Parker 6250 User Manual

6250 Servo Controller

User Guide

Compumotor Division Parker Hannifin Corporation p/n 88-013413-01B October 18, 1993

Important User Information

To ensure that the equipment described in this user guide, as well as all the equipment connected to and used with it, operates satisfactorily and safely, all applicable local and national codes that apply to installing and operating the equipment must be followed. Since codes can vary geographically and can change with time, it is the user's responsibility to identify and comply with

the applicable standards and codes.

damage to equipment and/or serious injury to personnel.

Personnel who are to install and operate the equipment should study this user guide and all referenced documentation prior to installation and/or operation of the equipment.

In no event will the provider of the equipment be liable for any incidental, consequential, or special damages of any kind or nature whatsoever, including but not limited to lost profits arising from or in any way connected with the use of this user guide or the equipment.

WARNING:

Failure to comply with applicable codes and standards can result in

The information in this user guide, including any apparatus, methods, techniques, and concepts described herein, are the proprietary property of Parker Compumotor or its licensors, and may not be copied, disclosed, or used for any purpose not expressly authorized by the owner thereof.

Since Parker Compumotor constantly strives to improve all of its products, we reserve the right to change this user guide and equipment mentioned therein at any time without notice.

For assistance in the United States, contact:

Compumotor Division of Parker Hannifin 5500 Business Park Drive Rohnert Park, CA 94928 Telephone: (800) 358-9070 Fax: (707) 584-8015

For assistance in Europe, contact:

Parker Digiplan 21 Balena Close Poole, Dorset England BH17 7DX Telephone: 0202-690911 Fax: 0202-600820

Compumotor

6250 Servo Controller User Guide

Revision B Change Summary

The following is a summary of the primary technical changes to this user guide since the last version was released. This user guide, p/n 88-013413-01B (released on October 18, 1993), supersedes 88-013413-01A.

Topic Description See Also

6250-ANI

is Released

Analog Voltage Override New Feature (see Continuous Mode Clarification: While in the continuous mode (MC1), one of the factors that

Drive Fault Monitoring Clarification: You must enable the input functions with the INFEN1

Encoders Clarification: The Compumotor E Series incremental encoders all have

Error Handling Clarification: When an error occurs, the controller will GOTO or GOSUB,

Homing Clarification: After the homing operation is successfully completed, the

Inputs: Debounce Time

Power Input (AC) Correction: The power connection drawing was misleading by stating the

Program & Command Buffer Execution Control

Program Debugging New Features & Clarifications:

Program Flow Control New Feature: The JUMP command was added to allow an unconditional

Analog Input Option

New Option/Feature: The 6250-ANI option was released at the same time this user guide revision B was released. The -ANI option is a ±10V, 14bit analog input (with anti-aliasing filter) that is sampled at the servo update rate (set with the SSFR command). One

DRIVE connector. The input value can be transferred to the terminal with the

TANI command, or used in a assignment or comparison operation using the [ANI] command (e.g., VAR1=1ANI). The TANI and [ANI] commands are

used only by the -ANI option, not the standard 6250.

Program Debugging

can stop motion is if the load trips a switch for a general-purpose input that is configured as a Kill input (INFNCi-C) or a Stop input (INFNCi-D).

command before the drive fault input will be recognized. Also, be sure to set the drive fault level (DRFLVL) appropriately for the drive you are using.

the same cable color codes.

depending on the error condition (an error resolution table is provided).

absolute position register is reset to zero. New Feature: The INDEB command has been included to allow you to set

the debounce time for the 24 general-purpose programmable inputs and the 2 trigger inputs. The range is 1 - 250 ms, in even increments. The default debounce time is 4 ms for the 24 inputs, and 25 ms for the trigger inputs.

AC input power range was 100 - 120VAC; it is actually 85 - 240VAC. Clarifications:

Deceleration after a stop input or command—In all variations of the COMEXS mode, upon receiving a stop input or stop command,

the preset AD/ADA value

Resuming after a stop or pause—In the COMEXR1 & COMEXS1 modes, you can resume program execution and/or motion with a !C command or the pause/

resume input (INFNCi-E)

Simulating Analog Input Voltages: (new feature) A new feature called Analog Voltage Override (enabled with the ANVOEN command and

programmed with the ANVO command) allows you to simulate a voltage on the analog input channels (input channels 1 - 3 on the

Programming Error Messages: (clarification) The 6200 can display error messages and/or a error prompt (?), depending on which error level is

selected with the ERRLVL command. The default error level (ERRLVL4) displays both the message and the error prompt).

Identifying Bad Commands: (new feature) When the 6200 detects an error with a command, you can issue the TCMDER command to find out which

command caused the error. This is especially useful when downloading a program.

branch to another program and not return. The reason program control does not return is because all nested IF, WHILE and REPEAT statements, loops, and subroutines are cleared.

only after the move in progress is completed

ANI input terminal is located on each

below) Pg. 67 & 95

motion will decelerate at

JOYSTICK connector).

Pg. 16, 54 & 68

Pg. 53

Pg. 19, 58 & 102

Pg. 12 & 103

Pg. 98

Pg. 49

Pg. 58 & 61

Pg. 5

Pg. 86

Pg. 60-61 & 86-87

Pg. 67 & 95

Pg. 97

Pg. 88

6250 User Guide

Change Summary

(continued)

Programming: Troubleshooting problems

Clarification: In Chapter 7, three resolutions were added to resolve the following problem situations:

• Start-up program (STARTP) will not run on power up

• Program execution stops at the INFEN1 command

• First time a program is run, the move distances are incorrect, but after downloading the program a second time the move distances are correct.

RMAs

Clarification: If you need to return a Compumotor product to affect repairs or upgrades, be sure to ship it to Suite D at the Rohnert Park

address.

RP240 New Features and Clarifications:

Data Read Immediate Mode: (new feature) The DREADI1 command allows continual input from the RP240 numeric keypad or the function keys (when

used in conjunction with DREAD and/or DREADF). Standard RP240 menus should not be used in this mode. Data can be read into numeric variables only.

Do not assign the same variable to read numeric

Power-up (default) Mode: (clarification) On power up, the 6200 defaults to a mode in which it controls the RP240 with the menu-driven functions listed on

page 50. To disable this menu, the power-up program (STARTP) must contain the DCLEARØ command.

Software Revision 1.1 Released

Variable Type Conversion

This version of the user guide was released at the same time that revision

1.1 of the 6250 software was released. New Feature: The VCVT( ) command has been added to allow you to

convert between variables (numeric-to-binary and binary-to-numeric).

and

function key data.

Pg. 108-109

Pg. 110

Pg. 91

Pg. 70

n/a

Pg. 73

TABLE OF CONTENTS

Overview........................................................................................................... iii

Chapter 1: Introduction ....................................................................................... 1

Chapter 2: Getting Started ................................................................................... 3

Chapter 3: Installation........................................................................................ 7

Chapter 4: Servo Tuning...................................................................................... 21

Assumptions................................................................................................................................. iii

Contents of This User Guide............................................................................................................. iii

Installation Process Overview .......................................................................................................... iv

Conventions................................................................................................................................. iv

6250 Description............................................................................................................................ 1

6250 Features............................................................................................................................... 2

Inspect The Shipment..................................................................................................................... 3

Bench Test................................................................................................................................... 4

➀ RS-232C Communications............................................................................................... 4

➁Connect Power Cable ..................................................................................................... 5

➂ Test Procedure ............................................................................................................. 5

Installation Precautions.................................................................................................................. 7

➀ Mount the 6250 ......................................................................................................................... 8

➁ System Connections .................................................................................................................. 9

Motor Driver Connections .................................................................................................... 9

End-of-Travel Limit Connections ........................................................................................... 11

Home Limit Connections...................................................................................................... 11

Encoder Connections ......................................................................................................... 12

Auxiliary +5V Output Connection........................................................................................... 12

Output and Input Pull-up Connections.................................................................................... 12

Enable Input Connection ..................................................................................................... 13

Programmable Inputs & Outputs Connections.......................................................................... 13

Trigger Input Connections.................................................................................................... 14

RP240 Front Panel Connections............................................................................................ 15

Joystick and Analog Input Connections.................................................................................. 15

ANI Analog Input Connections (6250-ANI Option Only).............................................................. 16

Extending 6250 System Cables ............................................................................................ 17

➂ Installation Verification ............................................................................................................... 17

➃ What's Next?............................................................................................................................ 19

Servo System Terminology .............................................................................................................. 21

Servo Tuning Terminology.................................................................................................... 21

Position Variable Terminology............................................................................................... 22

Servo Response Terminology............................................................................................... 23

6000 Series Servo Commands.......................................................................................................... 25

Servo Control Techniques................................................................................................................ 26

Proportional Feedback Control (SGP)..................................................................................... 26

Integral Feedback Control (SGI)............................................................................................ 27

Velocity Feedback Control (SGV).......................................................................................... 28

Velocity Feedforward Control (SGVF)..................................................................................... 28

Acceleration Feedforward Control (SGAF)............................................................................... 28

Tuning Setup Procedure.................................................................................................................. 29

Drive Tuning Procedure (Velocity Drives Only)..................................................................................... 31

Controller Tuning Procedure............................................................................................................. 32

Tuning Scenario............................................................................................................................. 38

Target Zone (Move Completion Criteria) .............................................................................................. 40

Chapter 5: Basic 6250 Features............................................................................. 43

Chapter 6: Advanced 6250 Features........................................................................ 79

Chapter 7: 6250 Programming Tips.......................................................................... 83

Chapter 8: Hardware Reference ............................................................................. 101

Chapter 9: Troubleshooting .................................................................................. 107

Appendix A: Reducing Electrical Noise ..................................................................... 111

Appendix B: Alphabetical Command List.................................................................... 113

Appendix C: Index .............................................................................................. 117

Before You Proceed With This Chapter............................................................................................... 43

6000 Series Software Reference Guide .................................................................................. 43

Compumotor Bulletin Board Service....................................................................................... 44

Basic Motion Control Concepts............................................................................................. 44

Support Software........................................................................................................................... 44

6000 DOS Support Disk....................................................................................................... 44

Motion Architect®.............................................................................................................. 44

6250 Safety Features ..................................................................................................................... 45

Scaling ........................................................................................................................................ 46

Acceleration & Deceleration Scaling (SCLA/PSCLA) ................................................................. 46

Velocity Scaling (SCLV/PSCLV)............................................................................................ 46

Distance Scaling (SCLD) ..................................................................................................... 47

End-of-Travel Limits ....................................................................................................................... 48

Homing ........................................................................................................................................ 48

Positioning Modes.......................................................................................................................... 51

Preset Mode ..................................................................................................................... 52

Continuous Mode............................................................................................................... 53

User Interface Options.................................................................................................................... 54

Programmable Inputs and Outputs .................................................................................................... 55

Output Functions ............................................................................................................... 55

Input Functions ................................................................................................................. 58

Thumbwheel Interface......................................................................................................... 63

PLC Interface.................................................................................................................... 65

Joystick Interface.......................................................................................................................... 65

-ANI 14-Bit Analog Input Option (6250-ANI Option Only)........................................................................ 68

RP240 Front Panel Interface ............................................................................................................ 68

Operator Interface Features................................................................................................. 69

Using the Default Mode ....................................................................................................... 70

Host Computer Operation ................................................................................................................ 72

Variables (Binary, Numeric, and String) .............................................................................................. 73

RS-232C Daisy-Chaining ................................................................................................................. 76

S-Curve Profiling............................................................................................................................ 79

X-Y Linear Interpolation................................................................................................................... 81

Creating Programs & Subroutines...................................................................................................... 83

Subroutines...................................................................................................................... 84

Stored Programs and Non-volatile Memory.............................................................................. 84

Automatic Program Execution .............................................................................................. 85

Controlling Execution of Programs and the Command Buffer................................................................... 85

Program Flow Control...................................................................................................................... 87

Unconditional Looping and Branching..................................................................................... 87

Conditional Looping and Branching........................................................................................ 89

Program Interrupts ......................................................................................................................... 92

Program Debug Tools...................................................................................................................... 93

Trace Mode....................................................................................................................... 93

Single-Step Mode............................................................................................................... 94

Simulating Analog Input Channel Voltages .............................................................................. 95

Simulating I/O Activation ..................................................................................................... 95

Programming Error Responses ............................................................................................. 97

Error Handling ............................................................................................................................... 98

General Specifications.................................................................................................................... 101

I/O Pin Outs & Circuit Drawings......................................................................................................... 102

Optional DIP Switch Settings............................................................................................................ 105

Troubleshooting............................................................................................................................. 107

Common Problems & Solutions ............................................................................................. 108

RS-232C Troubleshooting................................................................................................................ 109

Returning the System ..................................................................................................................... 110

6250 Servo Controller User Guide

O V E R V I E W

This user guide is designed to help you install, develop, and maintain your system. This section is intended to help you find and use the information in this user guide.

Assumptions

To effectively use this user guide to install, develop, and maintain your system, you should have a fundamental understanding of the following:

❏ Basic electronics concepts (voltage, switches, current, etc.) ❏ Basic motion control concepts (torque, velocity, distance, force, etc.) ❏ Basic programming skills (any high-level language such as BASIC, Fortran, or Pascal)

Contents of This User Guide

Chapter Purpose

➀

Introduction

➁

Getting Started

➂

Installation

➃

Servo Tuning

➄

Basic 6250 Features

➅

Advanced 6250 Features

➆

Programming Tips

➇

Hardware Reference

➈

Troubleshooting

Appendices A: Reducing electrical noise in your application

Describes the 6250 and provides a brief account of its features. Lists and describes the items you should have received with your

6250 shipment. A system's basic functionality.

Provides instructions for mounting, wiring up, and testing the 6250 system. Complete all instructions in Chapter 3 before tuning the 6250 in Chapter 4. Refer to the

Software Reference Guide

6000 Series commands used in Chapters 4 through 7. Instructs you on how to tune the 6250 for your application.

Sample applications are provided. Complete all tuning instructions before implementing motion features.

Describes the 6250's basic user features and instructs you on how to implement them in your application. Sample applications are provided.

Describes the 6250's advanced user features (S-Curve Profiling, Linear Interpolation) and instructs you on how to implement them in your application. Sample applications are provided.

Instructs you on how to implement the 6250's programming language in your application.

Use the electrical specifications, optional DIP switch settings (address & baud rate), and I/O signal descriptions and circuit drawings.

Describes methods for isolating and resolving hardware and software problems.

B: Alphabetical listing of the 6250's commands C: Index

Hardware Reference

bench test

procedure is provided to verify the

6000 Series

for detailed descriptions of the

as a quick-reference tool for 6250

Overview

iii

Installation Process Overview

➀ Review this entire user guide. Become familiar with the user guide's contents so that you can

quickly find the information you need. At times you may want to refer to the Software Reference Guide for detailed descriptions of the 6000 Series commands used in this user guide.

➁ Read Chapter 1, Introduction,

to develop a basic understanding of all system components, their functions, and interrelationships.

➂ Read Chapter 2, Bench Test, and verify that you have received all the proper components for

your system, and that all the items in your shipment have arrived without damage. Follow the step-by-step bench test procedures to verify the 6250's basic operability, as well as the functionality of the host computer (or terminal).

➃ Complete the system configuration, mounting, and wiring instructions provided in Chapter 3,

Installation. Do not deviate from the sequence or installation methods

provided.

➄ While in Chapter 3, be sure to use the Installation Verification procedures to check all the

system functions and features to ensure that you have completed the installation process correctly.

➅ After you successfully complete all procedures in Chapter 3, you will be ready to proceed to

Chapter 4, Servo Tuning, to tune the drive and the 6250 for your application. The tuning procedures in Chapter 4 are based primarily on using the Servo Tuner option for Motion Architect.

➆ After successfully completing all procedures in Chapter 4, you may proceed to Chapters 5

through 7 to implement the 6250's user features in your application.

Conventions

6000 Series

and the user documentation for all peripheral system components

Clockwise (CW, +) & Counter-clockwise (CCW, -) Directions

Throughout this user guide and the 6000 Series Software Reference Guide, you will find references to the clockwise (CW) and counter-clockwise (CCW) direction of motion. The

CW or CCW direction is determined either by the direction the motor shaft (see illustration at left), or by the sign (+ or -) of the commanded position (e.g., the D+8ØØØ distance command

Clockwise

(CW, +)

Counter-clockwise

(CCW, -)

indicates a 8,000-unit move in the clockwise direction). This convention is accurate only if you connect the drive and encoder as described in Chapter 3.

6000 Series Commands

The command language conventions are provided in the 6000 Series Software Reference Guide. Because some 6000 Series products have four-axis capability, the syntax

of the example commands in the Reference Guide shows data fields for all four axes; ignore the third and fourth data fields when entering commands or reading status commands for the

6250.

Related Publications

❏ 6000 Series Software Reference Guide, Parker Hannifin Corporation, Compumotor

Division; part number 88-012966-01 Motion Architect User Guide, Parker Hannifin Corporation, Compumotor Division; part

❏

number 88-013056-01

❏ Current Parker Compumotor Motion Control Catalog ❏ Schram, Peter (editor). The National Electric Code Handbook (Third Edition). Quincy, MA:

National Fire Protection Association

6250 Servo Controller User Guide

C H A P T E R ➀

6250 Description

Introduction

This chapter describes the 6250's basic functions & features.

The Compumotor 6250 is a stand-alone, two-axis servo controller. The 6250 provides sophisticated two-axis control of any standard ±10V analog input servo drive system.

The 6250 implements a dual processor approach, comprising a microprocessor for executing high-level motion programs and a digital signal processor (DSP) for high-speed, sophisticated servo control. This dual processor approach allows commands to be executed faster.

Using the 6000 Series Programming Language, you can program the 6250 via a PC or a dumb terminal. User programs are stored in the 6250's battery-backed RAM.

The 6250 also provides operator interface capabilities when used with the Compumotor RP240 Front Panel.

The 6250 comes standard with support software for the Microsoft® Windows™ and DOS operating environments:

❏ Motion Architect® is an innovative, easy-to-use Microsoft® Windows™ based programming

aide to help you easily create and implement complex motion programs. The Servo Tuner option, a special add-on module sold separately, allows you to visually gather data and tune your controller/drive system. For more information, refer to the

Guide.

❏ The 6000 DOS Support Disk contains a DOS-based program editor and terminal emulator package.

Also included are sample 6000 Command Language programs.

Motion Architect User

Additional 6250 features are listed below in the 6250 Features section.

➀

Introduction

System Hardware Block Diagram

Computer

Dumb Terminal

RP240

Front Panel

Optional ±10V,

14-bit Analog Input

6250

RS-232C Interface

Front Panel

Interface

6250-ANI

Option

Battery-backed

RAM

for

user programs

Motion

Chip

Axis #1

Operating System

Chip

Axis #2

-----------Microprocessor 68000 - 12MHz

Dual Port RAM

DSP

Drive Interface

- ±10V Analog Output

- Shutdown Output

- Drive Fault Input

- Inc. Encoder Interface

- Position Latch

- Output on Position

Limits

- CW & CCW End-of-travel

- Home

- Enable Input

- 2 Positon Latch Inputs

- 24 Prog. Inputs

- 24 Prog. Outputs

- 2 Auxiliary Prog. Outputs

I/O

Joystick Interface

Limit

Connections

I/O

Connections

Joystick

6250 Features

❏ 1 to 2 axes of optically isolated —10V analog interface servo control ❏ Servo feedback from incremental encoders. Analog feedback available with the

6250-ANI option.

❏ Controls servo drives in the velocity or torque mode ❏ Fast digital signal processor (DSP) for sophisticated servo control (digital

Proportional, Integral, and V elocity feedback, plus acceleration and velocity Feedforward—PIV&F)

❏ S-curve motion profiling ❏ Motion Architect

is standard

❏ Teach Mode ❏ Windows™-based visual data gathering and tuning aide available when using

the Motion Architect® Servo Tuner option

❏ DOS Support Disk provided ❏ 40,000 bytes of non-volatile memory for storing programs & paths ❏ Capability to interrupt program execution on error conditions ❏ 2-axis linear interpolation standard ❏ Variable storage, conditional branching, and math capability ❏ Program debug tools — single-step and trace modes, breakpoints, and

simulation of I/O

❏ Internal power supply ❏ Direct interface to RP240 Front Panel ❏ Operates stand-alone or interfaces to PCs & PLCs ❏ 3-wire, RS-232C interface to PC or dumb terminal ❏ 1.2 MHz pre-quadrature encoder feedback pulse frequency ❏ I/O capabilities (all I/O are isolated):

• ±10V analog control output (both axes )

• Shutdown output (both axes)

• Drive Fault input (both axes)

• Incremental encoder input (both axes)

• CW & CCW end-of-travel limit inputs (both axes)

• Home limit input (both axes)

• 3 8-bit analog inputs for joystick control and variable input

• 2 (trigger) inputs — use for hardware position latch (±1 count accuracy)

• 24 programmable inputs (Opto-22™ compatible)

• 24 programmable outputs (Opto-22™ compatible)

• 2 auxiliary programmable outputs that can be configured for accurate output on position within ±1 count

❏ 6250-ANI Option offers two ±10V, 14-bit analog inputs (one per axis) with anti-aliasing filter.

DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMDCMD+

DRIVE 2 ENCODER 2

SHLD COM SHTNC SHTNO DFT AGND ANI CMDCMD+

AUX

Rx Tx GND SHLD +5V OUT-P IN-P

TRG-A TRG-B GND OUT-A OUT-B GND ENBL

POWER

EARTH N/A

NEUT LINE

6250 Front Panel

ENCODER 1

Up to 2 Axes of control

Drive #1

Drive #2

RP240

+5V A+ AB+ BZ+ ZGND SHLD

+5V GND Rx Tx SHLD

J O Y S T

I C K

Motor #1

Motor #2

GRN

STATUS

RED

DRIVE1 OFF

DRIVE2 OFF

6250

2-AXIS SERVO CONTROLLER

P R O G R A M M A B L E

I N P U T S

Compumotor

Encoder

: READY : RESET

LIM 1/2

1CW 1CCW 1HOM GND 2CW 2CCW 2HOM GND SHLD

P R O G R A M M A B L E

O U T P U T S

6250 Servo Controller User Guide

C H A P T E R ➁

The information in this chapter will enable you to:

❏ Verify that each component of your 6250 system has been delivered safely and configured

properly

❏ Bench test the 6250's power and RS-232C interface to the host computer/terminal

Inspect The Shipment

Getting Started

If you need to return

any or all of the 6250

system components,

use the return

procedures in Chapter

Troubleshooting

You should inspect your 6250 shipment upon receipt for obvious damage to its shipping container. Report any damage to the shipping company as soon as possible. Parker Compumotor cannot be held responsible for damage incurred in shipment. The items listed below should be present and in good condition.

Part Part Number

6250 main unit (w/ship kit)

Ship kit: 6250 Servo Controller User Guide

* The 6250-ANI is an optional version of the 6250 which provides two ±10V, 14-bit analog inputs. If you ordered a

-ANI option, check the serial tag on the side of the 6250's chassis; it should say 6250-ANI.

Pre-Wired Connections

You should receive your 6250 with the following connections on the AUX connector prewired (from the factory):

+5V supplies power to OUT-P and IN-P. This provides power to the output and input pull-ups.

If this connection is broken, the 6250's analog command output signal is held to zero volts (independent of the DSP and microprocessor).

6000 Series Software Reference Guide Motion Architect® diskettes

Motion Architect Servo Tuner diskette (optional) Motion Architect User Guide DOS Support Disk DOS Support Disk Quick Reference 8-foot AC power cord

AUX

Rx Tx GND SHLD +5V OUT-P IN-P

TRG-A TRG-B GND OUT-A OUT-B GND ENBL

6250 (or 6250-ANI, if so ordered *) 88-013413-01 88-012966-01 95-013070-01

95-013070-02 95-013714-01 88-013056-01 95-012266-01 88-013258-01 71-009039-01

❏ Output and input pull-ups

(

OUT-P and IN-P) connected

to the +5V power supply (

❏ Enable input (

connected to ground (

ENBL)

GND)

+5V)

➁

Getting Started

Bench Test

This section leads you through step-by-step instructions to bench test your 6250 system.

This is a temporary (bench top) configuration; the permanent installation will be performed in Chapter 3, Installation. In this section, you will complete the following tasks:

➀ RS-232C Communications ➁ Connect Power Cable ➂ Test Procedure

➀ RS-232C Communications

To communicate with the 6250, your computer or terminal must have an RS-232C serial port.

The 6250 uses a three-wire implementation of standard EIA RS-232C signals.

Computer-toTerminal Conversion

Set Communication Parameters

Terminal Connections

If you are using an IBM/compatible computer, you must use a terminal emulator software package to communicate with the 6250. The 6250 comes standard with Motion Architect

for Windows™ and the 6000 DOS Support Disk; both provide a terminal emulator and program editor (refer to the Motion Architect User Guide or the 6000 DOS Support

Disk Quick Reference for installation and other user information). You may also use communication programs such as Crosstalk™, PC-Talk™, and PROCOMM™.

Make sure your computer or terminal is set to the following communication parameters. You can configure these parameters by using one of the terminal emulation software packages listed

above in Computer-to-Terminal Conversion. If you are using Motion Architect® or the 6000 DOS Support Disk, verify that the baud rate, data bit, parity, and stop bit parameters are set as follows:

❏ Baud Rate: 9600* ❏ Data Bits: 8 ❏ Parity: None ❏ Stop Bits: 1 ❏ Full Duplex ❏ XON/XOFF: Enabled

* If your terminal is not capable of 9600 baud, use the 6250's auto-baud function to automatically

set the 6250's baud rate equal to the terminal's baud rate. Refer to Optional DIP Switch Settings in Chapter 8 for instructions.

The Receive Data (Rx), Transmit Data (Tx), and Ground (GND) signals are on the 6250's AUX connector (shown below). The ground (GND) connection on the connector is signal ground or

common as opposed to earth ground (SHLD).

If you intend to daisy chain multiple 6250 servo controllers, do not attempt the daisy-chain connections now. Daisy-chain instructions are provided in Chapter 5,

Standard 9-Pin

COM Port Pin Outs:

Pin 3 = Transmit (Tx) Pin 2 = Receive (Rx) Pin 5 = Ground (GND)

6250 Servo Controller User Guide

Computer or

Terminal

(Serial Port)

Standard 25-Pin

COM Port Pin Outs:

Pin 2 = Transmit (Tx) Pin 3 = Receive (Rx) Pin 7 = Ground (GND)

NOTE

Basic 6250 Features

AUX

Tx Rx

GND

Rx Tx GND SHLD +5V OUT-P IN-P

TRG-A TRG-B GND OUT-A OUT-B GND ENBL

➁ Connect Power Cable

The 6250 is shipped with an 8-foot power cable that is prewired and keyed. Attach the power cable to the 6250's POWER connector as illustrated below.

85 - 240VAC

If you have a power source other than 85-240VAC, refer to Chapter 8 for specifications on alternative input power.

WARNING

DO NOT APPLY POWER

TO THE 6250 UNTIL

INSTRUCTED TO DO SO

IN THE FOLLOWING TEST PROCEDURE.

Protective

Rubber

Boot

EARTH

2-AXIS SERVO CONTROLLER

POWER

N/A

NEUT

LINE

Compumotor

➂ Test Procedure

Use the following procedure to test the 6250's power and RS-232C connections. In Chapter 3, Installation, you will test the analog output, end-of-travel and home limits, encoders, RP240, joystick, and programmable I/O.

➀ Apply power to the 6250 by plugging the power cable into a grounded power source.

CAUTION

The earth ground connection must be made by plugging into a grounded receptacle or by physically connecting the green wire to earth ground.

➁ Watch the LEDs on the 6250. The STATUS LED should be green, indicating the 6250 is ready

for operation. The other two LEDs should be red because the drives are not yet enabled with the DRIVE11 command.

If the STATUS LED is red, or if none of the LEDs illuminate, check your power source and cable connections. If these connections seem correct, disconnect power and consult Chapter 9, Troubleshooting.

➂ If you are using the 6000 DOS Support Disk, go to the Set-up menu and move the cursor down

to CHECK OUT and press ENTER to automatically verify the communication interface to the

6250. If the interface is not successful (Device not Ready message will flash on the screen), refer

to the RS-232C troubleshooting procedures in Chapter 9, Troubleshooting.

➃ Initiate the terminal emulator in Motion Architect or in the 6000 DOS Support Disk (refer to

the

Motion Architect User Guide or the 6000 DOS Support Disk Quick

Reference if necessary). You could also use your own terminal emulator package.

Press the RETURN key. The cursor should move down one or two lines each time you press the RETURN key. If the cursor does not move as described, refer to the RS-232C troubleshooting procedures in Chapter 9, Troubleshooting.

➁

Getting Started

C H A P T E R ➂

The information in this chapter will enable you to:

❏ Mount all system components properly ❏ Connect all inputs and outputs properly ❏ Verify that the complete system is installed properly

To ensure proper installation, you should perform all the bench test procedures in Chapter 2, Getting Started,

Installation Precautions

To help ensure personal safety and long life of system components, pay special attention to the following installation precautions.

Always remove power to the 6250 before performing wiring installation or changing DIP switch settings.

Installation

before proceeding with the permanent installation process in this chapter.

WARNING

Heat & Humidity

Operate the 6250 system at an ambient temperature between 32° and 122°F (0° to 50°C). Keep the relative humidity below 95%.

Electrical Noise

Minimize the potential for electrical noise before installing the 6250, rather than attempting to solve such problems after installation. You can prevent electrical noise by observing the following installation precautions:

For more information

on electrical noise,

refer to Appendix A.

❏ Do not route high-voltage wires and low-level signals in the same conduit. ❏ Ensure that all components are properly grounded. ❏ Ensure that all wiring is properly shielded.

➂

Installation

Airborne Contaminants

Contaminants that may come in contact with the 6250 should be carefully controlled. Particulate contaminants, especially electrically conductive material such as metal shavings, can damage the 6250.

Follow Installation Procedure

To ensure proper installation of the 6250 system, this chapter is organized in logical, linear steps. Deviating from this prescribed format may result in system problems.

➀ Mount the 6250 Servo Controller ➁ Perform system connections ➂ Perform the system test

➀ Mount the 6250

The 6250 should be installed in an enclosure that will protect it from atmospheric contaminants such as oil, metal, moisture, and dirt. Refer to the National Electrical Manufacturers Association (NEMA) specifications that pertain to your particular operating environment. The drawing below illustrates the 6250's dimensions.

4.20 (106.68)

inches (millimeters)

9.61 (244.10)

0.80 (20.32)

2.70 (68.58) 0.75 (19.05)

Provision for #10 Mounting Screws

(4 Plcs.)

10.00

(254.00)

10.80

(274.32)

11.60

(294.64)

0.60 (15.25)

Panel Layout

If you mount the 6250 in an enclosure with other equipment, be sure to maintain at least 2 inches of unrestricted air-flow space around the chassis. The maximum allowable ambient temperature directly below the 6250 is 122°F (50°C). Fan cooling may be necessary if adequate air flow is not provided.

➁ System Connections

6250 Servo Controller User Guide

This section describes procedures for the following 6250 system connections:

❏ Motor Drivers ❏ End-of-travel and home limits ❏ Encoders ❏ Auxiliary +5VDC output ❏ Output pull-up ( ❏ Programmable inputs and outputs (including auxiliary outputs ❏ Trigger inputs ( ❏ RP240 Front Panel ❏ Joystick and analog inputs ❏ ANI analog inputs (6250-ANI option only) ❏ Extending cables

Refer to the bench test procedures in Chapter 2 for the following connections:

❏ Power ❏ RS-232C communications

Refer to Chapter 5 for connection procedures on the following:

❏ PLC ❏ Thumbwheels ❏ RS-232C daisy-chain

Refer to Chapter 8, drawings and signal descriptions.

Motor Driver Connections

OUT-P)

TRG-A and TRG-B)

Hardware Reference

OUT-A and OUT-B)

NOTE

, for system specifications and detailed I/O circuit

Before you connect the drives to the 6250, configure your drives and connect the motors according to the user documentation for your drives.

CAUTION

Before connecting to your Motor/Drive system, be sure that power is not applied to the 6250.

The 6250 provides a standard ±10V analog control signal for use with any servo drive. The following table lists the 6250's motor driver connector pin outs; with this information you can connect the drives to the 6250's 9-pin screw terminal connectors as illustrated below. I/O circuit drawings are provided in Chapter 8, Hardware Reference.

Pin # Name In/Out Description

1 SHLD ----- Shield—internally connect to chassis (earth) ground. 2 COM ----- Signal common for shutdown. 3 SHTNC OUT Shutdown relay output to drives that require a closed contact to disable the drive.

4 SHTNO OUT Shutdown relay output to drives that require an open contact to disable the drive.

5 DFT IN Drive fault input. Set active level with the DRFLVL command. 6 AGND ----- Analog ground. 7 ANI IN ±10V, 14-Bit analog input (available only with the 6250-ANI option). 8 CMD- OUT Command signal return.

9 CMD+ OUT Command output signal (±10V signal).

The shutdown relay is active (disabling the drive) when no power is applied to the 6250. When the 6250 is powered up, the shutdown relay remains active until you issue the DRIVE11 command. Shutdown active (DRIVEØØ): this output is internally connected to COM. Shutdown inactive (DRIVE11): this output is disconnected from COM.

The shutdown relay is active (disabling the drive) when no power is applied to the 6250. When the 6250 is powered up, the shutdown relay remains active until you issue the DRIVE11 command. Shutdown active (DRIVEØØ): this output is disconnected from COM. Shutdown inactive (DRIVE11): this output is internally connected to COM.

➂

Installation

<<WARNING>> SAFETY FIRST <<WARNING>>

If your drive does not have a shutdown input, install a manual emergency-stop switch for the drive's power supply.

Connections to Compumotor and Digiplan Servo Drives

APEX Series Drive

A+ (pin 13) A– (pin 14)

SRVON (pin 23)

Voc (pin 24)

B+ (pin 29) B– (pin 30) Z+ (pin 43)

Z– (pin 44)

VIN (pin 49)

AGND (pin 50)

NOTE:

Apex Series A+ connected to 6250’s A– Apex Series A– connected to 6250’s A+

↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔

6250

A– A+ SHTNO +5V B+ B– Z+ Z– CMD+ CMD–

APEX Series

Reset

Gnd

Vel Int Enable

Enable In

Fault Out

Gnd Command+ Command–

Tach Output

Gnd

+15V

Gnd

-15V

CHA+ CHA– CHB+ CHB– CHZ+ CHZ–

Gnd

Drive

6250

ENCODER 1DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMDCMD+

+5V A+ A– B+ B– Z+ Z– GND SHLD

GND (pin 4)

RST (pin 5)

+15V (pin 6)

AOP (pin 10) AOP (pin 11) BOP (pin 12) BOP (pin 13) ZOP (pin 14) ZOP (pin 15)

BL Drive

V2 (pin 1) V1 (pin 2)

FT (pin 9)

↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔

6250

CMD– CMD+ GND COM SHTNO DFT A– A+ B+ B– Z+ Z–

NOTE: These connections will work only if BL jumper LK2 is set to position B (not the factory default position).

6250 Servo Controller User Guide

BL Drive

User I/O Connector

815

6250

DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMD– CMD+

ENCODER 1

+5V A+ A– B+ B– Z+ Z–

GND SHLD

Dynaserv Drive

A+ (pin 13) A– (pin 14)

SRVON (pin 23)

Voc (pin 24)

B+ (pin 29) B– (pin 30) Z+ (pin 43)

Z– (pin 44)

VIN (pin 49)

AGND (pin 50)

NOTE:

Dynaserv A+ connected to 6250’s A– Dynaserv A– connected to 6250’s A+

↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔

6250

A– A+ SHTNO +5V B+ B– Z+ Z– CMD+ CMD–

Dynaserv Drive

(50-pin Honda Connector)

DN1

6250

DRIVE 1 ENCODER 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMDCMD+

+5V A+ AB+ BZ+ ZGND SHLD

OEM670 Drive

CMD+ (pin 1) CMD– (pin 2)

FAULT (pin 9)

ENABLE (pin 10)

GND (pin 11) GND (pin 16)

UD2 & UD5 Drives

+15V, LSW1 & LSW2

VEL2 VEL1

FAULT

EXT.DIS

↔ ↔ ↔ ↔ ↔ ↔

6250

CMD+ CMD– DFT SHTNO COM AGND

↔ ↔ ↔ ↔ ↔ ↔

6250

SHTNO CMD– CMD+ AGND DFT COM

NOTE: These connections will work only if UD2/5 jumper LK1 is set to the 0V position (not the factory default position).

OEM670

6250

Drive

UD2 & UD5 Drives

(UR3, UR4 or UR8 Rack)

PL9

18V AC

+15V

–15V

RESET

READY

PSU FAULT

If a drive fault occurs, you must cycle power to the drives, unless you control RESET (PL9 pin 8 on UR4 & UR8 racks, PL4 pin 8 on UR3 rack) with one of the 6250’s general-purpose outputs. For additional instructions on detecting and reacting to UD rack faults, contact the Compumotor or Digiplan Applications Department.

DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI

CMD– CMD+

6250

PLB

G2 VEL2 VEL1

SCREEN

FAULT

EXT.DIS

LSW1 LSW2

DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMD– CMD+

➂

Installation

UD12 Drive

+15V, LSW & LSW2

VEL2 VEL1

FAULT

EXT.DIS

↔ ↔ ↔ ↔ ↔ ↔

6250

SHTNO CMD– CMD+ AGND DFT SHLD

NOTE: These connections will work only if UD12 jumper LK3 is set to position A (not the factory default position).

UD12 Drive

6250

(UR4 Rack)

PL9A

18V AC 0V 18V AC +15V 0V –15V 0V RESET READY PSU FAULT

G1 G2 VEL2 VEL1 SCREEN 0V FAULT EXT.DIS LSW1 LSW2

PLnC

DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMD– CMD+

If a drive fault occurs, you must cycle power to the drives, unless you control RESET (pin 8 on the PL9 connector) with one of the 6250's general-purpose outputs. For additional instructions on detecting and reacting to UD rack faults, contact the Compumotor or Digiplan Applications Department.

Z Drive

ENABLE+ ENABLE–

GND

GND CHA+ CHA– CHB+ CHB–

CHZ+ CHZ–

ANALOG+

ANALOG–

Indexer Connector

DRIVE FAULT (pin 9)

NOTE:

Z Drive CHA+ connected to 6250’s A– Z Drive CHA– connected to 6250’s A+

↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔ ↔

↔

6250

SHTNO COM AGND GND A– A+ B+ B– Z+ Z– CMD+ CMD–

DFT

Z Drive

I/O [1]

ENABLE+ ENABLE–

RTI+

RTI– RTO+ RTO–

GND

Tx Rx

GND CHA+ CHA– CHB+ CHB– CHZ+ CHZ–

ANALOG+ ANALOG–

INDEXER CONNECTOR

6250

ENCODER 1DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMDCMD+

To 6250 Logic Gnd To 6250 Programmable Output

Pin #7 and #19 are FAULT RESET+ and FAULT RESET– respectively. These connections are required if you need to clear a drive fault via the 6250. Activate the output for no longer than 140ms. If you choose not to make these connections, you will have to manually reset the Z Drive anytime a drive fault occurs.

+5V A+ A– B+ B– Z+ Z– GND SHLD

6250 Servo Controller User Guide

End-of-Travel Limit Connections

The 6250 provides CCW and CW end-of-travel limit inputs for both axes via the LIM 1/2 connector. End-of-travel inputs serve as safety stops that prevent the load from crashing into mechanical stops and damaging equipment or injuring personnel. The drawing below illustrates typical end-of-travel limit switch connections.

End-of-Travel Limits

LIM 1/2

1CW 1CCW 1HOM GND 2CW

Normally-closed switches*

2CCW 2HOM

* LHLVL command changes

GND

active level of switches

SHLD

NOTE

Motion will not occur until you do one of the following:

❏ Install limit switches ❏ Disable the limits with the LH command ❏ Change the active level of the limits with the

LHLVL command

Use of hardware

(and software) end-

of-travel limits is

discussed in detail in

the

End-of-Travel

Limits

section in Chapter 5.

Mount normally-closed switches such that the load forces them to open before it reaches the physical travel limit (leave enough room for the load to stop). When the load opens the limit switch, the motor comes to a halt. The actual stopping distance depends on motor speed and the Hard Limit Deceleration (LHADA and/or LHAD) setting. The motor will not be able to move in that same direction until you clear the limit (close the switch) and execute a

move in the opposite direction (or you can disable the limits with the LH command, but this is recommended only if the motor is not coupled to the load). Use the TLIM or TAS commands to check the status of the limit switches.

<< CAUTION >> RUNAWAY << CAUTION >>

If a

runaway

instability), the 6250 will shut down the drive if the maximum encoder position error (set with the SMPER command) is exceeded before an end-of-travel limit (either hardware of software) is

encountered. However, if the maximum encoder position error is not exceeded by the time the limit is encountered, the 6250 may not be able to stop the motor.

Home Limit Connections

Use the Home input to establish a home position or zero position reference point. The home input (TTL compatible) is used for homing the motor. The encoder's Z channel pulse can be used in conjunction with the home switch to determine the home position. To use the encoder's Z channel, the HOMZ command must be enabled.

Homing is discussed

in detail in the

Homing

section in Chapter 5.

The 6250 is shipped configured for use with normally-open home switches. You can, if you wish, reverse the home input polarity (to use normally-closed switches) with the HOMLVL command. The most common way to use the home switch is to mount it at a home reference position. The drawing below illustrates typical home limit switch connections to the 6250.

LIM 1/2

1CW 1CCW 1HOM GND 2CW 2CCW 2HOM GND SHLD

occurs (motor starts moving, usually at the fastest possible velocity, due to servo

Home Limit

CAUTION

Compumotor cannot guarantee proper homing performance with the home and end-of-travel limit inputs tied together.

Normally-open switch* * HOMLVL command changes

active level of switch

➂

Installation

Encoder Connections

The 6250 supports up to two incremental encoders. If you use encoders other than those supplied by Compumotor, pay special attention to the following requirements:

❏ Use incremental encoders with two-phase quadrature output. An index or Z channel output is ❏ It must be a 5V encoder to use the 6250's

The illustration below shows the wiring techniques that you must use to connect encoders to the 6250. Refer to Chapter 8 for the 6250's encoder input circuit drawing. If you are using the BL or Dynaserv drives, refer to the connection illustrations earlier in the Motor Driver Connections section.

optional. Differential outputs are recommended.

+5V output. Otherwise, it must be separately powered,

with TTL-compatible or open-collector outputs.

ENCODER 1 ENCODER 2

Encoder Connector Pin

+5V A+ AB+ BZ+ ZGND SHLD

If you are using a single-ended encoder leave the 6250's A-, B-, and Z- terminals not connected.

Each axis has a 9-pin Phoenix connector for incremental encoder connections. The pin-out description for the ENCODER connectors is provided below.

+5V A+ AB+ BZ+ ZGND SHLD

Outs

Pin In/Out Name Compumotor E Series

9 OUT +5V Red +5VDC output to power the encoder 8 IN A Channel + Brown A+ channel quadrature signal from encoder 7 IN A Channel - Brown/White A- channel quadrature signal from encoder 6 IN B Channel + Green B+ channel quadrature signal from encoder 5 IN B Channel - Green/White B- channel quadrature signal from encoder 4 IN Z Channel + Orange Z+ channel quadrature signal from encoder 3 IN Z Channel - Orange/White Z- channel quadrature signal from encoder 2 ----- Ground Black Isolated logic ground 1 ----- Shield Shield Internally connected to chassis ground (earth)

Auxiliary +5V Output Connection

The 6250 provides +5VDC output on the AUX, ENCODER, and RP240 connectors. As much as

1.8A is available. 1.8A is sufficient power for the total load on all the I/O connectors. For example, using two encoders (each drawing 250mA) and one RP240 (drawing 100mA), 1.2A would be left for other purposes. The drawing below illustrates example connections for powering the output pull-up.

+5VDC A Channel + A Channel B Channel + B Channel Z Channel + Z Channel Ground Shield

Note for Using Single-Ended Encoders

Encoder Cable Colors

Incremental

Encoder

Description

Output and Input Pull-up Connections

OUT-P (output pull-up) and IN-P (input

pull-up), located on the AUX connector, provide power to the outputs and inputs. The 6250 is shipped from the factory with OUT-P and IN-P connected to +5V to power the outputs and inputs (see illustration at right).

6250 Servo Controller User Guide

+5V supplies power to OUT-P and IN-P. This provides power to the output and input pull-ups. (As an alternative, you can connect OUT-P and IN-P to an external power source of up to 24V.)

If this switch is opened, the 6250's analog command output signal is held to zero volts (independent of the DSP and microprocessor).

Normally-closed

switch

AUX

Rx Tx GND SHLD +5V OUT-P IN-P

TRG-A TRG-B GND OUT-A OUT-B GND ENBL

Enable Input Connection

The ENBL (enable) input is located on the AUX connector. The 6250 is shipped with ENBL wired to GND (see drawing) to allow motor motion.

See the illustration above for an example connection using a normally-closed switch. Opening the switch sets the ±10V analog command output to zero volts and activates the shutdown outputs; this is done independent of microprocessor and DSP control. The encoder's position is retained when the ENBL input is activated. If the ENBL input is not grounded when motion is commanded, the error message WARNING: ENABLE INPUT INACTIVE will be displayed.

If error bit #9 of the ERROR command is enabled, the error program (ERRORP) will be executed. You can check the status of the ENBL input with the TINO, INO, TER and ER commands.

Programmable Inputs & Outputs Connections

The PROGRAMMABLE INPUTS connector provides 24 programmable inputs and the

PROGRAMMABLE OUTPUTS connector provides 24 programmable outputs. Two additional (and

functionally identical) programmable outputs, OUT-A and OUT-B, are available on the AUX connector. Two additional trigger (position latch) inputs are also available on the AUX connector, but due to their functional differences they are discussed later in the Triggers section. All these inputs and outputs are optically isolated and TTL compatible.

All 26 programmable outputs are pulled up using the OUT-P pin on the AUX connector (see illustration above). The 6250 is factory wired for +5VDC logic. If +5VDC is not to be used, disconnect OUT-P from the +5V terminal and connect OUT-P to an external supply of up to 24V. Note: Even if you use an external 24V supply the switching thresholds remain TTL compatible ( ≤ 0.4V = Low, ≥ 2.4 V = High).

Change inputs from

sourcing to sinking.

Programmable I/O Pin Outs

All 24 programmable inputs are pulled up to +5V by connecting the IN-P terminal to the +5V terminal on the AUX connector. If you wish to have the inputs sink current instead of source current, you can connect IN-P to GND. For compatibility with equipment operating at 24VDC, the inputs may be pulled up to 24VDC by using an external power supply. The trigger inputs (TRG-A & TRG-B) are internally tied to 5V, but can have up to 24V connected to them.

These I/O are typically used with normally-open or normally-closed switches; however, they can also be used with I/O module racks, PLCs, and thumbwheels (including the Compumotor TM8).

If you are using PLCs or thumbwheels, refer to the connection instructions and application considerations provided in the Programmable Inputs and Outputs section of Chapter 5.

Also provided in the Programmable Inputs and Outputs section are instructions for defining and controlling programmable inputs and outputs via programs written with the 6000 Series programming language.

The following table lists the pin outs on the two 50-pin flat cable headers labeled

PROGRAMMABLE INPUTS and PROGRAMMABLE OUTPUTS. Refer to Chapter 8, Hardware

Reference, for internal I/O schematics.

PROGRAMMABLE INPUTS Connector PROGRAMMABLE OUTPUTS Connector

Pin # Function Pin # Function Pin # Function Pin # Function

49 +5 VDC 23 Input #13 49 +5 VDC 23 Output #13 4 7 Input #1 (LSB) 21 Input #14 47 Output #1 (LSB) 2 1 Output #14 45 Input #2 19 Input #15 4 5 Output #2 19 Output #15 43 Input #3 17 Input #16 4 3 Output #3 17 Output #16 41 Input #4 15 Input #17 4 1 Output #4 15 Output #17 39 Input #5 13 Input #18 3 9 Output #5 13 Output #18 37 Input #6 11 Input #19 3 7 Output #6 11 Output #19 35 Input #7 09 Input #20 3 5 Output #7 09 Output #20 33 Input #8 07 Input #21 3 3 Output #8 07 Output #21 31 Input #9 05 Input #22 3 1 Output #9 05 Output #22 29 Input #10 03 Input #23 2 9 Output #10 03 Output #23

➂

Installation

Optional VM50 Adaptor

27 Input #11 01 Input #24 (MSB) 27 Output #11 01 Output #24 (MSB) 25 Input #12 25 Output #12

NOTE: All even-numbered pins are connected to logic ground (DC ground).

If you wish to use screw terminal connections for the 24 programmable I/O, Compumotor offers the VM50 adaptor (p/n VM50). If you wish to use screw terminal connections for both the 24 inputs and the 24 outputs, you will need two VM50 adaptors.

The pin numbers on the VM50's screw terminals correspond to the same pin outs on the

PROGRAMMABLE INPUTS and PROGRAMMABLE OUTPUTS connectors. The VM50 simply

attaches to the 6250 via the 2-foot, 50-pin ribbon cable that comes with the VM50 (see drawing below).

To order the VM50, contact your distributor or ATC, or call Compumotor at (800) 722-2282.

6250

Programmable I/O

Connectors

2-Foot Cable

(provided with VM50)

VM50 snaps on to any

standard DIN Rail

Trigger Input Connections

The 6250 provides two trigger (position latch) inputs. Like the programmable inputs described earlier, trigger inputs can be connected to PLC outputs, discrete switches, or electronic sensors, and are monitored under program control. The status of triggers A and B is represented respectively by bits 25 and 26 in the [IN], INFNC, INLVL, ONIN, and TIN commands.

Using the WAIT command, the 6250 can be programmed to wait until one or more inputs switch to a desired state before executing the next command.

Normally-open switches *

* The INLVL command changes the active level of inputs.

2 4 6 8 10 12 14 16 18 20

1 3 5 7 9 11 13 15 17 19

VM50 Adaptor Board

22 24 26232825302732293431363338354037423944414643484550

47 4921

AUX

Rx Tx GND SHLD +5V OUT-P IN-P

TRG-A TRG-B GND OUT-A OUT-B GND ENBL

Position Latch

Feature

The trigger inputs function identically to the regular 24 programmable inputs, except when they are programmed with the Trigger Interrupt Function (INFNCi-H) command to function as position latch inputs.

When configured as position latch inputs, the input enable/disable (INEN) command has no effect on the trigger inputs. Note: The position latch feature is discussed in the Programmable Inputs and Outputs section in Chapter 5)

6250 Servo Controller User Guide

RP240 Front Panel Connections (RP240 is optional)

Using a four-wire shielded cable, connect the RP240 to the 6250's RP240 connector (see below). For cable lengths up to 50 feet, use 20 AWG wire (cable lengths longer than 50 feet are not recommended). Refer to the RP240 User Guide for mounting instructions.

NOTE

For the 6250 to recognize the RP240, the RP240 connection must be made prior to powering up (or resetting) the 6250. If you connect the RP240 to the 6250 before powering up the 6250, the

6250 will recognize the RP240 and send the *RP24Ø CONNECTED message to the RS-232C terminal. If the 6250 does not detect a RP240 upon power up or reset, then the following message will be sent to the RS-232C terminal: *NO REMOTE PANEL.

Connector on back panel

of RP240

GND Rx Tx +5V

Connector on

RP240

+5V GND Rx Tx SHLD

Joystick and Analog Input Connections

You can use the three analog inputs on the JOYSTICK connector for 2-axis joystick control of the axes, and/or as a low-resolution analog input (8-bit A/D, 1mV/bit) for process control.

The Daedal JS6000 joystick is compatible with the Compumotor 6250. To order the JS6000, contact Daedal at (800) 245-6903 or contact your local distributor.

Refer to Chapter 5

for a detailed

discussion of joystick

control.

Joystick Connector Pin Outs

Pin In/Out Name Description

1 IN Analog Channel 1 8-bit analog input for joystick control of axis (can override with the ANVOEN and ANVO commands) 2 IN Analog Channel 2 8-bit analog input for joystick control of axis (can override with the ANVOEN and ANVO commands) 3 IN Analog Channel 3 8-bit analog input for joystick control of axis (can override with the ANVOEN and ANVO commands) 4 — Unused --------------8 — Shield Shield 14 — Ground Ground 15 IN Axes Select If only using one analog input, you can use this input to alternately control axes 1 or 2 1 6 IN Velocity Select

1 7 IN Joystick Release Input to release the 6250 from joystick mode (JOY). Same as issuing the !JOYØØ command. 18 IN Joystick Trigger Status of t hi s active-low input can be read by a program (using the INO or TINO commands) to 19 IN Joystick Auxiliary Stat u s o f th i s active-low input can be read by a program (using the INO or TINO commands) to 23 OUT +5VDC (out) +5V DC power output

The input range of the analog input is 0V to 2.5V. A joystick with a linear taper 5KΩ potentiometer (pot) with 60° of travel is recommended (the pot has 300° of travel, but typically only 60° is usable with a joystick). The pot should be adjusted so that its resistance is close to 0Ω when the joystick is all the way to one side, and about 1KΩ when the joystick is all the way to the other side. Also, connect a 1KΩ resistor between the analog input and +5V.

The JOYSTICK connector is a 25-pin D connector. The pin-out descriptions are provided in the table below. The 6250's internal analog input circuit diagram is provided in Chapter 8, Hardware Reference.

Input to select high or low velocity range (as defined with JOYVH or JOYVL command) Program execution will continue with the first statement after the joystick enable (JOY1) command. control program flow, or to enter the 6250 into joystick mode. control program flow, or to teach positions to a program.

➂

Installation

Analog Inputs

You can use the analog inputs for joystick control of the axes. An analog input can command an axis velocity from full CW to full CCW. The following drawing illustrates a typical joystick connection example.

Joystick potentiometers are 5KΩ with 60° of

usable travel adjusted to span

0Ω to 1KΩ.

The 1KΩ resistors for velocity select,

axes select, joystick trigger, & joystick auxiliary are for noise suppression only.

1KΩ Resistors

Joystick

X Axis

5KΩ

Y Axis

5KΩ

Axes Select Input

Velocity Select Input

Joystick Release Input

Joystick Trigger Input

Joystick Auxiliary Input

1 2

J O

Y S

I C

19 14

SHLD

+5VDC Analog Channel 1 Analog Channel 2

Velocity Select

Axes

Select

Joystick

Release

Joystick Trigger

Joystick Auxiliary

GND

N.C. Momentary Joystick Release

Velocity Select

Axes Select N.O. Momentary

Joystick Trigger Joystick Aux.

You can define two configurations (JOYAXH and JOYAXL) that define which axes are controlled by which channels. The axes select input allows you to select the current configuration. An axes select input high references the JOYAXH command. An axes select input low references the JOYAXL command.

One possible configuration is as follows: With axes select input high, analog channel #1 controls axis one and analog channel #2 controls axis two (JOYAXH1,2). With axes select input low, analog channel #3 controls both axes (JOYAXL3,3).

This input may be used to select either the high (high level-on input) or low (low level-on input) velocity range as defined with the JOYVH and JOYVL commands, respectively. The high range could be used to quickly move to a location while the low range could be used for accurate positioning. Refer to the illustration above. When this input is not connected, the

low velocity range is selected.

The joystick release input allows you to indicate to the 6250 that you have finished using the joystick and program execution may continue with the next statement. When a program enables joystick control of motion, program execution will stop and then resume when the user is finished with joystick mode (assuming the Continuous Command Execution Mode is disabled with the COMEXCØ command).

The joystick release input has an internal pull-up resistor to +5V. When the joystick release input is not grounded, joystick enable statements (JOY1) will be disabled upon execution. To enable the joystick mode, the joystick release input must be inactive (connected to ground). Refer to the illustration above.

The status of this input can be read by a program and may be used to control program flow (see INO and TINO command). Refer to the illustration above.

ANI Analog Input Connections (6250-ANI Option Only)

The 6250-ANI option offers two ±10V, 14-bit analog inputs (one ANI terminal found on each of the DRIVE connectors).

☞

Application

considerations are

discussed in Chapter 5.

6250 Servo Controller User Guide

These inputs are sampled at the servo sample rate (set with the SSFR command). The ANI input values are reported with the TANI and [ANI] commands.

±10V Analog Input Source

Ground

Signal Source

DRIVE 1

SHLD COM SHTNC SHTNO DFT AGND ANI CMDCMD+

Extending 6250 System Cables

This section describes options for extending 6250 system drive, encoder, and I/O cables. If you wish to order longer cables, contact Compumotor's Customer Service Department at (800) 722-2282 or contact your local Compumotor Distributor or ATC.

6250-to-Encoder Cables

Compumotor E Series encoders are supplied with a permanently attached 10-foot cable. The maximum cable length between Compumotor encoders and the 6250 is 100 feet. If you wish to lengthen the encoder cable yourself, use 24 AWG wire. Encoder cables should be shielded with the shield connected to SHLD (pin 1 on the ENCODER connector).

You can also order encoders through Compumotor's Custom Products Group with the exact cable length you want.

I/O Cables

To avoid interference from external noise, you must shield all I/O cables, regardless of the length. The maximum length of cables is determined by the environment in which the equipment will be used. For cables longer than 50 feet or in electrically noisy environments, you should follow the guidelines below (refer also to illustration below).

❏ 22 AWG wire is the minimum recommended wire size. ❏ Use twisted pair shielded cables and connect the shield to the

connector. Leave the other end of the shield disconnected.

❏ Do not route these signals in the same conduit or wiring trays as high-voltage AC wiring. ❏ Limit and trigger inputs are internally pulled up to +5VDC and are TTL compatible. In

electrically noisy environments or when using long cable lengths, use an external pull-up resistor with a value of 330Ω to 2.2KΩ between the input and +5V. The external resistor will lower the input impedance and will make the input less susceptible to electrical noise.

6250

Limit or Trigger

SHLD terminal on the 6250

470Ω

Input Switch

GND

Shield

➂ Installation Verification

This installation verification section is intended to be executed with the drive not connected to the 6250. Do not proceed until you are sure the drive is not connected.

➀ Return to the Test Procedure in Chapter 2 to test the drive/motor interface and the RS-232C

interface.

➁ Use the information in the following table to test the features appropriate to your application.

If you receive responses other than those expected, check your system wiring and refer to the command description in the

Long Cable

WARNING

6000 Series Software Reference Guide for assistance.

➂

Installation

NOTE

The following table is based on the assumption that you have not changed the active levels of the 6250's inputs and outputs. Verify these settings with the following

Command Entered Response Should Be

INLVL *INLVLØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØ HOMLVL *HOMLVLØØ LHLVL *LHLVLØØØØ OUTLVL *OUTLVLØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØ

Connections Test Procedure Response Format (left to right)

End-of-travel and Home limits

NOTE: If you are not using end-of-travel limits, issue the Disable Limits (LHØ,Ø) command

and ignore the first two bits in each response field.

➀ Close the end-of-travel switches and open the home switches. ➁ Enter the TLIM command. The response should be *TLIM11Ø_11Ø. ➂ Open the end-of-travel switches and close the home switches. ➃ Enter the TLIM command. The response should be *TLIMØØ1_ØØ1. ➄ Close the CW end-of-travel switch on axis 1 and open the home switch on axis 2. ➅ Enter the TLIM command. The response should be *TLIM1Ø1_ØØØ.

Analog Output Signal

➀ If the drives are connected to the 6250's DRIVE connectors, disconnect them now. ➁ Set all the gains to zero by entering the following: SGPØ,Ø, SGIØ,Ø, SGVØ,Ø,

SGAFØ,Ø, SGVFØ,Ø

➂ Enable the 6250 to send out the analog command by entering the DRIVE11 command. ➃ Set the DAC output limit to 10 volts by entering the DACLIM1Ø,1Ø command. ➄ Drive the analog output to the maximum positive range by entering the SOFFS1Ø,1Ø

command.

➅ Enter the TDAC command to check the analog output value. The response should be

*TDAC+1Ø,1Ø.

➆ Using a Digital Volt Meter (DVM), measure the actual analog output voltage between the

CMD+ (analog command) and CMD- (analog command return) terminals. Compare the DVM reading to the entry for the SOFFS command (see step 5). With SOFFS1Ø, the DVM should read between +9.995V and +10.005V in a properly grounded and noise-free environment. If the reading deviates more than 0.1V from +10V, then there is either a problem with the system's grounding connection or the 6250's DAC is not functioning properly.

➇ Repeat steps 5 through 7, using these servo output offset values:

SOFFS-1Ø,-1Ø SOFFSØ,Ø SOFFS.ØØ5,.ØØ5

Encoder Feedback

SOFFS-.ØØ5-.ØØ5.

➀ Enter the PSETØ,Ø command to set the commanded motor position on both axes to zero. ➁ Enter the TPE command to determine the actual motor position. The response should be

close to *TPE+Ø,+Ø (both motors at or about position zero).

➂ Enter the TPC command to determine the commanded motor position. The response

should be *TPC+Ø,+Ø (both motors at position zero).

➃ Enter the TPER command to determine the position error between the commanded position

(TPC) and the actual position (TPE). The response should be close to *TPER+Ø,+Ø.

➄ Rotate encoders 1 rev: If the encoders are not coupled to the motors, manually rotate both

encoders approximately one revolution in the clockwise direction. If the encoders are coupled to the motors, manually rotate both motors approximately one revolution.

➅ Enter the TPE command to determine the actual motor position. The response should be

close to *TPE+4ØØØ,+4ØØØ (That is the response if the encoder resolution is 4000 counts/rev and you have not changed the default resolution settings—the 6250's default resolution is 4000, which is set with the ERES command. If your encoder's resolution is not 4000 counts/rev, enter its resolution with the ERES command).

➆ Enter the TPER command. The response should be close to *TPER-4ØØØ,-4ØØØ

(4000-count position error), which is the difference between the commanded position (TPC)

Programmable Inputs (incl. triggers)

and the actual position (TPE).

➀ Open the input switches or turn off the device driving the inputs. ➁ Enter the TIN command.

The response should be *TINØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØ.

➂ Close the input switches or turn on the device driving the inputs. ➃ Enter the TIN command.

Programmable Outputs

The response should be *TIN1111_1111_1111_1111_1111_1111_11.

➀ CAUTION: Disconnect all programmable outputs before proceeding to step ➁. ➁ Enter the OUTALL1,26,1 command to turn on (sink current on) all outputs. ➂ Enter the TOUT command.

The response should be *TOUT1111_1111_1111_1111_1111_1111_11.

➃ Enter the OUTALL1,26,Ø command to turn off all outputs. ➄ Enter the TOUT command.

The response should be *TOUTØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØØØ_ØØ.

status

commands:

TLIM response: bit 1 = axis 1 CW limit bit 2 = axis 1 CCW limit bit 3 = axis 1 home limit bit 4 = axis 2 CW limit bit 5 = axis 2 CCW limit bit 6 = axis 2 home limit

TDAC response  (output voltage): ±axis 1, ±axis 2

TPER response (encoder counts): ±encoder 1, ±encoder 2

TPE response (motor counts): ±encoder 1, ±encoder 2

TPC response (commanded pos.): ±axis 1, ±axis 2

TIN response: bits 1-24 = prog. inputs 1 - 24 bits 25 & 26 = TRG-A & TRG-B

TOUT response: bits 1-24 = prog. outputs 1 - 24 bits 25 & 26 = OUT-A & OUT-B

6250 Servo Controller User Guide

Installation Verification (cont.)

RP240

Joystick inputs

➀ Cycle power to the 6250. ➁ If the RP240 is connected properly, the RP240's status LED should be green and one of the

messages on the computer or terminal display should read *RP24Ø CONNECTED. If the RP240's status LED is off, check to make sure the +5V connection is secure. If the RP240's status LED is green, but the message on the terminal reads *NO REMOTE

PANEL, the RP240 Rx and Tx lines are probably switched. Remove power and correct.

➂ Assuming you have not written a program to manipulate the RP240 display, the RP240

screen should display the following:

COMPUMOTOR 6250 SERVO CONTROLLER RUN JOG STATUS DRIVE DISPLAY ETC

➀ Open the joystick input switches or turn off the device driving the inputs. ➁ Enter the TINO command.

The response should be *TINOØØØØ_Ø1ØØ.

➂ Close the input switches or turn on the device driving the inputs. ➃ Enter the TINO command.

The response should be *TINO1111_11ØØ.

➃ What's Next?

At this point you should have successfully completed this chapter's mounting, connection, and test procedures for your 6250 system. If you intend to use thumbwheels or PLCs, or if you intend to daisy-chain multiple 6250s, refer to the connection instructions and application considerations provided in Chapter 5.

The following steps are recommended to prepare you for applying the 6250 in your application.

Step ➀ Couple the Load

Couple the motor to the load, and couple the encoder to the motor (or load, as appropriate).

Step ➁ Perform the Basic System Configuration

The set-up commands referred to in this step are not saved in the 6250's batterybacked RAM. Therefore, we suggest you add them to the startup (STARTP) program. For information in defining the startup program, refer to

Power Up

in Chapter 7,

Programming Tips

TINO response:

bit 1 = joystick auxiliary bit 2 = joystick trigger bit 3 = joystick axes select bit 4 = joystick velocity select bit 5 = joystick release bit 6 = Enable input bits 7 & 8 are not used

NOTE

Automatic Program Execution on

Number of Axes:

By configuring the number of axes in use, you limit the number of axes you can control. This may be desired if you are only using one of the two axes available. The INDAX command configures the number of axes. INDAX2 (the default setting) requires both command fields to be entered (e.g., A1,1). If you enter INDAX1, instead of entering A1,1 you should enter A1, and all responses from the 6250 will also only show the one field; if you enter the command A, the response will be *A1.

Drive Fault Level:

The drive fault level (DRFLVL) should be set to active high or active low for each axis (default is active low—DRFLVLØ). This output is active high (DRFLVL1) for the OEM670 and APEX series drives, and active low for the BL, UD2, UD5, and UD12 drives. If you are using the Dynaserv or any other drive that does not have a drive fault output, set the drive fault level to active low (DRFLVLØ).

NOTE

Once the drive fault level has been configured, you must enable the drive fault input with the INFEN command before the input is usable.

Encoder Resolution:

The encoder resolution is determined by the resolution of the encoder used with the servo drive/motor system. The encoder resolution is essentially the number of steps, or counts (post quadrature), per unit of travel. For example, Compumotor E Series encoders are 1,000-line encoders, and therefore have a 4,000 count/rev post-quadrature resolution.

➂

Installation

If the encoder is mounted directly to the motor, then to ensure that the motor will move according to the programmed distance and velocity, the 6250's resolution must match the encoder's resolution. Use the ERES command to set the 6250's resolution (default setting is 4,000 counts/rev, selectable range is 200 to 1,024,000).

NOTE

The programming examples throughout this user guide assume an encoder resolution of 4,000 counts post-quadrature (ERES4ØØØ,4ØØØ).

Kill's Effect on the Drive:

Normally, when you issue a Kill command (K, !K, or <ctrl>K) or activate a generalpurpose input configured as a kill input (see INFNCi-C command), motion is stopped at the hard limit (LHAD/LHADA) deceleration setting and the drive is left in the enabled state (DRIVE11).

However, your application may require you to disable (shut down or de-energize) the drive in a Kill situation to, for example, prevent damage to the motor or other system mechanical components. If so, set the 6250 to the Disable Drive on Kill mode with the KDRIVE1 command. In this mode, a kill command or kill input will shut down the drive immediately, letting the motor free wheel (without control from the drive) to a stop. When the drive is disabled (DRIVEØØ), the SHTNC relay output is connected to COM and the

SHTNO relay output is disconnected from COM. To re-enable the drive, issue the DRIVE11

command.

Step ➂ Determine Your Application's Motion Control Requirements

Applications can vary greatly from one to another. Consequently, the 6250 is equipped with many motion control features to satisfy a wide variety of application requirements—but not all features are appropriate for every application. Therefore, you must first determine the necessary motion features you need for your application. Once you have done that, you can proceed to Chapter 4 to tune the 6250, and Chapters 5 through 7 to find out how to implement the 6250's motion control features in your application.

Step ➃ Tune the Servo System (Chapter 4)

Chapter 4 describes the 6250's tuning options and how to implement them. To effectively tune the 6250, as well as the drives, we recommend using the interactive tuning

features in the Motion Architect® Servo Tuner option. It greatly improves your efficiency and gives you powerful graphical tools to measure the performance of the system. If you do not use Motion Architect, the only methods to monitor system performance are to use visual inspection (eyeballing it) or to use expensive lab equipment such as an oscilloscope.

NOTE

The Servo Tuner option is an add-on module and does not automatically come with the basic Motion Architect software package. To order your copy of the Motion Architect Servo Tuner, which is provided on a separate disk, contact your local Automation Technology Center.

Step ➄ Implement the Necessary 6250 Features (Chapters 5 - 7)

Chapters 5 through 7 describe how to implement the 6250's features in your application. You will develop your application by creating and refining motion programs using the 6000 Series

Command Language. We recommend you use Motion Architect® or the 6000 DOS Support Disk to aide in your programming efforts. Motion Architect and the 6000 DOS Support Disk are discussed briefly in Chapter 5, but for detailed user information refer to the Motion

Architect User Guide or the 6000 DOS Support Disk Quick Reference.

6250 Servo Controller User Guide

C H A P T E R ➃

In a Hurry?

We strongly recommend tuning the 6250 before attempting to execute any motion functions. If you must execute motion quickly (e.g., for testing purposes), you should at least complete the Tuning Setup Procedure and Drive and Controller Tuning Procedures (see pages 29 - 38)

until you have found a proportional feedback gain that can give a stable response for your system. Then you can proceed to execute your motion functions. Later on, you should read through this entire Servo Tuning chapter and follow its procedures to ensure your system is properly tuned.

Servo System Terminology

This section gives you with an overall understanding of the principles and the terminology used in tuning the Compumotor 6250 Servo Controller.

Servo Tuning

Servo Tuning Terminology

The 6250 uses a digital control algorithm to control and maintain the position and velocity. The digital control algorithm consists of a set of numerical equations used to periodically (once every servo sampling period) calculate the value of the control signal output. The numerical terms of the equations consist of the current commanded and actual position values (plus a few from the past sampling period) and a set of control parameters. Each control parameter, commonly called a gain, has a specific function (see Servo Control Techniques later in this chapter). Tuning is the process of selecting and adjusting these gains to achieve optimal servo performance.

When this control algorithm is used, the whole servo system is a closed loop system (see diagram below). It is called closed loop because the control algorithm accounts for both the command (position, velocity, tension, etc.) and the feedback data (from the encoder); therefore, it forms a closed loop of information flow.

➃

Servo Tuning

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Parker 6250 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual