Rate (user-units JOG Jog Parameters (ACCEL, LOW VELOCITY, or HIGH VELOCITY)

EDIT

> SETUP > COMAND

Probing Motor.............

)

−↑

−↑ COMMAND SETUP ↓−

−↑−↑

↓−

↓−↓−

DIR SHDWN D-RES

−↑

−↑ COMMAND SETUP ↓−

−↑−↑

STPRTE JOG

Configuring Motor Direction

EDIT

> SETUP > COMAND > DIR

1. Press the ↑ ↓ arrow keys to select the POSITIVE (CW) or NEGATIVE (CCW) motor direction.

2. Press ESC.

- Motor Direction -

↑

↑ POSITIVE ↓↓↓↓

↑ ↑

Configuring Shutdown Polarity

EDIT

> SETUP > COMAND > SHDWN

1. Press the up or down arrow key to select ACTIVE LOW (default) or ACTIVE HIGH.

2. Press ESC.

- Shutdwn Polarity -

↑

↑ ACTIVE LOW ↓↓↓↓

↑ ↑

↓−

↓−↓−

5-13

Chapter 5 - Configuring Impulse with an IDC Keypad

Configuring Drive Resolution

EDIT

> SETUP > COMAND > D-RES

- Drive Resolution 25000

1. Using the numeric keys , enter the operating step resolution. The valid ran ge for drive resolution is 200 to 100,000 in increments of 200 (divisible integer of 4X the tooth count of the motor).

2. Press ESC.

Configuring Stop Rate

This option allows you to define the deceleration rate to be used when a STOP or EOT input is

activated or the ESC key is pressed. The units are user-defined in units

and the valid range is 0.1 to

1000.00.

EDIT

> SETUP > COMAND > STPRTE

----- Stop Rate ----

100.0 RPS

1. Using the numeric and decimal keys, enter the desired stop rate. Note: this value will be in units selected in EDIT > SETUP > MECH > UNITS > User Units

2. Press ESC.

Configuring Jog Parameters

This option allows you to modify the jog parameters which are used by the Jog inputs (JOG+, JOG, JOG SPEED), and in the RUN > JOG menu of the keypad. The parameters to be configured are:

ACCEL = Jog Accel/Decel (default = 20 User-Units

)

LOW_V = Jog Low Speed (default = 0.50 User-Units) HIGH_V = Jog High Speed (default = 2.00 User-Units)

EDIT

> SETUP > COMAND > JOG

JOG PARAMETERS

ACCEL LOW_V HIGH _V

To enter a value for ACCEL (F1), LOW_V (F2), or HIGH_V (F3):

1. Press the F-key of the jog parameter being modified.

2. Using the numeric and decimal keys, enter the desired value. Note: this value will be in units selected in EDIT > SETUP > MECH > UNITS > User Units.

3. Press ESC.

5-14

MECHANICAL SETUP

The MECH SETUP menu allows you to configure (enter) the mechanical units and gear ratio for your application. Once configured, your keypad will use these units in all display and position reporting modes.

Chapter 5 - Configuring Impulse with an IDC Keypad

EDIT

> SETUP > MECH

MECH SETUP

UNITS RATIO

Configuring Mechanical Units (User Units)

This option allows you to select the units of distance, velocity, and acceleration used in the system. The units act only as a label and actual unit scaling is achieved by properly setting the gear ratio in EDIT > SETUP > MECH > RA T IO. The unit of STEPS can be selected by toggling between REVS and STEPS (F3).

EDIT

> SETUP > MECH > UNITS

[INCH] MM REVS

User Units

1. Press F1 for inches; press F2 for millimeters; or toggle F3 for revolutions per second or steps.

2. Press ESC.

Configuring Units Gear Ratio

This optio n allows you to enter the desired units-scaling-ratio for di stance, velocity, and acceleration. The ratio is motor revolution per user unit. Note: If user units REVS or STEPS has been selected, the Units Gear Ratio will be a “Fixed Ratio.” Inches or millimeters must be selected to allow entry of a gear ratio (see “Configuring Mechanical Units above).

EDIT

> SETUP > MECH > RATIO

To change the Numerator (motor revs):

1. Press any numeric key and th e Numerator value en try screen

Units Gear Ratio

1 to 1

- - - - Numerator - - - -

1 _

will appear. In the example to the right, #1 was pressed.

2. Enter the numerator value. Any number can be entered by moving the cursor to the left.

3. Press ESC.

To change the Denominator (user unit):

1. Press the right arrow key (→) and the Denominator value

- - - - Denominator - - - -

entry screen will appear.

2. Using the numeric keys, enter the numerator value.

3. Press ESC.

5-15

Chapter 5 - Configuring Impulse with an IDC Keypad

MOTOR TUNING SETUP (X-Smoothness)

Fine-tuning of the motor is recommended for all applications and should be accomplished before the motor load is connected. Fine-tuning produces extremely smooth perfor mance at 2 rps and below and is accomplished by configuring the three X-Smoothness components (X-SM1, X-SM2, and XSM3).

EDIT

Adjusting X-SM1

EDIT

> SETUP > TUNING

(X-SM2 and X-SM3 are adjusted using the same procedures)

> SETUP > TUNING > X-SM12

VALUE

1. Press VALUE (F1) to enter the X-Sm1 value directly.

2. Using the numeric keys, enter a value for L1.

3. Press the down arrow key (↓) to access the L2 Value screen.

4. Enter a value for L2.

5. Press ESC.

TEST SPEED (TEST_SP) This option allows you to modify the default test speed for component X-SM1. The speed is fixed in units of RPS. This component must be defined before movi ng to the next component, FINE adjustments.

TUNING SETUP

X-SM1 X-SM2 X-SM3

X-SM1 ADJUST

VALUE TEST_SP FINE

- ↑

↑ X-Sm1 L1 Value ↓

↑ ↑

↓ -

↓ ↓

- ↑

↑ X-Sm1 L2 Value ↓

↑ ↑

↓ -

↓ ↓

- X-Sm1 Test Speed -

0.0 RPS

5-16

1. Press TEST_SP (F2).

2. Using numeric and decimal keys, enter the test speed.

3. Press ESC.

FINE (Fine Adjustments) This option allows fine adjustment of values L1 and L2 of XSM1. When this menu is entered, the motor will run at the test

↑

↑ [L1] ←←←←--∗∗∗∗--→

↑ ↑ ↓

↓ L2 ←←←←--∗∗∗∗--→

↓ ↓

→ 0

→ →

→ 0

→ →

speed configured in the TEST SPEED option of X-SM1 (see above). Values L1 and L2 are selected by using the up and down arrows. The value is incremented (increased) by using the right arrow key (→) and decremented (decreased) by using the left arrow (←). Hold the arrow key down to incr ease/decrease the rate. The value is displayed on th e right side of the display (display example shows 0). Stop the motor at any time by pressing ESC. If an adjustment has been made t o values L1 or L2, you will be pr omp ted whethe r or no t to ke ep the new setting. Select YES to save the settings; select NO to restore the original settings.

1. Press FINE (F3).

2. Using the up and down arrow keys, select L1 or L2.

3. Using the left and right arrow keys, increase or decrease the Fine Adjustment value.

Chapter 5 - Configuring Impulse with an IDC Keypad

4. Press ESC.

5. Press YES (F 1) to s ave the n ew setti ngs, o r press NO (F3) t o restore the original settings.

Configure X-SM2 and X-SM3 using the same procedures as X-SM1 (i.e. VALUE, TEST SPEED, and FINE).

ADVANCED SETUP

The following parameters mus t be configured in the ADVANCED SETUP sub-menu:

ANTI-RESONANCE (A-RES)

GAIN 1 GAIN 2

Profiling (PRFILE)

MULTI (Mul tis tep pin g) DYNSM (Dy namic Smoothing) DSGAIN (Dynamic Smoothing Gain)

EDIT

> SETUP > ADVNCE >

Keep New Settings? YES NO

STOP RED TIMEOUT (I-STOP) IDLE MODE REDUCTION (I-IDLE)

TIMEOUT %RED

STALL DETECTION (STALL)

DISABLED ENABLED

-↑↑↑↑ ADVANCED SETUP ↓↓↓↓-

A-RES DYN-SM I-STOP

-↑↑↑↑ ADVANCED SETUP ↓↓↓↓-

I-IDLE STALL

Configuring Anti-Resonance Gain

EDIT

> SETUP > ADVNCE > A-RES

GAIN 1

This option allows you to configure the anti-resonance gain (#1) between 0 and 32,767. Setting gain at 0 disables the anti-resonance feature, regardless of the GAIN2 setting.

1. Press GAIN1 (F1).

2. Using numeric keys, enter a gain of between 0 and 32,767.

3. Press ESC.

GAIN2 (required only if GAIN1 was configured)

This optio n allows you to configure the anti-resonance gain (#2) bet ween 0.1and 25.0.

1. Press GAIN2 (F2).

2. Using numeric keys, enter a gain of between 0.1 and 25.0.

- - ANTI-RESONANCE - -

GAIN1 GAIN2

- Anti-Res Gain #1 -

- Anti-Res Gain #2 -

3. Press ESC.

5-17

Chapter 5 - Configuring Impulse with an IDC Keypad

Configuring Profiling Parameters

EDIT

> SETUP > ADVNCE > DYN-SM

- PROFILING -

MULTI DYNSM DSGAIN

MULTI (Multi-Stepping™)

This option allows you to enable or disable Multi-Stepping™ feature.

1. Press MULTI (F1).

2. Using arrow keys, select ENABLED or DISABLED.

−−−

−−− Multi-Stepping −−−

−−− −−− ↑

↑ DISABLED ↓↓↓↓

↑ ↑

−−−

−−− −−−

3. Press ESC.

DYNSM (Dynamic Smoothing™)

This option allows you to enable of disable the Dynamic Smoothing™ feature.

1. Press DYNSM (F2).

2. Using arrow keys, select ENABLED or DISABLED.

Dynamic Smoothing

↑

↑ DISABLED ↓↓↓↓

↑ ↑

3. Press ESC.

DSGAIN

This option allows you to enter a dynamic smoothing gain of between 20 and 2621. Setting gain to 2621 effectively disables the Dynamic Smoothing™ featur e. If Multi-Stepping™ been selected, the Dynamic Smoothing Gain will be fixed.

1. Press GAIN (F1).

2. Using numeric keys, enter a gain (0 to 2621).

−−−

−−− Dyn Sm Gain −−−

−−− −−−

−−−

−−− −−−

2621

3. Press ESC.

Configuring Stop Mode Current-Reduction Timeout (I-STOP)

This option allows you to set the Stop Mode current-reduction timeout in milliseconds. When the timeout period has elapsed, the command motor current will be reduced by up to 25%. Full current is restored on the next commanded step. Th e vali d rang e for the ti meou t is from 0 ms to 19 656 ms. Setting the timeout to 0 disables the Stop Mode feature and the display will read “Off”.

EDIT

> SETUP > ADVNCE > I-STOP

1. Using the numeric keys, enter the desired current-reduction timeout period.

2. Press ESC.

- Stop Red Timeout Off

5-18

Chapter 5 - Configuring Impulse with an IDC Keypad

Configuring Idle Mode Current Reduction Parameters

Use this option to set the Idle Mode current-reduction parameters (TIMEOUT and %RED).

TIMEOUT sets the Idle Mod e current reduction p eriod in seco nds. When the TIMEOUT pe riod has elapsed, the commanded motor current will be reduced by the p ercentage defined in EDIT > SETUP > ADVNCE > I-IDLE > %RED. Full current is restored on the next commanded step. The valid range for the timeout is 0 to 3600 seconds. Setting the timeout to 0 disables the Idle Mode feature and the display will read “Off”.

%RED (percentage of reduction) sets the percentage of current reduction that occurs after the Idle Mode TIMEOUT has expired. The valid range for percentage of reduction is 0 to100%. The Idle Mode reduction percentage takes preceden ce over the Stop Mode 2 5% reduction if both modes have been enabled.

EDIT

> SETUP > ADVNCE > I-IDLE

- IDLE MODE REDUCT - TMEOUT %RED

TIMEOUT

- Idle Mode Tmeout -

1. Press TMEOUT (F1).

Off

2. Using the numeric and decimal keys, enter the desired current-reduction period (seconds).

3. Press ESC.

%REDUCTION (required only if TIMEOUT was configured)

1. Press %RED (F2).

- Idle Mode %Redct -

2. Using the numeric keys, enter the desired percentage of

reduction (no decimal).

3. Press ESC.

Configuring Encoderless Stall-Detection (OLSD™)

This option allows you to enable or disable the OLSD™ feature. OLSD™ becomes active at velocities of 0.5 RPS and greater.

EDIT

> SETUP > ADVNCE > STALL

- Stall Detection -

↑

↑ DISABLED ↓↓↓↓

↑ ↑

1. Using the up and down arrows, toggle to DISABLED or ENABLED OLSD™ .

2. Press ESC twice to return to the EDIT > SETUP menu.

5-19

Chapter 5 - Configuring Impulse with an IDC Keypad

I/O SETUP

This optio n allows you to configure up to (4) digital inputs and one (1) d igital output.

EDIT

> SETUP > I/O

- - - - I/O SETUP - - - -

INPUT OUTPUT POLAR

Configuring Inputs

The input number (#1 - #4) is selected by using the right or left arrow key. The input function is selected by scrolling the list using the up or down arrow key. The INPUT menu consists of the inputs described in the table below.

Configurable Inputs Input Description

UNDEFINED The input position currently has no function

JOG + Jogs the motor in the positive direction

JOG - Jogs the motor in the negative direction

JOG SPEED Toggles between High and Low jog velocity

STOP Stops motion at the Stop Rate (internal move

KILL Instantly stops motion (internal move engine or

EOT End-of-Travel (also used for Homing moves)

[RESERVED] Reserved for future use - acts as UNDEFINED

MOVE SELECT Acts as a bit in a binary move selection number

WARM BOOT Resets the drive

1. Press INPUT (F1).

2. Using the right or l eft arrow key , sel ect the Input # (position) to be configured.

engine or external steps)

external steps)

- - - ←↑ Input #1 ↓→ - - -

UNDEFINED

5-20

3. Using the up or down arrow key, select the desired input function.

4. Press ESC

Chapter 5 - Configuring Impulse with an IDC Keypad

Configuring Outputs

The output function is selected by using the up or dow n arrow key. The OUTPUT menu consists of the outputs described in the table below.

Configurable Inputs Input Description

UNDEFINED The output position has no function

BRAKE Activated on a fault

MOVING Activated when receiving steps or the internal move

engine is active

[RESERVED] Reserved for future use - acts as UNDEFINED

STALLED Activated when the OLSD™ detects a stall

1. Press OUTPUT (F2).

- - - - ↑ Output #1 ↓ - - - -

2. Using the up or down arrow key, select the desired output

UNDEFINED

function.

3. Press ESC

Configuring Input/Output Polariti es

This option allows you to define the active polarity of the inputs and output. The polarity refers to the electrical sense of the node (i.e. an ACTIVE LOW input must be grounded to be asserted).

The inputs and output are selected by using the left and right arrow keys. The polarity is selected by toggling between ACTIVE LOW and ACTIVE HIGH using the up and down arrow keys.

1. Press POLARITY (F3).

2. Using the right or left arrow key, select the desired input or output.

3. Using the up or down arrow key, toggle to the desired polarity.

4. Press ESC.

- - - ←↑ Input #1 ↓→ - - -

ACTIVE LOW

5-21

Chapter 5 - Configuring Impulse with an IDC Keypad

Move Menus - Using Stored Moves

This feature is only available of your Impulse is equipped with the optional Motion Node.

The MOVE menu allows you to edit the Stored-Move parameters (also see Edit > Stored Move menu in Application Developer).

EDIT

> MOVE

- - - STORED MOVES - - PROFLE SCAN

Stored-Move Profiles

The PROFLE (profile) menu allows you to configure the seven (7) possible stored -move profiles executed by the internal move engine. The move number is selected by using the up or down arrow keys, and the move profile parameters are selected by using the left or right arrow keys. Units of acceleration, deceleration, velocity , and distance are defined in EDIT > SETUP > MECH > UNITS, and scaled by EDIT > SETUP > MECH > RATIO.

There are three (3) types of stored-move profiles:

INC - Incremental ABS - Absolute HOME - Home Routine

Incremental moves are indexed the commanded distance from the current position.

Absolute moves are indexed to the commanded position.

Home moves provide a built-in routine to automatically find an exact position to reference all moves

from (i.e. to find the zero position after a system power cycle.) Home moves require the use of at least one EOT limit switch and one input configur ed as an EOT . Home moves do not requ ire the use of a home swi tch.

5-22

Home moves are executed as follows:

1. The drive begins moving in the direction specified by the sign of the velocity. Note: Negative

velocities are only valid with Home moves. The move distance is always forced to be the sign opposite of the velocity sign.

2. The drive moves at the commanded velocity until an EOT switch is encountered and decels at the rate defined in EDIT > SETUP > COMAND > STPRTE.

3. The drive then switches direction and moves at 1/16 the commanded velocity to find the leading edge of the EOT switch.

4. The drive then per forms a final incremental move from the edge of the EOT s witch equal to the defined move distance.

Chapter 5 - Configuring Impulse with an IDC Keypad

Configuring Stored-Move Profiles

There are five (5) stored move parameters to be configured: Acceleration, Deceleration, Velocity, Distance, and Move Type.

1. Press PROFLE (F1).

←↑ Move #1 Accel ↓→

2. Using the up or down arrow key, select the Move # (1 - 7) to configured.

3. Using the right or left arrow key, select the move parameter to be configured.

Note: Step 4 applies to Accel, Decel, Velcty, and PosDis. Step 5 applies to MvType.

4. Using the numeric a nd decimal keys, enter the desired v alue of the parameter.

5. Using F1, F2, or F3, select the Move Type.

6. Press ESC.

0.0 RPS

←↑ Move #1 Decel ↓→

0.0 RPS

←↑ Move #1 Velcty ↓→

0.0 RPS

←↑ Move #1 PosDis ↓→

0.0 RPS

←↑ Move #1 MvType ↓→ [INC] ABS HOME

Move Selection Input Scan Time

This option allows you to set the move selection input scan time in milliseconds. The scan time serves as a timeout for which the move selection inputs must be held in a stable state. If any move selection input changes state within the scan time, the timeout is reset (debounce). When the scan time has expired, the move corresponding to the binary number on the move selection inputs will be executed. The valid range of the scan time is 0 ms to 19660 ms.

Configuring Scan Time

1. Press SCAN (F2).

2. Using the numeric keys, enter the desired scan time in milliseconds.

3. Press ESC twice to return to the EDIT menu.

Move Sel Scan Time

0 ms

5-23

Chapter 5 - Configuring Impulse with an IDC Keypad

UNIT#

This menu allows you to configur e the unit num ber for use in RS232 C daisy chains or RS48 5 buses. The valid range for unit numbers is 1 - 99.

EDIT

> UNIT#

1. Using the numeric keys, enter the desired unit number for the drive.

Very Important! - Send the File to the Drive

When all setup parameters have been configured and the motor has been probed, use the COPY menu (COPY > FRM PAD) to send the project file to the drive.

- - - Unit Number - - 1

5-24

Chapter 6 - Hardware Reference

Impulse Specifications

Electrical Characteristics

Power Requirements 120 VAC ±10% single phase, 50/60 Hz, 500 VA max @ 4 A Current Output Range 0.75 - 4.0 Amps Motor Inductance Range 2 - 80 mH Motor Resolution 25,600 Steps/Rev internal.

Pre-scaled for the range 200 - 100,000

Motor Frame Size - NEMA 17 - 34

Step & Direction Inputs

Input Voltage *5 VDC (see note at bottom) Input Current 5 - 15 mA Setup Time (Direction) 250 ns Max. Frequency (Step) 2 MHz

Shutdown Inputs

Single-Ended Mode Input Voltage (VDC) HIGH: 3 V min. to 5 V max. LOW: 0 V min. to 1.5 V max. Differential Mode (VDC between + and -) HIGH: 2 V min. to 5 V max. LOW: -5 V min. to -2 V max. Input Current (any terminal @ 0 V to Gnd) -1 mA to 15 mA

Digital Inputs

Input Voltage HIGH: 3 V min. to 24 V max. LOW: 0 V min. to 1.5 V max. Input Current @ 0 V -2.5 mA (inputs 1 & 2); -3.8 mA (inputs 3 & 4)

Digital Output

Current Sink (ON state, Max.) 100 mA Output Voltage (ON state @ 100 mA Max.) 0.4 V Output Voltage (OFF state, Max.) 24 V

Environmental

Operating Ambient Temperature 0 to 50° C Storage Temperature -40 to 80° C Relative Humidity (Maximum) 95% non-condensing Altitude above Sea Level 10,000 ft. [3,048 m]

Thermal Characteristics

Cooling Internal Heat Dissipation @ 4 A (typical) 32 W

Physical Characteristics

Dimensions (inches [mm]) H = 5.60 [142]; W = 1.78 [45]; D = 6.37 [162] Weight 1.75 lbs [.794 kg] *External current-limiting resistor required for 12V and 24V power supply connections. Use 560 Ohm, 1/4 W resistor for 12

V connection. Use 1.3 KΩ resistor for 24 V connection.

6-1

Chapter 6 - Hardware Reference

Remote Mounting Your Keypad

The keypad can easily be mounted and sealed to NEMA 4 specifications by using the included mounting gasket and 6-foot communication cable. Warning: Do not attach the gasket to the keypad. Attach the gasket with the adhesive side toward the mounting enclosure. A pressure-seal is formed between the gasket and the keypad, while the adhesive maintains the seal between the enclosure and the gasket.

A Keypad Mounting Temp late is included with every keypad, and a not to scale mo unting dimensions drawing can be found on the next page for reference. Please pay particular attention to the CAUTION on the template.

1) When mounting the keypad on wall-type surfaces (as shown in the illustration below) be absolutely certain that you have accurately estimated the proper length of mounting screws. Your keypad may be damaged if a mounting screw is allowed to extend more than 0.20 inches into the keypad.

2) When mounting the keypad to a metal surface, it is highly advisable that the keypad be insulated from the metal surface by using non-conductive fasteners (screws, washers, etc.).

Warning

End View of Wall-Mounted Keypad with Cover Removed

Mounting Screw

mounting surface

The circuit board may be damaged if any mounting screw is allowed to extend more than 0.20’’ into the keypad.

keypad gasket

Circuit Board

Extending the Cable Length to Your Keypad

The keypad cable may be extended if necessary, but at longer distances your keypad may require a separate, regulated 5 VDC (500mA) power supply as shown in the illustration below. Consult IDC Applications Engineering if you have questions about this procedure.

GND

+5V

+5V Regulated Power Supply

N/C GND

RX TX +5V

KEYPAD

COM PORT

+5V RX TX COM SHLD

Keypad

6-2

Keypad Mounting *Template

*CAUTION - this is scaled-down version of the keypad template. Use this drawing only for dimensions and locations of mounting holes. The actual template is included with your keypad and may also be found at: http://www.idcmotion.com/support/index.html

KEYPAD MOUNTING TEMPLATE

Chapter 6 - Hardware Reference

CAUTION:

Your Keypad will be damaged if mounting

screws extend more than 0.2 inches into the keypad.

3/16" CLEARANCE HOLES (4)

5/32" CLEARANCE HOLES (3)

CUT THE SE H O L ES FOR 6/32 CAPTIVE MOUNTING.

CUT THE SE H O L ES FOR M3.5 CAPTIVE MOUNTING.

CUT THE SE H O L ES FOR

BALL-HEAD REMOVABLE MOUNTING.

6-3

Chapter 6 - Hardware Reference

Impulse I/O Schematics

Digital Inputs

+5V

IN1_BUF

4.99K IN1/IN2

Digital Output

AM26LS32

COM

TO COMMON

Impulse internal

+5V

CMPD914

4.02k

COM

Impulse internal

+5V

COM

external

IN3/IN4

LIMIT SWITCH

COM

external

Inputs 1, 2

Inputs 3, 4

6-4

MMBT2222ALT1

OUT

2.43K

Impulse internal

+ANA

10K

COM

PULL-UP +5V, +12V, or 24V

RELAY COIL

OUT

COM

TO PULLUP COMMON

external

SOURCING INPUT

Chapter 6 - Hardware Reference

Step, Direction, and Shutdown Inputs

Application Notes:

1.When w iring TTL signal s to other manuf acturer’s ind exers, the Step TT L command sign als from the controller shoul d be wired to Step +, the Direction signal to Dir +, and the Shutdown sig nal to SD + (Step -, Dir -, and SD - should not be connected). Remember to connect commons.

2.Activating the Shutdown input (logic low) disables the drive amplifier and de-energizes the motor. When this input is off (logic high) the drive is enabled and the motor is energized.

Fault Output

COM

237

2.2n 50V

COM

COM 237

2.2n 50V COM

4.99K

4.99K 4.99K

AM26LS32

4.99K

Impulse internal

COM

4.99K

+5V

STEPDIRSD-

STEP+, DIR+, SD+

SINKING

external

DIFFERENTIAL DRIVER

external

OUTPUT

COM

STEPDIRSD-

STEP+ DIR+ SD+

Single-Ended

Installation

Differential

Installation

+5V

FAULT

237

4N35

Impulse internal

FAULT+

FAULT-

external

EQUIVALENT

CIRCUITS

FAULT+

FAULT-

Drive Faulte d

No Fault Present

6-5

Chapter 6 - Hardware Reference

Using IDC Position Sensors as EOT Limit Switches with the Impulse

Four IDC position sensors may be used as EOT limit switches with the Impulse. Co nnection information for all four sensors is provided below.

+5V

COM

Impulse internal

+5V

INPUT

COM

INPUT

external

N.C. Reed Switch

PSR-2 Only

PSR-2

•The PSR-2 pos ition sensor is a nor-

mally closed Reed Switch and must be connected to two (2) separate inputs, as shown here. This leaves two (2) inputs for move selects, which allows for the selection of three (3) stored moves.

•The PSR-2 position sensor contains a

series diode and cannot be used in series, as is the RPS-2 sensor shown

below

• Note: If you need to configure more

than 3 stored moves, the position sensors below only require one input for connection.

RPS-2

•The RPS-2 position sensor is a nor-

mally closed Reed Switch and must be connected in series as shown here.

COM

Impulse internal

+5V

COM

Impulse internal

COM

INPUT

COM

RPS-2 Only

external

N.O. Reed Switch

RPS-1

PSR-1

RPS-1

PSR-1

•The RPS-1 or PSR-1 position sensors

are normally open Reed Switches and must be connected in parallel as shown here.

6-6

Optional Accessories for Your Impulse

Impulse I/O Accessories

Accessory (P/N & Description)

DB25BO

Chapter 6 - Hardware Reference

Screw Terminal Breakout Board See page next page f or conn ec tio n information.

SS-IO SS-IO-6

25-pin D-Shell I/O cable that connects Impulse to other devices or PLC

SS-IO is 2 ft. SS-IO-6 is 6 ft.

See the next page for wire color codes

SS-RS232

Cable for connecting Impuls e to PC (9-pin Comm. Port)

Dimensions:

2.0L x 1.0W x 0.8D

PCS-5004

PC-Keypad Cable for copying programs between keypad and PC

6-7

Chapter 6 - Hardware Reference

DB25BO Screw Terminal Breakout Board

When connected to the Impulse, the DB25BO terminals will match the pinouts of the 25-pin connector as shown below.

DB25BO

Screw Terminal Breakout

Board

25-pin Connector on Impulse Drive

SS-IO/SS-IO-6 Cables

Pin Impulse Signal Wire Color Pin Impulse Signal Wire Color Pin Impulse Signal Wire Color

IDC Cable P/N: SS-IO/SS-IO-6

Note: Cable SHIELD is internally connected to

the DB25 metal housing.9 Drain Violet 18 COM Violet/White

6-8

Impulse-Applicable IDC Motors

S12 Hybrid Step Motor

Electrical Specs. S12T

Continuous Stall Torque oz-in [N-m] 35 [0.25] Recommended Current/Phase Amps 1.0

Winding Resistance @ Ambient Ohms 5.52

Inductance mH 8.8 Max. Winding Temperature °F [°C] 212 [100]

Mechanical Specs.

Rotor Inertia oz-in-s2 [kg-m2] 5.1x10

Axial Shaft Load lbs [N] 10 [45] Radial Shaft Load @ 0.5 inches lbs [N] 5 [22] Motor Weight lbs [kg] 0.66 [0.3] Step Angle (full step) degrees 1.8

(BOTH ENDS)

S12T

Chapter 6 - Hardware Reference

Note:

• IDC step motors require a torque safety margin of at least 30%.

-4

IDC Motor Wiring

Series

YELLOW

WHT/YEL

WHT/RED

RED

SHIELD

BLACK

WHT/BLK WHT/ORG

ORANGE

6-9

Chapter 6 - Hardware Reference

S21, S22, S23 Hybrid Step Motor Specifications

.002

Electric al Specs. S21T S21V S22T S22V S23T S23V

Continuous Stall Torque oz-in [N-m] 65 [0.46] 100 [0.71] 125 [0.88]

Recommended Current/Phase Amps 1.05 2.1 1.5 3.0 1.75 3.5

Winding Resistance @ Ambient Ohms 5.4 1.35 4.8 1.2 4.4 1.1

Inductance mH 18 4.5 18 4.5 18 4.5

Max. Winding T emperature °F [°C] 212 [100] 212 [100] 212 [100]

Mechanical Specs.

Rotor Inertia oz-in-s2 [kg-m2] 1.66x10-3[1.17x10-5] 3.31x10-3[2.34x10-5] 4.97x10-3[3.51x10-5]

Axial Shaft Load lbs [N] 25 [111] 25 [111] 25 [111]

Radial Shaft Load @ 0.5 inches lbs [N] 5.6 [25] 5.6 [25] 5.6 [25]

Motor Weigh t lbs [kg] 1.6 [0.73] 2.4 [1 .1 ] 3. 2 [1 .5 ]

Step Angle (full step) degrees 1.8 1.8 1.8

S21T S21V S22T S22V S23T S23V

.003

.002

6-10

IDC Mot or Wiring

Series

YELLOW

WHT/YEL

WHT/RED

RED

SHIELD

BLACK

WHT/BLK WHT/ORG

ORANGE

Parallel

WHT/YEL

SHIELD

WHT/BLK

YELLOW

WHT/RED

RED

BLACK

WHT/ORG

ORANGE

Notes:

• T = Series V = Parallel

• Parallel (V) wiring: 50% duty cycle max above 5 rps (300 rpm).

• IDC step motors require a torque safety margin of at least 30%.

S32, S33 Hybrid Step Motor Specifications

(4)

.003

Chapter 6 - Hardware Reference

1/2-14NPS

.001

Electrical Specs. S32T S33T

Continuous Stall Torque oz-in [N-m] 300 [7.1] 400 [5.3] Recommended Current/Phase Amps 2.8 3.5 Winding Resistance @ Ambient Ohms 1.03 .96

Inductance mH 10 10 Max. Winding Temperature °F [°C] 212 [100] 212 [100]

Mechanical Specs.

Rotor Inertia oz-in-s2 [kg-m2] 0.017 [3.51x10-5] 0.0265 [3.51x10-5]

Axial Shaft Load lbs [N] 50 [222] 50 [222]

Radial Shaft Load @ 0.5 inches lbs [N] 14.5 [64.4] 14.5 [64.4]

Motor Weight lbs [kg] 5.1 [2.3] 8.3 [3.8]

Step Angle (full step) degrees 1.8 1.8

S32T S33T

0.23/0.21 THRU ON A 3.875 B.C.

Notes:

• T = Series V = Parallel

• Parallel (V) wiring: 50% duty cycle max above 5 rps (300 rpm).

• IDC step motors require a torque safety margin of at least 30%.

IDC Motor Wiring

Series

YELLOW

WHT/YEL

WHT/RED

RED

SHIELD

BLACK

WHT/BLK WHT/ORG

ORANGE

Parallel

YELLOW

WHT/RED

WHT/YEL

SHIELD

BLACK

WHT/ORG

ORANGE

WHT/BLK

RED

Wire Color on Quick

Disconnect Cables

Drive

Connection

Red w/ Black B-

Red w/ White B+

Green *GND

Red w/ Yellow A-

Red A+

*Gray-colored Quick Disconnect Cables

are shielded - connect shield to GND.

IDC Quick Disconnect Cable

P/N QF3-12

6-11

Chapter 6 - Hardware Reference

P21, 22 Hybrid Step Motor Specifications

2.22

1.11 .02

.03

.02

.005.219

.205

.010

2.625 AB

THRU

.02

4X .010

EQ SP AS SHOWN

ON A

.021.11

2.22

.81

.06

1.500 .002 .002

.2500 .2495

.001

.02

.02.70

.004

.20

.02

P21: 2.205 MAX P22: 3.090 MAX

.31 .02

8X #24 AWG CONDUCTOR

CABLE X 144.0 LONG MIN

WITH FOIL SHIELD AND DRAIN APPROXIMATE SIZE .23 DIA

.75

.04

.2500 .2495

.001

.004

Note: Specs. apply to parallel (120 VAC) connections .

Electrical Specs. P21V P22V

Continuous Stall T orque oz-in [N-m] 100 200

Recommended Current/Phase Amps 1.3 2.0

Winding Resistance @ Ambient Ohms 4.7 3.7 Inductance mH 20 16

Max. Winding Temperature °F [°C] 248 [120]

Mechanical Specs.

Rotor Inertia oz-in-s2 [kg-m2] 0.0035 [2.48x10-5] 0.0061 [4.32x10-5]

Axial Shaft Load lbs [kg] 10 [44] Radial Shaft Load @ 0.75 inches [19mm] lbs [kg] 15 [66] Motor Weight lbs [kg] 1.9 [0.86] 2.7 [1.23] Step Angle (full step) degrees 1.8

P21V P22V

2X 4-40 UNC-2B EQ SP AS SHOWN

1.812 A.010 C

180

.10

BCON A

6-12

IDC Motor Wiring

Parallel

YELLOW

WHT/RED

RED

WHT/YEL

SHIELD

BLACK

WHT/ORG

ORANGE

WHT/BLK

Note:

• IDC step motors require a torque safety margin of at least 30%.

P/K 31, 32, 33Step Motor Specifications

Electrical Specs. P31V P32V P33V

Continuous Stall Torque oz-in [N-m] 450 [3.2] 920 [6.5] 1260 [8.9] Recommended Current/Phase Amps 2.9 3.3 4.0 Inductance mH 14 30 25 Max. Winding Temperature °F [°C] 212 [100] 212 [100] 212 [100]

Mechanical Specs. P31V P32V P33V

Rotor Inertia oz-in-sec .0202 .038 .0567 Axial Shaft Load lbs [N] 305 [1350] 305 [1350] 305 [1350] Radial Shaft Load @ 0.5 inches lbs [N] 665 [285] 665 [285] 110 [489] Motor Weight lbs [kg] 5 8.4 11.9 Step Angle (full step) degrees 1.8 1.8 1.8

Chapter 6 - Hardware Reference

EQ and EM Encoder Cables Qui ck Disconnect Moto r Cable Motor Dimensions

Signal *Pin Color Wire Color Signal Motor D K T X LMAX

A+ B Red Red w/ Black B- P31 .5000 .1250 .555 (3.70) 4.44

A- C Pink/Purple Red w/ Whit e B+ P32 .5000 .1250 . 555 (5.22) 5.96

B+ N Green Green *GND P33 . 625 0 .1875 .705 (6. 74) 7.48

B- P Blue Red w/ Yellow A-

Z+ M Yellow Red A+

Z- U Orange *Connect shield of gray QF3-12

+5V K White

COM T Black

Shld --- ---

*EQ Cable only. Brown-NC

IDC Quick Disconnect Cable

Encoder

Cable

cable to GND.

P/N QF4-12 (18AWG)

IDC Motor Wiring

Series

YELLOW

WHT/YEL

WHT/RED

RED

SHIELD

BLACK

WHT/BLK WHT/ORG

ORANGE

Parallel

YELLOW

WHT/RED

RED

WHT/YEL

SHIELD

BLACK

WHT/ORG

ORANGE

WHT/BLK

6-13

Chapter 6 - Hardware Reference

This page intentionally left blank

6-14

Chapter 7 - Troubleshooting the Impulse

This chapter covers common faults, their possible causes and remedies. Also include in this chapter are Impulse Limits Tables for a variety of operational parameters, e.g. the Acceleration/ Deceleration/Velocity Limits Table.

The Impulse drive detects and resolves fault conditions. Faults are signaled by either a steady red or flashing red LED on the front panel. A solid gr een LED indicates no rmal operation. Mos t faults are cleared by either 1) cycling power , 2) sending a RESET command via the serial port or con figurable logic input, or 3) probing the motor if the LED is steady red.

Read the CAUTION below before troubleshooting your Impulse.

CAUTION!

• Always use caution when wo rking with m echanic al syst ems. Gea rs and screw-dr iven cylinders are capable of exerting tremendous force against an obstruction.

• Always ensure that power to your system is OFF before performing any mainte- nance activity, or making any connections or adjustments.

• Do not insert objects into the Impulse drive. High voltages could cause personal injury, and equipment could be damaged beyond repair.

Chapter 7 - Troubleshooting the Impulse

Do not open the Impulse drive. The factory warranty will be voided if the drive is

•

opened.

Troubleshooting Table

This table provides possible remedies to other problems you might have with your application.

Symptom Possible Causes Possible Remedies

Motor moves the wrong distance

Motor stalls (1 LED flash) Acceleration and/or velocity are too

Motor moves the wrong direction

Wrong gear ratio. Check distance units. Motor stalled or slipping. Check motor current anti-resonance

Control and drive resolutions don’t match.

high. Motor configured incorrectly. Check mot or current , inductance,

The motor phases are mis-wired. Check per manual, or swap A+ with

The system’s direction is opposite the configured drive direction.

settings. Check Speed Torque requirements

of move. Decrease acceleration. Reduce acceleration and/or velocity.

anti-resonance settings.

A-. Change the control’s direction pa-

rameter.

The controller does not respond to keypad input.

The keypad has been disabled. Check the DIP switch settings on the

back of the keypad.

Incorrect unit address. Change the unit address.

7-1

Chapter 7 - Troubleshooting Your Impulse

Symptom Possible Causes Possible Remedies

The keypad is blank, but the backlight is on.

The keypad is blank and the backlight is off.

It is difficult to read the display The contrast potentiometer needs

Can’t Communicate over RS232, but keypad works.

Can’t Communicate over RS232, and keypad does NOT work.

Steady Red LED Motor not probed. If using Application Developer, use

1 LED Flash (Stall) Motor stalled. Motor may not produce enough

You have an older keypad that requires new firmware. The Impulse requires a keypad with Version 3.00 firmware or higher.

The keypad is not receiving a good +5VDC signal.

adjustment If the keypad works, the Impulse

RS232 port is working. Something else is configured wrong (i.e. wiring, configuration, address).

Impulse is configured as RS485. Check the label to make sure you

The keypad is disabled. Enable keypad through DIP switch

The serial port is not working. Call IDC (or your distributor) for ap-

Call IDC for a free firmware upgrade to your keypad.

Check wiring, verify that the +5VDC is between 4.8 and 5.2V.

Adjust the contrast with the pot on the back of the keypad.

Refer to Chapter 5, RS232 Troubleshooting, for help on this subject.

don’t have an RS485 version. Either connect to RS485 or call IDC (or your distributor) to exchange units.

on back of keypad and try again.

plication assistance.

the Project Wizard or select Run > Probe Motor from the main menu. If using a keypad, select RUN > PROBE.

torque for the application.

2 LED flashes (Undervoltage Fault)

3 LED flashes (Overvoltage Fault)

4 LED flashes (Over Current Fault)

5 LED flashes (Interlock Fault)

“Nuisance fault” - using a non-IDC motor.

Indicates that the high-voltage power supply has fallen below 110 VDC for more than 3 seconds. This prevents the drive from trying to operate a motor with insufficient power to meet speed-torque performance objectives.

Bus voltage is too high. This is usually caused by a regeneration event that overwhelms the internal powerdump circuit. It can also be caused by high line voltage or voltage spikes.

The motor is mis-wired or internally shorted. The Impulse is protected against such shorts, but you will need to correct the problem to prevent the fault.

Motor connector does not contain an interlock jumper, motor has been disconnected, or interlock jumper is loose.

Call IDC for assistance.

Verify power supply voltage integrity.

Eliminate the regen event by reducing the load or make the move less aggressively by reducing the commanded acceleration or velocity. Check your AC line voltage to verify it is within the Impulse’s limits.

With power off recheck connections. Check Impulse current setting to make sure you did not accidentally damage a winding by using a higher current than the motor is rated for . Check to see the motor phases are not shorted to one another or to the case of the motor. The resistance in each phase should be about the same; only a few ohms. If the phases are open or have large resistances, the motor is probably damaged and should be replaced.

Ensure interlock jumper is securely wired into motor connector. Ensure motor connector is securely plugged into the motor jack on the drive.

7-2

Chapter 7 - Troubleshooting the Impulse

Symptom Possible Causes Possible Remedies

6 LED flashes (Over Temperature Fault)

7 LED Flashes (EEPROM Checksum Fault)

Limits Tables

Velocity Limits at ALL RESOLUTIONS are: Min = 0.00002 RPS Max = 100 RPS

Acceleration and Deceleration Limits are the following:

Internal Fan or Heatsink Tunnel is clogged or restricted (internal temp. has exceeded 68° C (154° F).

Ambient air in cabinet is too hot. The Impulse can produce 20 Watts

The cooling fan is not turning. Cooling fan is inoperable. Return unit

At power-up the drive tests the integrity of its non-volatile memory by computing a checksum. This fault indicates an abnormal or defective condition in the drive.

An error occured during download or EEPROM write.

Remove obstruction (clean by blowing shop air through the tunnel.

of heat. If multiple units are installed next to each other, the cabinet must be adequately ventilated to remove heat.

to factory for repair. The fault can be cleared by issuing a

default configuration from Application Developer and then reconfiguring the drive for the target motor. If the fault recurs, the drive is definitely defective. The user should not be able to cause this fault inadvertently through any combination of commands or actions.

Step

Resolution

200 0.001 1000000

400 0.001 500000 1000 0.001 200000 2000 0.001 100000 5000 0.001 40000

10000 0.001 20000 18000 0.001 11110 25000 0.001 8000 25400 0.001 7874 25600 0.001 7812 36000 0.001 5555 50000 0.001 4000 50800 0.001 3937

100000 0.001 2000

Accel/ Decel Limits

Min (RPS

)Max (RPS

)

7-3

Chapter 7 - Troubleshooting Your Impulse

This page intentionally left blank

7-4

Chapter 8 - Product Support

Factory Authorized Distributors

IDC has more than 45 factory-trained and authorized automation technology distributors located throughout North America, Western Europe, and the Pacific Rim. Each has been selected for their technical expertise, their local market knowledge, and exemplary business practices. They are ready to assist you in applying Industrial Devices’ systems, as well as other complementary equipment. Contact us at (800) 747-0064 or (707) 789-1000 (from outside the U.S.) for the name of the distributor in your area.

Regional Offices

IDC Distributors are supported by local, direct IDC Regional Managers. IDC Regional Managers are available to assist with unusually demanding applications, present on site customer seminars, determine custom product needs, or respond to high volume requirements.

Toll Free Technical Support

Industrial Devices employs a large staff of mechanical and electrical engineers, whose full time responsibility is to help you select the proper system, install it correctly, and get it up and operating to your satisfaction. The Applications Engineering department is open from 6am to 5pm Pacific Time, Monday through Friday. The toll free number is (800) 747-0064. Outside of the United States call (707) 789-1000. The technical support fax number is (707) 789-0175. Email should be directed to: support@idcmotion.com.

CAD Library

Chapter 8 - Product Support & Warranty Information

IDC actuator, motor, and gear-motor CAD drawings (in .dxf format) are available to save you valuable design time and prevent transcription errors. Low volume requests are complimentary. Check the web site for CAD drawings that may be downloaded.

Web Site

Check us out at www.idcmotion.com for information on our products and support.

8-1

Chapter 8 - Product Support & Warranty Information

Warranty & Repairs

Industrial Devices Corporation (IDC) warrants this product to be free of defects in material and workmanship for a period of two (2) years from the date of shipment to the end user. Products that have been improperly used or damaged, in the opinion of IDC, are not subject to the terms of this warranty.

IDC maintains a repair facility at its factory in Petaluma, California for products manufactured by IDC. Prior approval by IDC is required before returning any product for any reason. All returned packages must be accompanied by an RMA# (Return Material Authorization number).

To obtain return authorization, contact your local IDC distributor or IDC. Please note the following procedure:

1. Obtain the model and serial number of the defective unit.

2. Prepare a purchase order for possible repair cost, in the event that the unit is not warranted.

3. Contact your IDC distributor or IDC (1-800-747-0064) for an RMA#.

4. Provide information describing the nature of the failure. The better the information, the faster we’ll have your problem resolved.

5. Ship unit prepaid to the address below (be sure to include your RMA # on the shipping label):

Attn: Repair Department RMA# _ _-_ _ _

Industrial Devices Corporation, LLC 3925 Cypress Drive Petaluma, CA 94954

8-2

Appendix A - Recommended Wiring Practices

Appendix A: Recommended Wiring Practices for IDC Controls

When configuring your Impulse please follow the wiring practices listed below:

• Earth ground your machine at one point using a star configuration (shown at right). Multiple earth grounds can cause a ground loop (see Preventing Ground Loop below).

• Avoid long cable runs. The longer the cables, the lower the signal-to-noise ratio in your application.

• Use shielded motor and encoder cables along the entire cable run.

• Separate the signal wires (I/O, encoder, etc.) from the motor wires, AC power wires, and other sources of noise in your application.

• Avoid extending cables in the field via junction boxes, terminal strips, or Molex connectors. These types of connectors are typically unshielded (as is wire going into and out of the connector) and are places where noise may be injected into the system.

• Connect cable shields at the control end of your machine. Connect the motor cable shield to GND, and connect the encoder shield to COM on the control.

• Do not connect the logic common (COM) of the IDC control to earth ground on your machine or to the GND terminal on the control/drive. Separating earth ground from logic common minimizes the potential for ground loops.

• Use shielded cables inside your panel (if control is panel or cabinet-mounted) for I/O and encoder wiring.

• Use differential, line-driven encoders with shielded, twisted-pair encoder cables. Single-ended TTL encoders are susceptible to noise and should be avoided.

• For optimum noise immunity use IDC motors and encoders with IDC controls.

Preventing a Ground Loop

Possible Ground Loop

Insert an ungrounded adapter to break the ground loop.

Additional Wiring Practices When Connecting an IDC Control to a PLC

• Connect the PLC logic common and the IDC COM terminals together.

• Disconnect the jumper between Pull-Up (or P-Up) and +12 VDC on the IDC control. Connect the positive terminal of the PLC power supply to Pull-Up (or P-Up), and connect the Power Supply common to the COM terminal on the IDC control, or to the PLC logic common (these should both be at the same potential).

•IDC inputs are Sourcing, so PLC outputs connected to IDC inputs should be Sinking.

•IDC outputs are Sinking, so PLC inputs connected to IDC ouputs should be Sourcing.

Do Not

Connect

Pig-tail

Wire

A-1

Appendix A - Recommended Wiring Practices

A-2

Appendix B - Impulse Advanced Programming

The purpose of this section is to provide the information necessary for the user to communicate with an Impulse drive over a serial connection without using IDC Application Developer. Since the Impulse communications protocol is not ASCII character based, the terminal window in IDC Application Developer and terminal emulation programs such as Windows™ HyperTerminal are not compatible for use with the Impulse drive. Therefore, the topics covered here are considered advanced and require the user to understand how to directly interface with a PLC or PC serial port through programming (i.e. C or C++) or a MMI / soft PLC software package.

Communications Protoco

Transmission Frame

The Impulse drive does not use the ASCII character set for encoding and parsing serial data but rather transmits actual numeric data in the form of bytes. This convention allows for faster and more efficient serial communications by reducing the number of bytes required for data transmission and eliminating the need to convert ASCII character strings into raw data. Therefore, data references from this point forward represent actual numbers not of 1 not the ASCII text character ‘1’.

The core of the Impulse communication protocol consists of a series of bytes called the transmission frame. The structure of the transmission frame is as follows:

BYTE #1 BYTE#2 BYTE#3…#n BYTE #n+1 BYTE #n+2

Unit

Address

Unit Address

This byte specifies the address of the unit for which this transmission frame is intended. The valid range for the unit address is 1 to 255 and the factory default address is 1.

Parameter Index

Parameter

Index

ASCII text. For example, a ‘1’ means a value

Data

Bytes

Checksum

Lower Byte

Checksum

Upper Byte

This byte specifies the index of the parameter to be written to or read from. Parameter reads and writes are determined by the state of the most significant bit of the parameter index byte. If the bit is zero, the transmission frame is designated as a write. If the bit is one, the transmission frame is designated as a read. The valid range for the parameter index is 1 to 127 for writes and 129 to 255 for reads. For example, if BYTE #2 in the transmission frame equals 5, this would define a write to parameter index #5 however, if BYTE #2 equals 133, this would define a read from parameter index #5. A parameter index can be converted to a read by simply taking the index and adding 128, thus setting the most significant bit to 1.

Data Bytes

These bytes specify the data to be written to or read from the parameter index. All parameter index data is in word format (2 bytes) with the least significant byte preceding the most significant byte. Therefore, the smallest number of data bytes is 2.

Checksum Bytes

These bytes contain the unsigned sum of the Unit Address, Parameter Index and Data Bytes. These bytes are using for transmission integrity verification.

B-1

Appendix B - Impulse Advanced Programming

Byte Receive Time Out

Since there is no end of transmission frame deliminator, the Impulse assumes if no bytes are received for 60 ms, the transmission is complete. The receive time out is reset on every byte received therefore, the host system must insure that the latency between transmitted bytes is less than 60 ms.

Receive Buffer Overrun

The Impulse receive buffer is 25 bytes however, there are no valid transmission frames of this length.

Reading and Writing Parameter Data

The Impulse does not support continuous data streaming due to its condensed receive buffer. Therefore, the host system must wait for a drive response before sending additional read or write transmission frames.

Read Queries

The following example illustrates a read request of parameter index #113 (Commanded Position) from unit #2. Bytes are shown in hexadecimal format.

02 F1 F3 00

Checksum Upper Byte

Checksum Lower Byte (Address + Index)

Read Parameter Index (113 + 128)

Unit Address #2

After sending the read request, the host system would need to wait for the drive to respond before sending another read query or write request. The drive responds to a read with unit address, parameter index, data and checksum. Assuming the commanded position is 25000 steps, the response would be as follows:

02 71 A8 61 00 00 7C 01

Checksum Upper Byte

Checksum Lower Byte (Address + Index)

Cmd Position Upper Byte, Upper Word

Cmd Position Lower Byte, Upper Word

Cmd Position Upper Byte, Lower Word

Cmd Position Lower Byte, Lower Word

Parameter Index 113

Unit Address #2

B-2

Since Commanded Position is a 32-bit value, the data field in the transmission frame is 4 bytes (2 words).

Impulse PCW-5181 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual