Rockwell Automation 1756-HYD02 User Manual

Download

ControlLogix Hydraulic Servo Module

User Manual

Catalog Numbers

1756-HYD02

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

) describes some important differences between solid state equipment and hard-

WARNING

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

IMPORTANT

ATTENTION

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence

SHOCK HAZARD

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

Allen-Bradley, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Preface

What is the 1756-HYD02 Module?

Installing the 1756-HYD02 Module

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Who Should Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

The Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1

What the Module Does . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Using A ControlLogix Hydraulic Servo Module in the

ControlLogix System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Physical Features of the ControlLogix Hydraulic Servo Module . 10

Certifying Agency Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Full Class I Division 2 Compliance. . . . . . . . . . . . . . . . . . . . . . . . . 11

Preventing Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Removal and Insertion Under Power . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter Summary and What’s Next . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2

What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Note the Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Keying the Removable

Terminal Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Connecting Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Two Types of RTBs (each RTB comes with housing) . . . . . . . . . 16

Wiring the 1756-HYD02 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Wiring Registration Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wiring the Home Limit Switch Input. . . . . . . . . . . . . . . . . . . . . . . 20

Wiring the OK Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connecting LDTs to Your Hydraulic Module . . . . . . . . . . . . . . . . 21

Assembling The Removable Terminal Block and the Housing. . . . . . 23

Choosing the Extended-Depth Housing . . . . . . . . . . . . . . . . . . . . . . . 24

Suggestions for Using the Extended-Depth Housing . . . . . . . . . . 25

Cabinet Size Considerations With the

Extended-Depth Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installing the Removable Terminal Block. . . . . . . . . . . . . . . . . . . . . . . 26

Removing the Removable Terminal Block . . . . . . . . . . . . . . . . . . . . . . 28

Removing the Module from the Chassis. . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter Summary and What’s Next . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3Publication 1756-UM525A-EN-P - June 2003 3

Table of Contents

Configuring the 1756-HYD02 Module

Using the 1756-HYD02 Module Features

Chapter 3

Using RSLogix 5000 Configuration Software. . . . . . . . . . . . . . . . . . . . 31

Overview of the Configuration Process . . . . . . . . . . . . . . . . . . . . . . . . 32

Creating a New Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Configuring General Module Features . . . . . . . . . . . . . . . . . . . . . . . . . 35

Configuring the Axes Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Downloading New Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . 37

Editing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Reconfiguring Module Parameters in Run Mode . . . . . . . . . . . . . . . . . 39

Reconfiguring Module Parameters in Program Mode . . . . . . . . . . . . . 39

Chapter Summary and What’s Next . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Chapter 4

What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Using General Module Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Servo Update Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Module Fault Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fully Software Configurable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Electronic Keying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Using Axes Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Motion Planner Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Units Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Servo Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Feedback Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Conversion Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Homing Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Hookup Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Tune Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Dynamics Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Gains Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Output Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Limits Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Offset Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Fault Actions Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Tag Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Chapter Summary and What’s Next . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4 Publication 1756-UM525A-EN-P - June 2003

Troubleshooting the 1756-HYD02 Module

Specifications

Glossary

Table of Contents

Chapter 5

What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Using the Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Using the OK Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Using the FDBK Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Using the DRIVE Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Using RSLogix 5000 to Troubleshoot the Module. . . . . . . . . . . . . . . . 81

Warning Signal in Controller Organizer . . . . . . . . . . . . . . . . . . . . . 81

Fault Message in Status Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Notification in Axis Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Chapter Summary and What’s Next . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Appendix A

Index

Publication 1756-UM525A-EN-P - June 2003 5

Table of Contents

6 Publication 1756-UM525A-EN-P - June 2003

Preface

Using This Manual

Who Should Use This

This preface describes how to use this manual.

To effectively use this manual, you should be able to program and operate the Rockwell Automation ControlLogix controllers to efficiently use your

Manual

ControlLogix Hydraulic Servo module. In this manual, we also refer to the module as the 1756-HYD02 module.

If you need more information about programming and operating the ControlLogix controllers, refer to the Logix5000 Controller User Manual, publication number

The Purpose of This Manual

This manual describes how to set up, configure and troubleshoot your 1756-HYD02 module. The following table lists describes each section in this manual:

1756-UM001

If you are looking for this information: See this section

Description of the module and what it does. Chapter 1

What is the 1756-HYD02 Module?

Step by step description of how to install and wire the module.

Description of how to use RSLogix 5000 programming software to configure the module.

Complete listing of the module’s features, including the general module features and features that specifically affect the data coming from axes connected to either of the module’s channels.

Description of how to troubleshoot any problems with the module, including the use of status indicators on the module and software fault messages in RSLogix 5000.

Specifications for the module. Appendix A

Chapter 2

Installing the 1756-HYD02 Module

Chapter 3

Configuring the 1756-HYD02 Module

Chapter 4

Using the 1756-HYD02 Module Features

Chapter 5

Troubleshooting the 1756-HYD02 Module

Specifications

7Publication 1756-UM525A-EN-P - June 2003 7

Preface Preface

What is the 1756-HYD02 Module?

This chapter describes the ControlLogix Hydraulic Servo module.

For more information about: See page:

What the Module Does 9

What the Module Does

Using A ControlLogix Hydraulic Servo Module in the ControlLogix System

Certifying Agency Approvals 11 Preventing Electrostatic Discharge 12 Removal and Insertion Under Power 12

THe 1756-HYD02 module is typically used for accurate positioning and control of a hydraulic cylinder. The module can be wired to a linear displacement transducer (LDT) for feedback and a proportional or servo valve for control of a hydraulic axis and connects to a hydraulic system to close a high-speed position loop. Each Logix controller can support up to 16 1756-HYD02 modules. Each 1756-HYD02 module can control up to two axes.

The 1756-HYD02 module monitors the position feedback via the linear displacement transducer (LDT) input and generates an analog command reference for the valve to make sure that the actuator (cylinder) follows the profile. The 1756-HYD02 module closes the position loop at a programmed rate using position feedback as the input and produces a +/-10V analog output velocity command.

The module is programmed with motion instructions in the RSLogix 5000 programming software and must be in the same chassis as the ControlLogix controller that controls the module. If you distribute motion control that uses the 1756-HYD02 module across different locations, place a ControlLogix controller in each chassis that has a 1756-HYD02 module. In this case, use a 1756-SYNCH module to synchronize motion between the multiple chassis.

Transducers connected to the 1756-HYD02 must accept external interrogation signals. In this case, the transducer generates its position information each time that it receives an interrogation pulse. Do not use transducers configured for internal interrogation because they will not be properly synchronized to the module.

9Publication 1756-UM525A-EN-P - June 2003 9

Chapter 1 What is the 1756-HYD02 Module?

Using A ControlLogix Hydraulic Servo Module in the ControlLogix System

A ControlLogix Hydraulic Servo module mounts in a ControlLogix chassis and uses a removable terminal block (RTB) or interface module (IFM) to connect all field-side wiring.

Before you install and use your module you should have already:

• installed and grounded a ControlLogix chassis and power supply. To install these products, refer to the publications listed in on page 7.

• ordered and received an RTB or IFM and its components for your application.

IMPORTANT

RTBs and IFMs are not included with your module purchase. You must order them separately. For more information, contact your local distributor or Rockwell Automation representative.

Physical Features of the ControlLogix Hydraulic Servo Module

ControlLogix Backplane Connector

Top and

bottom

guides

Indicators

Connector pins

Removable

Terminal

Block

Locking tab

Slots for keying the RTB

41623

10 Publication 1756-UM525A-EN-P - June 2003

What is the 1756-HYD02 Module? Chapter 1

The table below lists the physical features on the ControlLogix Hydraulic Servo module.

ControlLogix Hydraulic Servo Module Physical Features

Feature: Description:

ControlLogix backplane connector

Connectors pins Input/output and grounding connections are made to the

Locking tab The locking tab anchors the RTB on the module, maintaining

Slots for keying Slots mechanically key the RTB to prevent you from making

Status indicators Indicators display the status of communication, module

Top and bottom guides Guides provide assistance in seating the RTB onto the

The interface to the ControlLogix system; it connects the module to the backplane.

module through these pins with the use of an RTB.

wiring connections.

the wrong wire connections to your module.

health and presence of input/output devices. Use these indicators to help in troubleshooting.

module.

Certifying Agency Approvals

If the ControlLogix Hydraulic Servo module has obtained any agency approvals, for example, CE/CSA/UL, the module label is marked as such.

Full Class I Division 2 Compliance

The ControlLogix Hydraulic Servo module maintains CSA Class I Division 2 system certification. The module can be placed in an environment other than only 100% hazard free.

IMPORTANT

The 1756-HYD02 module should not be pulled under power, nor should a powered RTB be removed, in a Class I Division 2 environment.

Publication 1756-UM525A-EN-P - June 2003 11

Chapter 1 What is the 1756-HYD02 Module?

Preventing Electrostatic Discharge

Removal and Insertion Under Power

The 1756-HYD02 module is sensitive to electrostatic discharge.

ATTENTION

You can install or remove the module while chassis power is applied if you observe the following precautions.

This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment:

• Touch a grounded object to discharge potential static.

• Wear an approved grounding wriststrap.

• Do not touch connectors or pins on component boards.

• Do not touch circuit components inside the equipment.

• If available, use a static-safe workstation.

• When not in use, store the equipment in appropriate static-safe

packaging.

Chapter Summary and What’s Next

WARNING

Repeated electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance that can affect module operation.

We do not recommend removing and inserting the 1756-HYD02 module while under power if the servo loop is closed. Make sure the servo loop is open, that is, flashing green feedback indicator, before removing or inserting the module under power.

In this chapter, you read a description of the 1756-HYD02 module. Chapter 2 describes

Installing the 1756-HYD02 Module

When you insert or remove the module while backplane power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

However, as stated on the previous page, the 1756-HYD02 module should not be pulled under power, nor should a powered RTB be removed, in a Class I Division 2 environment.

12 Publication 1756-UM525A-EN-P - June 2003

Installing the 1756-HYD02 Module

Chapter

What This Chapter Contains

This chapter describes how to install the 1756-HYD02 module.

The 1756-HYD02 module mounts in a ControlLogix chassis and uses a removable terminal block (RTB) to connect all field-side wiring.

Before you install your module, make sure you:

For information about: See page:

Installing the Module 14 Keying the Removable Terminal Block 15 Connecting Wiring 16 Assembling The Removable Terminal Block and

the Housing Installing the Removable Terminal Block 26 Removing the Removable Terminal Block 28 Removing the Module from the Chassis 29

• install and ground a ControlLogix chassis and power supply.

• order and receive an RTB, and its components, for your application.

For more information on all the ControlLogix chassis and power supplies, see

Note the Power

the ControlLogix Selection Guide, publication

This module receives power from the 1756 chassis power supply and requires two sources of power from the backplane:

1756-SG001

Requirements

• 700mA at 5.1V

• 2.5 mA at 24V

Add this current to the requirements of all other modules in this chassis to prevent overloading the backplane power supply.

13Publication 1756-UM525A-EN-P - June 2003 13

Chapter 2 Installing the 1756-HYD02 Module

Installing the Module

You can install or remove the module while chassis power is applied.

ATTENTION

The module is designed to support Removal and Insertion Under Power (RIUP). However, when you remove or insert an RTB with field-side power applied, unintended machine motion or loss of process control can occur. Exercise extreme caution when using this feature.

1. Align circuit board with top and bottom chassis guides.

Printed Circuit Board

20861-M

2. Slide module into chassis until module tabs ‘click’.

Locking Tab

20862-M

14 Publication 1756-UM525A-EN-P - June 2003

Installing the 1756-HYD02 Module Chapter 2

Keying the Removable Terminal Block

Key the RTB to prevent inadvertently connecting the incorrect RTB to your module. When the RTB mounts onto the module, keyed positions match up. For example, if you place a U-shaped keying band in position #4 on the module, you cannot place a wedge-shaped tab in #4 on the RTB or your RTB will not mount on the module.

Use a unique keying pattern for each slot in the chassis.

1. Insert the U-shaped band with the long side near the terminals.

2. Push the band onto the module until it snaps in place.

U-shaped

Keying Band

20850-M

3. Key the RTB in positions that correspond to unkeyed module positions. Insert the wedge-shaped tab on the RTB with the rounded edge first. Push the tab onto the RTB until it stops.

IMPORTANT

When keying your RTB and module, you must begin with a wedge-shaped tab in position #6 or #7.

Wedge–shaped Keying Tab

Module side of RTB

Publication 1756-UM525A-EN-P - June 2003 15

20851–M

Chapter 2 Installing the 1756-HYD02 Module

Connecting Wiring

This module uses an RTB or a Bulletin 1492 Interface Module (IFM)

(1)

to connect all field-side wiring. Use an extended-depth cover (1756-TBE) for applications with heavy gauge wiring or requiring additional routing space. The maximum wire gauge that can be used with the 1756-HYD02 module is #14 AWG (2.08 sq. mm) stranded.

If you are using an RTB to connect wiring to you module, follow the directions beginning below.

An IFM has been prewired before you received it. If you are using an IFM to connect wiring to the module, consult the documentation that came with it to connect wiring, skip this section and move to page 23.

Two Types of RTBs (each RTB comes with housing)

• Cage Clamp - Catalog number 1756-TBCH

• Spring Clamp - Catalog number 1756-TBSH or TBS6H

Cage Clamp

1. Insert the wire into the terminal.

2. Turn the screw clockwise to close the terminal on the wire.

Strain relief area

20859-M

(1)

The Bulletin 1492 IFM may not be used in any application that requires agency certification of the ControlLogix system. Use of the IFM violates the UL, CSA and FM certifications of this product.

16 Publication 1756-UM525A-EN-P - June 2003

Installing the 1756-HYD02 Module Chapter 2

Spring Clamp

1. Insert the screwdriver into the outer hole of the RTB.

2. Insert the wire into the open terminal and remove the screwdriver.

Strain relief area

20860-M

Recommendations for Wiring Your RTB

TIP

Consider the following when wiring your RTB:

• Begin wiring the RTB at the bottom terminals and move up.

• Use a tie to secure the wires in the strain relief area of the RTB.

• The jumper bar part number is 97739201. Contact your local

Rockwell Automation sales representative to order additional jumper bars, if necessary.

• Order and use an extended-depth housing, that is cat.

no.1756-TBE, for applications that require heavy gauge wiring. For more information, see page 24.

Publication 1756-UM525A-EN-P - June 2003 17

Chapter 2 Installing the 1756-HYD02 Module

Wiring the 1756-HYD02 Module

+OUT-0

-OUT-0

+ENABLE-0

-ENABLE-0 DRVFLT-0 CHASSIS

IN_COM

HOME-0

REG24V-0

REG5V-0

CHASSIS

+INT-0

-INT-0

+RET-0

-RET-0

LDT CMN

CHASSIS

+OK

Use the wiring example in Figure to wire to your module.

+OUT-1

-OUT-1 +ENABLE-1

-ENABLE-1 DRVFLT-1 CHASSIS IN_COM HOME-1 REG24V-1 REG5V-1

-OK CHASSIS +INT-1

-INT-1 +RET-1

-RET-1 LDT CMN CHASSIS

General cable C0720

General cable C0721

General cable C0720

General cable C0722

To valve driver/amplifier

To hydraulic control unit or To valve or pump

To home limit switch

To registration sensor

To LDT

NOTES:

General cable C0720

1. This is a general wiring example illustrating Axis 1 wiring only. Other

configurations are possible with Axis wiring identical to Axis 1.

2. Make sure that any transducer connected to the 1756-HYD02 module

uses an external interrogation signal.

3. Do not exceed the specified isolation voltage between power sources.

To E-stop relay coil

43394

18 Publication 1756-UM525A-EN-P - June 2003

From 1756-HYD02

Installing the 1756-HYD02 Module Chapter 2

Wiring Registration Sensors

The registration inputs to the servo module can support 24V or 5V registration sensors. These inputs should be wired to receive source current from the sensor. Current sinking sensor configurations are not allowed because the registration input common (IN_ COM) is shared with the other 24V servo module inputs.

- 24V Registration Sensor

24V dc

Field Power

General cable C0720

REG24V IN_COM

Supply

–

24 Volt

Registration

Sensor

Supply Output

Common

43395

From 1756-HYD02

- 5V Registration Sensor

General cable C0720

REG5V IN_COM

5V dc

Field Power

Supply

–

5 Volt

Registration

Sensor

Supply Output

Common

43395

Publication 1756-UM525A-EN-P - June 2003 19

Chapter 2 Installing the 1756-HYD02 Module

Wiring the Home Limit Switch Input

The home limit switch inputs to the servo module are designed for 24V nominal operation. These inputs should be wired for current sourcing operation.

24V dc

Field Power

Supply

+–

From 1756-HYD02

General cable C0720

HOME

IN_COM

43396

Wiring the OK Contacts

A set of isolated solid- state OK relay contacts is provided for optional interface to an E- stop string, which controls power to the associated pumps. The OK contacts are rated to drive an external 24V pilot relay, for example, Allen-Bradley 700-HA32Z24, whose contacts can be incorporated into the E-Stop string.

24V dc

Field Power

Supply

+–

OK Pilot Relay

General cable C0720

+OK

-OK

43397

OK Pilot Relay Contacts

20 Publication 1756-UM525A-EN-P - June 2003

Start

CR1

Stop

CR1

24V AC/DC or 120VAC typical

43398

Installing the 1756-HYD02 Module Chapter 2

Connecting LDTs to Your Hydraulic Module

Because the number of LDTs that you can connect to your 1756-HYD02 module is continually changing, we cannot list all the available LDTs here. Figure shows the connections for two example LDT types–Temposonic and Balluff–that were available for connection to the 1756-HYD02 module at the time of this printing.

+/-12V dc

Interrogate

Temposonics II,

RPM or DPM

Ground

Output Pulse

IMPORTANT

Remember, there are other suppliers with compatible LDTs. Before connecting an LDT to your module, we recommend you make sure it is the best available LDT for your application.

Also, when wiring an LDT to your module, always follow the LDT manufacturer’s instructions on making connections.

24V Connections +/- 15V Connections

Interrogate (-)

+24V

Ground

Interrogate (+)

No shield connections on these examples

Pulse (-) Output

Pulse (+) Output

Table lists the LDT connections.

Balluff BTL type

+15V

-15V

Ground

Interrogate (-)

Interrogate (+)

Pulse (-) Output

Pulse (+) Output

43473

LDT Connections for Fabricating Your Own LDT Cable

Function

(1)

1756-HYD02 RTB Wiring (Numbers below

represent terminal numbers)

Temposonics II RPM or DPM

(2)

Balluff

BTL type

Channel 0 Channel 1 24V dc +/- 15V dc

(+) Interrogate 26 25 9 - Yellow 1 - Yellow 1 - Yellow (-) Interrogate 28 27 10 - Green 3 - Pink 3 - Pink Power Supply N/A 5 - Red (+/-12V) 7 - Brown (+24V) 7 - Brown (+15V)

8 - White (-15V)

Ground 34 33 1 - White 6 - Blue

6 - Blue

8 - White

Output Pulse 30 (+)

32 (-)

(1)

(+) and (-) wires of the same function should be a twisted pair within the cable.

(2)

Do not connect to pins 2, 3, 4, 6 or 7

Publication 1756-UM525A-EN-P - June 2003 21

29 (+) 31 (-)

8 - Purple 2 - Gray (+)

5 - Green (-)

2 - Gray (+) 5 - Green (-)

Chapter 2 Installing the 1756-HYD02 Module

PC with

RSLogix 5000™

Figure shows an application wiring example using a 1-axis loop with a differential LDT input. (The power supplies and servo amplifiers are user-supplied.)

24V Power Supply

+–C

ControlLogix controller

1756-HYD02

+ OUT

– OUT

CHASSIS

+INT & –INT

+RET & –RET

CHASSIS

Drive Output

+–C

+/– 15V dc

Power Supply

for LDTs

Servo or

Proportional

Amplifier

Valve

Piston-type Hydraulic

Cylinder and LDT

Earth Ground

IMPORTANT: This module’s analog output require an external amplifier to drive the valve.

43474

22 Publication 1756-UM525A-EN-P - June 2003

Installing the 1756-HYD02 Module Chapter 2

Assembling The Removable

Removable housing covers the wired RTB to protect wiring connections when the RTB is seated on the module.

Terminal Block and the Housing

1. Align the grooves at the bottom of each side of the housing with the side edges of the RTB.

Housing

Groove

Side edge of RTB

Groove

Strain relief area

Side edge of RTB

RTB

2. Slide the RTB into the housing until it snaps into place.

IMPORTANT

If additional wire routing space is required for your application, use extended-depth housing 1756-TBE.

20858-M

Publication 1756-UM525A-EN-P - June 2003 23

Chapter 2 Installing the 1756-HYD02 Module

Choosing the Extended-Depth Housing

There are two housing options you must consider when wiring your ControlLogix Hydraulic Servo module. When you order an RTB for your I/O module, you receive a standard-depth housing with the RTB. If your application uses heavy gauge wiring, you can order an extended-depth housing. This housing does not come with an RTB.

You can use one of the housings listed below:

This housing: should be used with this RTB: and allows up to this

capacity of wires:

1756-TBCH Cage clamp 336 sq. mm 1756-TBS6H Spring clamp 1756-TBE Any RTB using heavy gauge wiring 628 sq. mm

The figure below shows the difference, in terms of capacity, between the housing options.

IMPORTANT

The housings shown are used with a spring clamp RTB, but the capacity for each remains the same regardless of RTB type.

Maximum Area = 336 sq. mm

36 - 18AWG wires

23 - 14AWG wires

Standard-Depth Housing Extended-Depth Housing

IMPORTANT

The housings use the following maximum areas:

• standard-depth housing maximum area = 336 sq. mm

• extended-depth housing maximum area = 628 sq. mm

Maximum Area = 628 sq. mm

40 - 14AWG wires

30484-M

24 Publication 1756-UM525A-EN-P - June 2003

Installing the 1756-HYD02 Module Chapter 2

Suggestions for Using the Extended-Depth Housing

12.7mm (0.5in)

TIP

Consider the following when deciding to use an extended-depth housing on your I/O module. It is recommended you use the 1756-TBE when:

• using >36 18AWG wires

• using >23 14AWG wires

Cabinet Size Considerations With the Extended-Depth Housing

When you use an extended-depth housing (1756-TBE), the module depth is increased. Figure shows the difference, in terms of depth, between a module using a standard-depth housing and one using an extended-depth housing.

144.73mm (5.698in)

131.75mm

3.18mm (0.125in)

(5.187in)

Standard-Depth Housing

Extended-Depth Housing

IMPORTANT

Rear Surface of ControlLogix Chassis

41682

The depth from front of the module to the back of the chassis is as follows:

• standard-depth housing = 147.91mm (5.823in)

• extended-depth housing = 157.43mm (6.198in)

Publication 1756-UM525A-EN-P - June 2003 25

Chapter 2 Installing the 1756-HYD02 Module

Installing the Removable Terminal Block

Install the RTB onto the module to connect wiring.

ATTENTION

Shock hazard exists. If the RTB is installed onto the module

while the field-side power is applied, the RTB will be electrically live. Do not touch the RTB’s terminals. Failure to observe this caution may cause personal injury.

The RTB is designed to support Removal and Insertion Under Power (RIUP). However, when you remove or insert an RTB with field-side power applied, unintended machine motion or loss of process control can occur. Exercise extreme caution when using this feature. It is recommended that field-side power be removed before installing the RTB onto the module.

Before installing the RTB, make certain:

• field-side wiring of the RTB has been completed.

• the RTB housing is snapped into place on the RTB.

• the RTB housing door is closed.

• the locking tab at the top of the module is unlocked.

1. Align the top, bottom and left side guides of the RTB with the guides on the module.

Left side guides

Bottom guide

Top guide

20853-M

26 Publication 1756-UM525A-EN-P - June 2003

Installing the 1756-HYD02 Module Chapter 2

2. Press quickly and evenly to seat the RTB on the module until the latches snap into place.

Locking tab

20854-M

3. Slide the locking tab down to lock the RTB onto the module.

Publication 1756-UM525A-EN-P - June 2003 27

Chapter 2 Installing the 1756-HYD02 Module

Removing the Removable Terminal Block

If you need to remove the module from the chassis, you must first remove the RTB from the module.

ATTENTION

Shock hazard exists. If the RTB is removed from the module

while the field-side power is applied, the module will be electrically live. Do not touch the RTB’s terminals. Failure to observe this caution may cause personal injury.

1. Unlock the locking tab at the top of the module.

2. Open the RTB door using the bottom tab.

3. Hold the spot marked PULL HERE and pull the RTB off the module.

IMPORTANT

Do not wrap your fingers around the entire door. A shock hazard exists.

20855-M

28 Publication 1756-UM525A-EN-P - June 2003

Installing the 1756-HYD02 Module Chapter 2

Removing the Module from the Chassis

Follow the steps below to remove the 1756-HYD02 module from the ControlLogix chassis.

1. Push in the top and bottom locking tabs.

Locking tabs

20856-M

2. Pull module out of the chassis.

20857-M

Publication 1756-UM525A-EN-P - June 2003 29

Chapter 2 Installing the 1756-HYD02 Module

Chapter Summary and What’s Next

In this chapter, you read about Installing the 1756-HYD02 Module. Chapter 3 explains Configuring the 1756-HYD02 Module.

30 Publication 1756-UM525A-EN-P - June 2003

Chapter

Configuring the 1756-HYD02 Module

This chapter describes how to configure a ControlLogix Hydraulic Servo module.

For information about: See page:

Overview of the Configuration Process 32 Creating a New Module 33 Configuring General Module Features 35 Configuring the Axes Features 36 Downloading New Configuration Data 37 Editing Configuration 38 Reconfiguring Module Parameters in Run Mode 39

Using RSLogix 5000 Configuration Software

Reconfiguring Module Parameters in Program Mode

You must configure your module upon installation. The module does not work until it has been configured.

IMPORTANT

Use RSLogix 5000 software, version 12 or greater, to configure your ControlLogix Hydraulic Servo module.

The ControlLogix Hydraulic Servo module can only be used in a local chassis.

31Publication 1756-UM525A-EN-P - June 2003 31

Chapter 3 Configuring the 1756-HYD02 Module

Overview of the Configuration Process

Figure shows an overview of the configuration process.

New Module

1. Select the

Hydraulic Servo module.

2. Choose a Major

Revision

General Tab

Name Description Slot number Comm. format Minor revision Keying choice

Make custom configuration choices here

Application Specific Screens

Edit a module’s configuration here

Configuration complete

Pop-up menu leads to a module’s configuration properties

A series of tabs in RSLogix 5000 provide access to change a module’s configuration data

43466

32 Publication 1756-UM525A-EN-P - June 2003

Configuring the 1756-HYD02 Module Chapter 3

Creating a New Module

Use this pull-down menu to go offline

After you have started RSLogix 5000 and created a controller, you must create a new module. The wizard allows you to create a new module and configure it.

IMPORTANT

You must be offline when you create a new module.

1. If your application is online, go offline.

2. Access the Select Module Type screen.

A. Select I/O Configuration.

B. Right-click to see the menu.

C. Select New Module.

Publication 1756-UM525A-EN-P - June 2003 33

Chapter 3 Configuring the 1756-HYD02 Module

A. Select the Hydraulic

Servo module

3. Select the module type.

B. Make sure the

Major Revision number matches the label on the side of your module

C. Click here.

4. Begin configuration on the naming screen.

A. Name the module.

B. Add a description (optional).

C. Make sure the Minor

Revision number matches the label on the side of your module.

If you are altering the default configuration, click here.

Go to page 35.

E. Select the slot in which

your module resides.

F. Choose an Electronic

Keying method. A detailed explanation of this field is provided on page 44.

If you are using default configuration, click here and you are finished configuring your module.

Go to page 37.

34 Publication 1756-UM525A-EN-P - June 2003

Configuring the 1756-HYD02 Module Chapter 3

Configuring General Module Features

Inhibit the connection to the module

If you want a Major Fault on the Controller to occur if there is connection failure with the I/O module while in Run mode, click here

This Fault box is empty when you are offline. If a fault occurs while the module is online, the type of fault will be displayed here

You see the series of wizard screens after the naming screen. Use these screens to configure general features on the 1756-HYD02 module.

Click here to move to the next page

Set the Servo Update Period – The correct servo update period is based on the transducer lengths and the number of recirculations on each axis associated with the module. The Feedback tab, described on page 58, has a utility that calculates the minimum update period.

For more information on the Associated Axes, see the Configuring the Axes Features beginning on page 36.

Publication 1756-UM525A-EN-P - June 2003 35

Chapter 3 Configuring the 1756-HYD02 Module

Configuring the Axes Features

Click on New Axis to create a new axis tag that will contain the axis data. The New Tag pop-up screen appears, as shown below.

You must create an axis before you can associate it with a channel on the 1756-HYD02 module.

1. Create the new axis tag as shown below.

The new axis tag must be:

² named ² of the AXIS_SERVO data type ² of the controller scope

A. Associate the channel(s) with the new

axis tag.

B. Click on the ellipsis (. . .) to access the

axis properties wizard.

2. Access the axis properties as shown below.

36 Publication 1756-UM525A-EN-P - June 2003

Click on the necessary tab and make changes to the axis properties.

Configuring the 1756-HYD02 Module Chapter 3

3. Configure the axis properties on the wizard screens that appear. The General screen is shown below.

For a full description of all the configurable features available on the Axis properties wizard, see the Using Axes Features section beginning on page 52.

Downloading New Configuration Data

Use this pull-down menu to download the new configuration.

After you have changed the configuration data for a module, the change does not actually take effect until you download the new program which contains that information. This downloads the entire program to the controller overwriting any existing programs.

This completes the download process.

Publication 1756-UM525A-EN-P - June 2003 37

Chapter 3 Configuring the 1756-HYD02 Module

Editing Configuration

After you set configuration for a module, you can review and change it. You can change configuration data and download it to the controller while online. This is called dynamic reconfiguration.

Your freedom to change some configurable features, though, depends on whether the controller is in Remote Run mode or Program mode.

IMPORTANT

Although you can change configuration while online, you must go offline to add or delete modules from the program.

The editing process begins on the main page of RSLogix 5000.

A. Right-click on the 1756-HYD02

module.

B. Select Properties.

C. Click on the tab of the page you

want to view or reconfigure.

38 Publication 1756-UM525A-EN-P - June 2003

Configuring the 1756-HYD02 Module Chapter 3

Reconfiguring Module Parameters in Run Mode

Reconfiguring Module Parameters in Program Mode

Use this pull-down menu to switch to Program mode

Your module can operate in Remote Run mode or Hard Run mode. You can only change any configurable features that are enabled by RSLogix 5000 in Remote Run mode.

If any feature is disabled in either Run mode, change the controller to Program mode and make the necessary changes.

Follow these steps to change configuration in Program mode.

1. Make sure the module is in Program Mode.

Use this pull-down menu to download the new configuration.

2. Make any necessary changes.

3. Download the new configuration.

4. Return to Run Mode, if necessary.

Publication 1756-UM525A-EN-P - June 2003 39

Chapter 3 Configuring the 1756-HYD02 Module

Chapter Summary and What’s Next

In this chapter you read about:

• configuring ControlLogix Hydraulic Servo modules

• editing module configuration

• configuration tags

Chapter 4 explains

Using the 1756-HYD02 Module Features

40 Publication 1756-UM525A-EN-P - June 2003

Chapter

Using the 1756-HYD02 Module Features

This chapter describes the 1756-HYD02 module’s configurable features.

For more information about: See page:

What This Chapter Contains 42 Using General Module Features 42

Servo Update Period 42 Module Fault Reporting 43 Fully Software Configurable 43 Electronic Keying 44

Using Axes Features 52

General Tab 52 Motion Planner Tab 54 Units Tab 56 Servo Tab 57 Feedback Tab 58 Conversion Tab 59 Homing Tab 60 Hookup Tab 62 Tune Tab 63 Dynamics Tab 64 Gains Tab 65 Output Tab 68 Limits Tab 70 Offset Tab 72 Fault Actions Tab 74 Tag Tab 76

41Publication 1756-UM525A-EN-P - June 2003 41

Chapter 4 Using the 1756-HYD02 Module Features

What This Chapter Contains

Using General

This chapter is broken into the two sections.

The general module features include:

Module Features

Section: Description: Begins on

page:

Using General Module Features

Using Axes Features

This section describes features that affect the module in a general sense. For example, the 1756-HYD02 module offers electronic keying options that you can configure to set the degree of protection your application needs against using the wrong 1756-HYD02 module.

This section describes features that are specific to the axes connected to channels 0 and 1 on the 1756-HYD02 module.

•Servo Update Period

• Module Fault Reporting

• Fully Software Configurable

• Electronic Keying

Servo Update Period

Servo update period is the period at which the position feedback is sampled and the loop is closed to generate a new output value. The time of this period is a user-defined setting. You can choose from one of the following settings:

•250μs

•500μs

• 1000μs

• 1500μs

• 2000μs

With LDTs, the minimum Servo Update Period is dependent on the length of the transducer. Use the Calculated Values tool on the Feedback tab of the Axis properties dialog in RSLogix 5000, in conjunction with the response of your hydraulic application, to calculate suggested minimum update periods. The coarse update period of the associated motion group must be at least 3x the maximum configured 1756-HYD02 module servo update period or RSLogix 5000 will generate an error.

42 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Module Fault Reporting

The 1756-HYD02 module provides hardware and software indication when a module fault has occurred. The module’s LED fault indicator and the RSLogix 5000 programming software graphically display faults; the software also offers a message describing the nature of the fault. This feature allows you to determine how your module has been affected and what action should be taken to resume normal operation.

For more information on using RSLogix 5000 to troubleshoot your module, see Chapter 5, Troubleshooting the 1756-HYD02 Module.

Fully Software Configurable

The RSLogix 5000 software offers a custom, easily understood interface for users to write configuration. All module features are enabled or disabled through the configuration portion of the software.

You can also use the software to interrogate any module in the system to retrieve

• serial number

• revision information

• catalog number

• vendor identification

• error/fault information

• diagnostic counters.

By eliminating such tasks as setting hardware switches and jumpers, the software makes module configuration easier and more reliable.

Publication 1756-UM525A-EN-P - June 2003 43

Chapter 4 Using the 1756-HYD02 Module Features

Electronic Keying

The electronic keying feature automatically compares the expected module, as shown in the RSLogix 5000 I/O Configuration tree, to the physical module before I/O communication begins. You can use electronic keying to help prevent communication to a module that does not match the type and revision expected.

For each module in the I/O Configuration tree, the user-selected keying option determines if, and how, an electronic keying check is performed. Typically, three keying option are available.

You must carefully consider the benefits and implications of each keying option when selecting between them. For some specific module types, fewer options are available.

•Exact Match

• Compatible Keying

• Disable Keying

Electronic keying is based on a set of attributes unique to each product revision. When a Logix5000 controller begins communicating with a module, this set of keying attributes is considered.

Keying Attributes

Attribute Description

Vendor The manufacturer of the module, for example, Rockwell

Automation/Allen-Bradley.

Product Type The general type of the module, for example, communication

adapter, AC drive, or digital I/O.

Product Code The specific type of module, generally represented by its catalog

number, for example, 1756-IB16I.

Major Revision A number that represents the functional capabilities and data

exchange formats of the module. Typically, although not always, a later, that is higher, Major Revision supports at least all of the data formats supported by an earlier, that is lower, Major Revision of the same catalog number and, possibly, additional ones.

Minor Revision A number that indicates the module’s specific firmware revision.

Minor Revisions typically do not impact data compatibility but may indicate performance or behavior improvement.

You can find revision information on the General tab of a module’s Properties dialog box.

44 Publication 1756-UM525A-EN-P - June 2003

General Tab

Using the 1756-HYD02 Module Features Chapter 4

IMPORTANT

Changing electronic keying selections online may cause the I/O communication connection to the module to be disrupted and may result in a loss of data.

Exact Match

Exact Match keying requires all keying attributes, that is, Vendor, Product Type, Product Code (catalog number), Major Revision, and Minor Revision, of the physical module and the module created in the software to match precisely in order to establish communication. If any attribute does not match precisely, I/O communication is not permitted with the module or with modules connected through it, as in the case of a communication module.

Use Exact Match keying when you need the system to verify that the module revisions in use are exactly as specified in the project, such as for use in highly-regulated industries. Exact Match keying is also necessary to enable

Publication 1756-UM525A-EN-P - June 2003 45

Chapter 4 Using the 1756-HYD02 Module Features

Automatic Firmware Update for the module via the Firmware Supervisor feature from a Logix5000 controller.

EXAMPLE

In the following scenario, Exact Match keying prevents I/O communication:

• The module configuration is for a 1756-IB16D module with module

revision 3.1. The physical module is a 1756-IB16D module with module revision 3.2. In this case, communication is prevented because the Minor Revision of the module does not match precisely.

Module Configuration Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IB16D Major Revision = 3

Minor Revision = 1

Communication is prevented

Physical Module Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IB16D Major Revision = 3

Minor Revision = 2

IMPORTANT

Changing electronic keying selections online may cause the I/O Communication connection to the module to be disrupted and may result in a loss of data.

46 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Compatible Keying

Compatible Keying indicates that the module determines whether to accept or reject communication. Different module families, communication adapters, and module types implement the compatibility check differently based on the family capabilities and on prior knowledge of compatible products.

Compatible Keying is the default setting. Compatible Keying allows the physical module to accept the key of the module configured in the software, provided that the configured module is one the physical module is capable of emulating. The exact level of emulation required is product and revision specific.

With Compatible Keying, you can replace a module of a certain Major Revision with one of the same catalog number and the same or later, that is higher, Major Revision. In some cases, the selection makes it possible to use a replacement that is a different catalog number than the original. For example, you can replace a 1756-CNBR module with a 1756-CN2R module.

Release notes for individual modules indicate the specific compatibility details.

When a module is created, the module developers consider the module’s development history to implement capabilities that emulate those of the previous module. However, the developers cannot know future developments. Because of this, when a system is configured, we recommend that you configure your module using the earliest, that is, lowest, revision of the physical module that you believe will be used in the system. By doing this, you

Publication 1756-UM525A-EN-P - June 2003 47

Chapter 4 Using the 1756-HYD02 Module Features

can avoid the case of a physical module rejecting the keying request because it is an earlier revision than the one configured in the software.

EXAMPLE

In the following scenario, Compatible Keying prevents I/O communication:

• The module configuration is for a 1756-IB16D module with module

revision 3.3. The physical module is a 1756-IB16D module with module revision 3.2. In this case, communication is prevented because the minor revision of the module is lower than expected and may not be compatible with 3.3.

Module Configuration Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IB16D Major Revision = 3

Minor Revision = 3

Communication is prevented

Physical Module Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IB16D Major Revision = 3

Minor Revision = 2

48 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

EXAMPLE

In the following scenario, Compatible Keying allows I/O communication:

• The module configuration is for a 1756-IB16D module with module

revision 2.1. The physical module is a 1756-IB16D module with module revision 3.2. In this case, communication is allowed because the major revision of the physical module is higher than expected and the module determines that it is compatible with the prior major revision.

Module Configuration Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IB16D

Major Revision = 2 Minor Revision = 1

Communication is allowed

Physical Module Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IB16D

Major Revision = 3 Minor Revision = 2

IMPORTANT

Changing electronic keying selections online may cause the I/O communication connection to the module to be disrupted and may result in a loss of data.

Publication 1756-UM525A-EN-P - June 2003 49

Chapter 4 Using the 1756-HYD02 Module Features

Disabled Keying

Disabled Keying indicates the keying attributes are not considered when attempting to communicate with a module. Other attributes, such as data size and format, are considered and must be acceptable before I/O communication is established. With Disabled Keying, I/O communication may occur with a module other than the type specified in the I/O Configuration tree with unpredictable results. We generally do not recommend using Disabled Keying.

ATTENTION

Be extremely cautious when using Disabled Keying; if used incorrectly, this option can lead to personal injury or death, property damage, or economic loss.

If you use Disabled Keying, you must take full responsibility for understanding whether the module being used can fulfill the functional requirements of the application.

EXAMPLE

In the following scenario, Disable Keying prevents I/O communication:

• The module configuration is for a 1756-IA16 digital input module.

The physical module is a 1756-IF16 analog input module. In this case, communication is prevented because the analog

module rejects the data formats that the digital module configuration requests.

Module Configuration Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IA16 Major Revision = 3 Minor Revision = 1

Communication is prevented

Physical Module Vendor = Allen-Bradley

Product Type = Analog Input Module Catalog Number = 1756-IF16 Major Revision = 3 Minor Revision = 2

50 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

EXAMPLE

In the following scenario, Disable Keying allows I/O communication:

• The module configuration is for a 1756-IA16 digital input module.

The physical module is a 1756-IB16 digital input module. In this case, communication is allowed because the two digital modules share common data formats.

Module Configuration Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IA16 Major Revision = 2 Minor Revision = 1

Communication is allowed

Physical Module Vendor = Allen-Bradley

Product Type = Digital Input Module Catalog Number = 1756-IB16 Major Revision = 3 Minor Revision = 2

IMPORTANT

Changing electronic keying selections online may cause the I/O communication connection to the module to be disrupted and may result in a loss of data.

Publication 1756-UM525A-EN-P - June 2003 51

Chapter 4 Using the 1756-HYD02 Module Features

Using Axes Features

Associated axes can be connected to channels 0 and 1 on the 1756-HYD02 module during initial configuration or on the Associated Axes tab of the module’s properties in RSLogix 5000.

IMPORTANT

When configuring Servo Axes features, remember the following:

• The 1756-HYD02 module only works with AXIS_SERVO data type tags.

• When a parameter transitions to a read-only state, any pending changes to parameter values are lost, and the parameter reverts to the most recently saved parameter value.

• When multiple workstations connect to the same controller using RSLogix 5000 and invoke the Axis Wizard or Axis Properties dialog, the firmware allows only the first workstation to make any changes to axis attributes. The second workstation switches to a Read Only mode, indicated in the title bar, so that you may view the changes from that workstation, but not edit them.

After you have created an AXIS_SERVO tag, you must configure the axis connected to that tag. You configure the axis properties on a series of tabs in RSLogix 5000. The tabs that are available in the axis properties portion of RSLogix 5000 are described in the rest of this section.

For more information on how to configure the Axes Servo features, or anything else on the 1756-HYD02 module, see Chapter 3,

1756-HYD02 Module

or the RSLogix 5000 online help.

Configuring the

General Tab

The table below lists the configurable features available on the General tab.

Feature: Definition:

Axis Configuration Selects and displays the intended use of the axis.

• Feedback Only - If the axis is to be used only to display position information from the feedback

interface. This selection minimizes the display of axis properties tabs and parameters.

• Servo - If the axis is to be used for full closed loop operation. This selection maximizes the display of

axis properties tabs and parameters.

Motion Group Selects and displays the Motion Group to which the axis is associated. An axis assigned to a Motion Group

appears in the Motion Groups branch of the Controller Organizer, under the selected Motion Group sub-branch.

Selecting <none> terminates the Motion Group association, and moves the axis to the Ungrouped Axes sub-branch of the Motions Groups branch.

52 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Feature: Definition:

Ellipsis button (. . .) Opens the Motion Group Properties dialog box for the Assigned Motion Group, where you can edit the

properties of the Assigned Motion Group.

If no Motion Group is assigned to this axis, this button is disabled.

New Group Opens the New Tag dialog box, where you can create a new Motion Group tag. This button is enabled only if

you have not created a Motion Group tag.

Module Selects and displays the name of the motion module to which the axis is associated.

Displays <none> if the axis is not associated with any motion module.

Module Type This read-only field displays the type of motion module, if any, associated with the axis.

Displays <none> if the axis is not associated with any motion module.

Channel Selects and displays the channel–either 0 or 1–to which the axis is assigned.

Disabled when the axis is not associated with any motion module.

Publication 1756-UM525A-EN-P - June 2003 53

Chapter 4 Using the 1756-HYD02 Module Features

Motion Planner Tab

The table below lists the configurable features available on the Motion Planner tab.

Feature: Definition:

Output Cam Execution Targets

Program Stop Action Select how a specific axis stops when the controller undergoes a mode change, or when a Motion Group

Use this field to set the maximum number of output cams that will be used on the axis. This value allocates controller memory to allow the motion planner to build CAM association tables.

Stop (MGS) instruction is executed:

• Fast Disable: The axis is decelerated to a stop using the current configured value for maximum

deceleration. Loop closure is maintained until the axis motion has stopped; at that time, the axis is disabled (i.e., Drive Enable is disabled, and the axis loop is disabled).

• Fast Shutdown: The axis is decelerated to a stop using the current configured value for maximum

deceleration. Once the axis motion is stopped, the axis is placed in the shutdown state (i.e., Drive Enable is disabled, the loop is disabled, and the OK contact is opened). To recover from this state, a reset instruction must be executed.

• Fast Stop: The axis is decelerated to a stop using the current configured value for maximum

deceleration. Loop closure is maintained after the axis motion has stopped. This mode is useful for gravity or loaded systems, where closed loop control is needed at all times.

• Hard Disable: The axis is immediately disabled (i.e. Drive Enable is disabled, the axis loop is disabled,

but the OK contact is left closed). Unless the drive is configured to provide some form of dynamic breaking, this selection results in the axis coasting to a stop.

• Hard Shutdown: The axis is immediately placed in the shutdown state (i.e. Drive Enable is disabled,

the axis loop is disabled, but the OK contact is left open). Unless the drive is configured to provide some form of dynamic breaking, this selection results in the axis coasting to a stop. To recover from this state, a reset instruction must be executed.

54 Publication 1756-UM525A-EN-P - June 2003

Feature: Definition:

Master Delay Compensation

Master Delay Compensation helps a slave approach zero tracking error when gearing or camming to the actual position of a master axis. When camming or gearing off of actual feedback, some delay exists between when the master position data is generated and when the controller acts on that data for a slave. This delay causes a slave response to lag behind a master. You can compensate for this delay with the Master Delay Compensation.

The Position Camming and Gearing functions, when applied to a slave axis, perform Master Delay Compensation to compensate for the delay time between reading the master axis command position and applying the associated slave command position to the output of the slave’s axis loop. When the master axis is running at a fixed speed, this compensation makes sure that the slave axis command position accurately tracks the actual position of the master axis.

The Master Delay Compensation algorithm extrapolates the position of the master axis at the predicted time when the command position will be applied to the slave’s axis loop. The total position update delay created by the Coarse Update Period of the motion group, and, if the master or the slave involves an AXIS_SERVO_DRIVE data type, it also includes the delay term that is proportional to the SERCOS Update Period.

The motion planner implements a 1st order extrapolation algorithm that results in zero tracking error while the master axis is moving at constant velocity. If the master axis accelerates or decelerates the tracking error is non-zero and proportional to the acceleration or deceleration rate and also proportional to the square of the total position update delay time.

Using the 1756-HYD02 Module Features Chapter 4

Enable Master Position Filter

Master Position Filter Bandwidth

If your application does not require zero tracking error between the master and the slave axis, disable the Master Delay Compensation feature to eliminate the disturbances the extrapolation algorithm introduces to the slave axis. When the Master Delay Compensation feature is disabled (bit cleared), the slave axis appears to be more responsive to the master’s movements, and runs generally smoother than when Master Delay Compensation feature is enabled (bit set). However, when the master axis is running at a constant velocity, the slave lags the master by a tracking error that is proportional to the speed of the master.

Since the master axis position is measured in discrete feedback counts and is inherently noisy, the extrapolation process amplifies that noise according to the total position update delay. The greater the delay, the greater the noise introduced by the extrapolator.

This feature also includes an extrapolation filter to filter the noise introduced by the extrapolation process. The time constant of the filter is fixed at 4x the total position update delay (independent of the Master Position Filter Bandwidth), which again is a function of the Coarse Update Period and the SERCOS Update Period, if a AXIS_SERVO_DRIVE data type.

Note that Master Delay Compensation, even if explicitly enabled, is not applied in cases where a slave axis is gearing or camming to the master axis’ command position. Since the ControlLogix controller generates the command position directly, there is no intrinsic master position delay to compensate for.

When checked, this field enables the Master Position filter to eliminate high frequency oscillations or spikes from the master position signal being sent to the 1756-HYD02 module. High speed axis oscillation typically causes the oscillations and spikes in the signal. By removing the high frequency noise, the application may be able to accurately operate on true variation of the master position signal.

Caution should be used when applying filtering since, by definition, it makes the system less responsive. Bandwidth used on the Master Position filter. The servo position loop is also a filter. To be effective, the

master position filter bandwidth should be less than or equal to position loop bandwidth. However, remember that this filter adds propagation delay.

Publication 1756-UM525A-EN-P - June 2003 55

Chapter 4 Using the 1756-HYD02 Module Features

Units Tab

Use the Units tab to determine the programming and configuration units used to define your motion axis. When RSLogix 5000 software is online and the controller transitions to hard run, or the axis loop is on (i.e., active), then all the attributes on this tab transition to a read only state. When any attribute transitions to a read only state, then any pending attribute changes are reverted.

The table below lists the configurable features available on the Units tab.

Feature: Definition:

Position Units User-defined engineering units (rather than feedback counts) used to label all motion-related values (e.g.,

position or velocity) These position units can be different for each axis.

Position Units should be chosen for maximum ease of use in your application. For example, linear axes might use position units of inches or meters whereas rotary axes might use units of revolutions or degrees.

Average Velocity Timebase Specifies the time (in seconds) to be used to calculate the average velocity of the axis. This value is

computed by taking the total distance the axis travels in the amount of time specified, and dividing this value by the timebase.

The average velocity timebase value should be large enough to filter out the small changes in velocity that would result in a "noisy" velocity value, but small enough to track significant changes in axis velocity. A value of 0.25 to 0.50 seconds should work well for most applications.

56 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Servo Tab

For an axis of the data type AXIS_SERVO, configured for Servo operation (i.e. closed loop operation) in the General tab of this dialog box, use the SERVO tab to:

• configure an external drive.

• configure the drive fault input.

• select up to two axis attributes whose status can be monitored.

The table below lists the configurable features available on the Servo tab.

Feature: Definition:

External Drive Configuration

Loop Configuration Currently, only Position Servo is available. Enable Drive Fault Input When selected, this feature enables the drive fault input. When the drive fault is detected, appropriate

Drive Fault Input - Normally Open or Closed

Enable Direct Drive Ramp Control

Direct Drive Ramp Rate This attribute specifies the rate at which the analog output changes from the current value to the requested

Real Time Axis Information

- Attribute 1

Select the Hydraulic drive type. This drive type selection enables proportional, integral and differential (PID) position loop gains with Feed-Forwards and Directional scaling for the axis loop.

The Torque and Velocity options are not valid on the 1756-HYD02 module.

action is taken based on the Drive Fault Action specified in the Fault Actions tab of this dialog box. On hydraulic systems, you can use this input if the valve or hydraulic power unit has an output indicating a fault condition.

Specifies the usual state of the drive fault output:

• Normally Open - sources current when a fault is present

• Normally Closed - sources current when a fault is not present

Check this box to enable direct drive ramp rate control.

value when a Motion Direct Drive On (MDO) command is given. The ramp rate is specified in V/s. The value should be selected to allow the axis to change speed rapidly without causing excessive shock.

The first axis attributes whose status is transmitted – along with the actual position data – to the Logix processor. Once the attribute is selected, the real time axis information is automatically updated in the axis tag structure, as long as Auto Tag Update is enabled.

If a GSV is done to one of these loop status attributes without having selected this attribute via the Real Time Axis Information attribute, the attribute value will be static and will not reflect the true value in the hydraulic module.

Real Time Axis Information

- Attribute 2

Publication 1756-UM525A-EN-P - June 2003 57

The second axis attributes whose status is transmitted – along with the actual position data – to the Logix processor. Once the attribute is selected, the real time axis information is automatically updated in the axis tag structure, as long as Auto Tag Update is enabled.

Chapter 4 Using the 1756-HYD02 Module Features

Feedback Tab

Use the Feedback tab to select a feedback type. RSLogix 5000 displays multiple feedback types for the 1756-HYD02 module. At this release of the 1756-HYD02 module, only the LDT type is available. The table below lists the configurable features available on the LDT feedback option.

Feature: Definition:

LDT Type Selection determines what type of LDT provides feedback to the 1756-HYD02 module.

• PWM - also called Gated or DPM

• Start/Stop Rising Edge

• Start/Stop Falling Edge

Recirculations Recirculations is the process of acquiring a measurement from an LDT. You can repeat the measurement process

several times for each interrogation. The repetition of the measurement process is done automatically inside LDTs with PWM type output. When configuring the LDT, you can select the number of times the process is repeated; that number is used in this field.

Note that this field is enabled only if you have chosen PWM for LDT Type.

Calibration Constant

The calibration constant (also called Gradient on some LDTs) is a number that is engraved on each LDT by the manufacturer. It specifies the characteristics of that individual transducer. Because each transducer has its own calibration constant, this number is used to calculate the conversion constant for the axis; the conversion constant changes when an LDT is changed on an axis.

To calculate the Minimum Servo Update Period, use one of the following formulas: For μs/in: For m/s:

Minimum Servo Update Period =

[Length (in) X Calibration Constant (μs/in) + Recirculation delay (approximately 25μs)] X Recirculations

Minimum Servo Update Period =

[Length (m) X Calibration Constant (m/s) + Recirculation delay (approximately 0.000025s)] X Recirculations

These formulas do not assume a pre-existing calibration constant or conversion constant. Also, for an LDT with SSI interface the formulas above apply. However, the specifications for LDTs with SSI interface vary in nature; we recommend that you apply the manufacturers update period recommendations rather than have RSLogix 5000 compute a minimum servo update period. If it is a rotary (non-LDT) transducer with SSI interface then the Servo Update Period can be simply defaulted to 250 μs.

Since both axes of the module must be updated at the module's configured servo update rate, make sure the selected Servo Update Period on the Associated Axes tab is greater than the largest computed limit value above for the two axes associated with the module.

To calculate the new conversion constant when an LDT is changed, use one of the following formulas: If the calibration constant is in μs/in: If the calibration constant is in m/s:

New conversion constant =

Old conversion constant X New calibration constant

Old calibration constant

New conversion constant =

Old conversion constant X Old calibration constant

New calibration constant

You must type the new conversion constant in the Conversion Constant field on the Conversion tab. RSLogix 5000 does not automatically update the field after you use the Calculate button on this tab.

Length LDT length defines the stroke of travel of the hydraulic cylinder. LDT length is used with the number of recirculations

to calculate the minimum servo update period.

Scaling Scaling defines the relationship between the transducer unit of measure, as defined in the transducer length field,

and the user’s unit of measure (e.g. 39.37 inches/meter) defined on the Units tab.

Enable Absolute

Absolute Feedback is always enabled for LDT.

Feedback

58 Publication 1756-UM525A-EN-P - June 2003

Feature: Definition:

Absolute Feedback Offset

Calculated Values:Conversion Constant

The absolute offset is used to place the machine zero point at the desired location relative to the zero point of the LDT. The LDT zero point is inside the transducer head and physically unattainable.

Calculation derived from values based on the configuration values entered for the LDT.

The calculated conversion "K" constant is derived based on the LDT configuration values entered on the Feedback tab. After proper LDT values are entered and the Calculate button is selected, the resultant "K" value is calculated. This "K" value must be taken from this tab and entered in as the Conversion constant on the Conversion tab.

You must type the new conversion constant in the Conversion Constant field on the Conversion tab. RSLogix 5000 does not automatically update the field after you use the Calculate button on this tab.

Using the 1756-HYD02 Module Features Chapter 4

Calculated Values:Minimum Servo Update Period

Calculation derived from values based on the configuration values entered for the LDT.

You can use the calculate button located on the Feedback tab to calculate the appropriate K constant value. The calculated K constant is derived based on the LDT configuration values entered on the Feedback tab, and must be taken from that tab and used here.

Conversion Tab

Use this tab to view the Positioning Mode and configure the Feedback Resolution for an axis. The table below lists the configurable features available on the Conversion tab.

Feature: Definition:

Positioning Mode The Linear positioning mode is the only positioning mode available on the 1756-HYD02 module. This mode

provides a maximum total linear travel of 230,000 feedback counts. With this mode, the unwind feature is disabled and you can specify the positive and negative travel limits for the axis to limit the linear travel distance traveled by the axis.

Conversion Constant Type the number of feedback counts per position unit. This conversion – or “K” – constant allows axis

position to be displayed, and motion to be programmed, in the position units set in the Units tab. The conversion constant is used to convert axis position units into feedback counts and vice versa. You can calculate this value on the Feedback tab.

Publication 1756-UM525A-EN-P - June 2003 59

Chapter 4 Using the 1756-HYD02 Module Features

Homing Tab

The table below lists the configurable features available on the Homing tab.

Feature: Definition:

Mode Select one of the following homing modes:

• Active: The homing sequence automatically moves the axis to find the home switch. Active homing

sequences use the trapezoidal velocity profile.

• Passive: Homing redefines the absolute position of the axis on the occurrence of a home switch. Passive

homing is most commonly used to calibrate uncontrolled axes, although it can also be used with controlled axes to create a custom homing sequence. Passive homing, for a given home sequence, works similar to the corresponding active homing sequence, except that no motion is commanded; the controller just waits for the switch events to occur.

• Absolute: The absolute homing process applies the configured Home Position to the reported position of the

absolute feedback device to establish the true absolute position of the axis. The only valid Home Sequence for an absolute Homing Mode is immediate.

The following examples assume that an initial motion is in a positive axial direction.

• Active Homing Configurations

• Active Immediate Home

• Active Bi-directional Home with Switch

• Active Uni-directional Home with Switch

• Passive Homing Configurations

• Passive Immediate Home

• Passive Home with Switch

Position This value, listed in position units, specifies the axis’ absolute position after the specified homing sequence has

been completed. In most cases, this position will be set to zero, although any value within the software travel limits can be used. After the homing sequence is complete, the axis is left in this position.

Offset Type the desired offset (if any) in position units the axis is to move, upon completion of the homing sequence, to

reach the home position. In most cases, this value will be zero.

Sequence Select which event sets the Home Position:

• Immediate: Sets the Home Position to the present actual position, without motion.

• Switch: Sets the Home Position when axis motion encounters a home limit switch.

Limit Switch Specifies the usual state of the home limit switch:

• Normally Open

• Normally Closed

60 Publication 1756-UM525A-EN-P - June 2003

Feature: Definition:

Active Home

For active homing sequences, except for the Immediate Sequence type, select the desired homing direction: Sequence Group: Direction

• Forward Bi-directional - The following events occur: a. The axis moves forward at the rate specified in the Speed field until a homing event occurs (i.e. a switch

turns ON).

b. When the switch turns ON, the axis reverses its direction at the rate specified in the Return Speed field

until the switch turns OFF.

c. If an Offset value is specified, the axis continues in reverse for the corresponding distance.

When the axis stops moving, it is in the Home Position. The graphic below shows this sequence.

Step A – Speed

Step C –

Offset

Using the 1756-HYD02 Module Features Chapter 4

Step B –

Return Speed

Switch ON

Switch OFF

Home Position

• Forward Uni-directional – The following events occur: a. The axis moves forward at the rate specified in the Speed field until a homing event occurs (i.e. a switch

turns ON).

b. When the switch turns ON, the axis continues forward at the rate specified in the Return Speed field until

the switch turns OFF.

c. If an Offset value is specified, the axis continues forward the corresponding distance.

When the axis stops moving, it is in the Home Position.

• Reverse Bi-directional – The following events occur: a. The axis moves in reverse at the rate specified in the Speed field until a homing event occurs (i.e. a switch

turns ON).

b. When the switch turns ON, the axis moves forward at the rate specified in the Return Speed field until the

switch turns OFF.

c. If an Offset value is specified, the axis continues moving forward the corresponding distance.

When the axis stops moving, it is in the Home Position.

• Reverse Uni-directional – The following events occur: a. The axis moves in reverse at the rate specified in the Speed field until a homing event occurs (i.e. a switch

turns ON).

b. When the switch turns ON, the axis continues in reverse at the rate specified in the Return Speed field until

the switch turns OFF. c. If an Offset value is specified, the axis continues in reverse the corresponding distance. When the axis stops moving, it is in the Home Position.

Speed The moving axis’ speed used in the first leg of an active homing sequence. The homing speed specified should be

less than the maximum speed and greater than zero.

Publication 1756-UM525A-EN-P - June 2003 61

Chapter 4 Using the 1756-HYD02 Module Features

Feature: Definition:

Return Speed The moving axis’ speed in the return leg(s) of an active homing sequence. The home return speed specified

should be less than the maximum speed and greater than zero.

Hookup Tab

Use this tab to configure and initiate axis hookup test sequences for the axis. The table below lists the configurable features available on the Hookup tab.

Feature: Definition:

Test Increment Specifies the distance the axis travels when executing the Output & Feedback test. Feedback Polarity Polarity of the LDT feedback.

• Positive

• Negative

When you execute either the Feedback Test or the Output & Feedback Test, this field is automatically set:

When properly configured, this setting makes sure that axis Actual Position value increases when the axis is moved in the user defined positive direction. This feature makes sure that programmatic requests to move in a positive direction result in positive motion on the axis.

Output Polarity Polarity of the analog output to the drive.

• Positive

• Negative

When you execute the Output & Feedback Test, this field is automatically set:

When properly configured, this setting and the Feedback Polarity setting ensure that, when the axis loop is closed, it is closed as a negative feedback system and not an unstable positive feedback system. This feature makes sure that programmatic requests to move in a positive direction result in positive motion on the axis.

Test Feedback Runs the Feedback Test, which checks and, if necessary, reconfigures the Feedback Polarity setting. When

the test is initiated, you must manually move the axis. If physically moving the axis is too difficult, we recommend that you combine Test Feedback and Test Output & Feedback features to cause the movement.

Test Output & Feedback Runs the Output & Feedback Test, which checks and, if necessary, reconfigures both the polarity of feedback

(the Feedback Polarity setting) and the polarity of the output to the valve (the Output Polarity setting), for an axis configured for Servo operation in the General tab of this dialog box.

Executing any test operation automatically saves all changes to axis properties.

62 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Tune Tab

The table below lists the configurable features available on the Tune tab.

Feature: Definition:

Travel Limit Sets the axis’ travel limit during the tune test. If the hydraulic module determines that the axis will not be

able to complete the tuning process before exceeding the tuning travel limit, it will terminate the tuning profile and report that this limit was exceeded.

Speed Sets the maximum speed for the tune process. This value should be set to the desired maximum operating

speed of the axis (in engineering units) prior to running the tune test.

Direction Sets the direction of the tuning motion profile. Negative indicates reverse direction; positive indicates

forward direction.

Tune Selects the gains to be determined by the tuning test:

• Position Error Integrator

• Velocity Feedforward

• Output Filter

• Velocity Error Integrator

Start Tuning Begins the tuning test. If the tuning process completes successfully, the following attributes are set:

• Gains tab - Set the following attributes here:

• Velocity Feedforward Gain (if checked under Tune, above)

• Position Proportional Gain and Position Integral Gain (if checked under Tune, above)

• Dynamics tab - Set the following attributes here:

• Maximum Velocity

• Maximum Acceleration

• Maximum Deceleration

• Output tab - Set the following attributes here:

• Velocity Scaling

• Low Pass Output Filter (see Note, below)

• Limits - The Position Error Tolerance attribute is set on this tab.

You can use this selection to adjust bandwidth values as needed. During tuning, if the controller detects a high degree of tuning inertia, it enables the Low Pass Output Filter and calculates and sets a value for Low Pass Output Filter Bandwidth. Executing a Tune operation automatically saves all changes to axis properties.

ATTENTION: This tuning procedure may cause axis motion with the controller in program mode.

Publication 1756-UM525A-EN-P - June 2003 63

Chapter 4 Using the 1756-HYD02 Module Features

Dynamics Tab

The parameters on this tab can be edited in two ways:

The parameters on this tab become read-only when the controller is online if the controller is set to Hard Run mode, or if a Feedback On condition exists.

When RSLogix 5000 is offline, the parameters described in Table can be edited and the program saved to disk using either the Save command or by clicking on the Apply button. You must re-download the edited program to the controller before it can be run.

• Type parameter changes in the fields available on this tab and use the OK or Apply buttons to save your edits.

• Edit in the Manual Adjust dialog. To do so: a. Click on the Manual Tune button. b. Use the spin controls to edit parameter settings.

Your changes are saved the moment a spin control changes any parameter value.

The table below lists the configurable features on the Dynamics tab.

Feature: Definition:

Maximum Velocity The steady-state speed of the axis, it is initially set to Tuning Speed by the tuning process. This value is

typically set to about 90% of the maximum speed rating of the motor. We recommend this value be set to 70% of the maximum speed where the maximum pressure is twice the valve-rated pressure and 57% of the maximum speed where the maximum pressure is three times the valve-rated pressure. This provides sufficient “head-room” for the axis to operate at all times within the speed limitations of the motor. Any change in value, caused by manually changing the spin control, is instantly sent to the controller.

Maximum Acceleration The maximum acceleration rate of the axis, in Position Units/second, it is initially set to approximately 85%

of the measured tuning acceleration rate by the tuning process. This provides sufficient “head-room” for the axis to operate at all times within the acceleration limits of the cylinder (or axis). Any change in value, caused by manually changing the spin control, is instantly sent to the controller.

Maximum Deceleration The maximum deceleration rate of the axis, in Position Units/second, it is initially set to approximately 85%

of the measured tuning deceleration rate by the tuning process. This provides sufficient “head-room” for the axis to operate at all times within the deceleration limits of the cylinder (or axis). Any change in value, caused by manually changing the spin control, is instantly sent to the controller.

64 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Gains Tab

Use this tab to perform the following offline functions:

• Adjust gain values that have been automatically set by the tuning process, that is, in the Tune tab.

• Manually configure gains for the position loop.

The 1756-HYD02 module uses a single digital control loop with proportional, integral, differential and feed-forward gains. The parameters on this tab can be edited in two ways:

• Type parameter changes in the fields available on this tab and use the OK or Apply buttons to save your edits.

• Edit in the Manual Adjust dialog. To do so: a. Click on the Manual Tune button. b. Use the spin controls to edit parameter settings.

Your changes are saved the moment a spin control changes any parameter value.

The parameters on this tab become read-only when the controller is online if the controller is set to Hard Run mode, or if a Feedback On condition exists.

When RSLogix 5000 is offline, the parameters described in Table can be edited and the program saved to disk using either the Save command or by clicking on the Apply button. You must download the edited program to the controller before it can be run.

Publication 1756-UM525A-EN-P - June 2003 65

Chapter 4 Using the 1756-HYD02 Module Features

The table below lists the configurable features available on the Gains tab.

Feature: Definition:

Position Gains: Proportional Position gain is used with position error to correct an axis’ position. The proportional gain specifies the

amount of correction (velocity command) that the controller applies for each unit of position error. You must determine how much position error is expected while an axis runs at a specific speed.

To produce a component of the Velocity Command that ultimately attempts to correct for the position error, multiply the Position Gains:Proportional by the Position Error.

• Too little Position Gains:Proportional results in excessively compliant, or mushy, axis behavior.

• Too large a Position Gains:Proportional, on the other hand, can result in axis oscillation due to loop

instability.

To set the gain manually, you must first set the velocity output scaling factor in the Output tab of this dialog.

If you know the desired position loop gain in inches per minute per mil or millimeters per minute per mil, use the following formula to calculate the corresponding P gain:

Position Gains:Proportional = 16.667 * Desired Loop Gain (IPM/mil)

If you know the desired gain bandwidth of the position loop in Hertz, use the following formula to calculate the corresponding P gain:

Position Gains:Proportional = Bandwidth (Hertz) x 6.28

The typical value for the Position Gains:Proportional is ~100 Sec-

Position Gains: Integral The Integral (i.e., summation) of Position Error is multiplied by the Position Gains: Integral, or Pos I Gain, to

produce a component to the Velocity Command that ultimately attempts to correct for the position error. Position Gains: Integral improves the steady-state positioning performance of the system. Increasing the integral gain generally increases the ultimate positioning accuracy of the system. Excessive integral gain, however, results in system instability.

In certain cases, Position Gains: Integral control is disabled. One such case is when the analog output to the axis’ drive is saturated. Continuing integral control behavior in this case would only exacerbate the situation. When the Integrator Hold parameter is set to Enabled, the axis loop automatically disables the integrator during commanded motion.

The Position Gains: Integral is also disabled when the axis’ actual position is within the deadband compensation window of the target position. This keeps the axis from hunting when valves with overlapped spools are used.

While the Position Gains: Integral is typically established by the automatic axis loop tuning procedure (in the Tuning tab of this dialog), its value may also be set manually. Before doing this, the Velocity Scaling factor for the axis must be established for the drive system. Once this is done, the Position Gains: Integral can be computed based on the current or computed value for the Position Gains:Proportional using the following formula:

Position Gains: Integral =.025 X 0.001 s/ms X (Position Gains:Proportional)

Assuming a Position Gains:Proportional value of 100 Sec-1 this results in a Position Gains: Integral value of

0.25 1/ms-s

66 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Feature: Definition:

Position Gains: Differential Velocity Error is multiplied by the Position Gains: Differential to produce a component to the analog output

or Velocity Command that ultimately attempts to correct for the velocity error, creating a damping effect. Thus, increasing the Position Gains: Differential results in smoother motion, enhanced acceleration, reduced overshoot, and greater system stability. However, too much Position Gains: Differential leads to high frequency instability and resonance effects.

Feedforward Gains: Velocity

Feedforward Gains: Velocity scales the current Command Velocity by the Feedforward Gains: Velocity and adds it as an offset. Hence, the Feedforward Gains: Velocity allows the following error of the hydraulic closed loop system to be reduced to nearly zero when running at a constant speed. This is important in applications such as electronic gearing, position camming, and synchronization applications, where it is necessary that the actual axis position not significantly lag behind the commanded position at any time.

The optimal value for Feedforward Gains: Velocity is 100%. However, you may need to adjust the value to accommodate axes with non-linear characteristics and other application considerations.

Feedforward Gains: Acceleration

Feedforward Gains: Acceleration scales the current Command Acceleration by the Feedforward Gains: Acceleration and adds it as an offset to the analog output generated by the position loop. With this done, the position loops do not need to generate much of a contribution to the analog output, hence the Position and/or Velocity Error values are significantly reduced.

When used in conjunction with the Feedforward Gains: Velocity, the Feedforward Gains: Acceleration allows the following error of the hydraulic closed loop system during the acceleration and deceleration phases of motion to be reduced to nearly zero. This is important in applications such as electronic gearing, position camming, and synchronization applications, where it is necessary that the actual axis position not significantly lag behind the commanded position at any time.

Remember, however, because the output is scaled in velocity, the Feedforward Gains:Acceleration calibration is application-dependent.

Integrator Hold The integrator is always enabled. With this setting, the position loop temporarily disables the integrators

while the command position is changing. Point-to-point moves use this feature to minimize the integrator wind-up during motion.

Manual Tune This button accesses the Gains tab of the Manual Tune dialog for online editing.

The Manual Tune button is disabled when RSLogix 5000 is in Wizard mode, and when you have not yet saved or applied your offline edits to the other parameters in this table.

Publication 1756-UM525A-EN-P - June 2003 67

Chapter 4 Using the 1756-HYD02 Module Features

Output Tab

Use the Output tab for offline configuration of the following:

The parameters on this tab can be edited in two ways:

• Scaling values that are used to generate gains.

• The analog loop’s low-pass digital output filter.

• Type parameter changes in the fields available on this tab and use the OK or Apply buttons to save your edits.

• Edit in the Manual Adjust dialog. To do so: a. Click on the Manual Tune button. b. Use the spin controls to edit parameter settings.

Your changes are saved the moment a spin control changes any parameter value.

The parameters on this tab become read-only when the controller is online if the controller is set to Hard Run mode, or if a Feedback On condition exists.

When RSLogix 5000 is offline, the following parameters can be edited and the program saved to disk using either the Save command or by clicking on the Apply button. You must download the edited program to the controller before it can be run.

The table below lists the configurable features available on the Output tab.

Feature: Definition:

Velocity Scaling Converts the output of the position loop into equivalent voltage to an external hydraulic axis. This

conversion “normalizes” the units of the position loop gain parameters so that variations in feedback resolution, drive scaling, or mechanical gear ratios do not affect their values. The automatic loop tuning procedures typically establish the Velocity Scaling value, but these values can be calculated, if necessary, using the following guidelines.

Velocity Scaling = 100% / (Speed @ 100%)

For example, if this axis is using position units of inches, and the hydraulic system is designed such that with an input of 100% (e.g. 10 Volts) the axis goes 55.6 inches per second, the Velocity Scaling attribute value would be calculated as:

Velocity Scaling = 100% / (55.6) = 1.8% / Inches Per Second

68 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Feature: Definition:

Direction Scaling Ratio The directional scaling ratio compensates for the difference in the maximum speed in the extend vs. retract

direction on single-ended hydraulic cylinders. Different piston areas on the cap (blind) end compared to the rod end of the cylinder cause the speed difference.

Hydraulic Cylinder

Cap End

Piston

Rod End

Rod

Enable Low-pass Output Filter

Low-pass Output Filter Bandwidth

Cap End Area =

Rod End Area =

Depending on your Feedback Polarity Setting

Directional Scaling Ratio =

[(Cylinder Radius)

x (pi)]

–

x (pi)]

Cap End Area Rod End Area

Rod End Area Cap End Area

[(Rod Radius)

x (pi)]

To find this value, you can run the auto-tune routine in both directions and find the ratio of the velocity scaling in the two directions.

Enables the axis loop’s low-pass digital output filter.

During tuning, if the controller detects a high degree of tuning inertia, it enables the Low Pass Output Filter and calculates and sets a value for Low Pass Output Filter Bandwidth.

This Hertz bandwidth value filters out high frequency variation of the hydraulic module output to the drive. All output from the hydraulic module greater than the Filter Bandwidth setting will be filtered-out, and not sent to the drive.

If the Low-pass Output Filter Bandwidth value is set to zero, the low-pass output filter is disabled. The lower the Filter Bandwidth value, the greater the attenuation of these high frequency components of the output signal. Because the low-pass filter adds lag to the position loop, which pushes the system towards instability, decreasing the Filter Bandwidth value usually requires lowering the Position or Velocity Proportional Gain settings to maintain stability. The output filter is particularly useful in high inertia applications where resonance behavior can severely restrict the maximum bandwidth capability of the position loop.

Manual Adjust Click on this button to access the Output tab of the Manual Tune dialog for online editing.

The Manual Tune button is disabled when RSLogix 5000 is in Wizard mode, and when you have not yet saved or applied your offline edits to the above parameters.

Publication 1756-UM525A-EN-P - June 2003 69

Chapter 4 Using the 1756-HYD02 Module Features

Limits Tab

Use the Limits tab to set the following parameters offline:

The parameters on this tab can be edited in two ways:

• Enable positive and negative software travel limits

• Set maximum positive and negative software travel limits

• Configure Position Error Tolerance

• Configure Position Lock Tolerance

• Set the module’s Output Limit

• Type parameter changes in the fields available on this tab and use the OK or Apply buttons to save your edits.

• Edit in the Manual Adjust dialog. To do so: a. Click on the Manual Tune button. b. Use the increase/decrease arrows to edit parameter settings.

Your changes are saved the moment increase/decrease arrows change any parameter value.

The parameters on this tab become read-only when the controller is online if the controller is set to Hard Run mode, or if a Feedback On condition exists.

The table below lists the configurable features available on the Limits tab.

Feature: Definition:

Soft Travel Limits Enables software overtravel checking for an axis when Positioning Mode is set to Linear (on the Conversion

tab).

If an axis is configured for software overtravel limits, and if that axis passes beyond these maximum travel limits (positive or negative), a software overtravel fault is issued. The response to this fault is specified by the Soft Overtravel setting (on the Fault Actions tab). Software overtravel limits are disabled during the tuning process.

When Soft Travel Limits are enabled, the travel limits are active even if the axis has not been honed or before an absolute home position has been established. Under this condition, maximum positive and maximum negative travel limit positions are not necessarily related to user-defined references.

Soft Travel Limits:Maximum Positive

Soft Travel Limits:Maximum Negative

70 Publication 1756-UM525A-EN-P - June 2003

Type the maximum positive position to be used for software overtravel checking, in position units. The Maximum Positive limit must be greater than the Maximum Negative limit.

Type the maximum negative position to be used for software overtravel checking, in position units. The Maximum Negative limit must be less than the Maximum Positive limit.

Using the 1756-HYD02 Module Features Chapter 4

Feature: Definition:

Position Error Tolerance Specifies how much position error the axis loop tolerates before issuing a position error fault. This value is

interpreted as a +/- quantity.

For example, setting Position Error Tolerance to 0.75 position units means that a position error fault will be generated whenever the position error of the axis is greater than 0.75 or less than -0.75 position units.

This value is set to twice the following error at maximum speed based on the measured response of the axis, during the autotuning process. In most applications, this value provides reasonable protection in case of an axis fault or stall condition without nuisance faults during normal operation. If you need to change the calculated position error tolerance value, the recommended setting is 120% to 150% of the position error while the axis is running at its maximum speed.

Position Lock Tolerance Specifies the maximum position error the hydraulic module accepts to indicate the Position Lock status bit is

set. This is useful in determining when the desired end position is reached for position moves. This value is interpreted as a +/- quantity.

For example, specifying a lock tolerance of 0.01 provides a minimum positioning accuracy of +/- 0.01 position units.

Output Limit Provides a method of limiting the maximum analog output voltage of a physical axis to a specified level. The

analog output for the axis as a function of position loop error, both with and without analog output limiting.

The analog output limit may be used if the valve cannot accept the full +/-10V range of the analog output. In this case, the analog output limit value effectively limits the maximum command sent to the valve. For example, if the valve can only accept command signals up to +/-7.5V, set the analog output limit value to

7.5V.

Manual Adjust This button accesses the Limits tab of the Manual Tune dialog for online editing.

The Manual Tune button is disabled when RSLogix 5000 is in Wizard mode, and when you have not yet saved or applied your offline edits to the above parameters.

Publication 1756-UM525A-EN-P - June 2003 71

Chapter 4 Using the 1756-HYD02 Module Features

Offset Tab

Use the Offset tab to make offline adjustments to the following values:

The parameters on this tab can be edited in two ways:

• Deadband Compensation

• Velocity Offset

•Output Offset

• Type parameter changes in the fields available on this tab and use the OK or Apply buttons to save your edits.

• Edit in the Manual Adjust dialog. To do so: a. Click on the Manual Tune button. b. Use the spin controls to edit parameter settings.

Your changes are saved the moment a spin control changes any parameter value.

Feature: Definition:

Friction/Deadband Compensation: Friction Compensation

Friction/Deadband Compensation: Window

The percentage of output level added to the current positive value, or subtracted from the current negative value, for the purpose of moving an axis that is stuck in place due to static friction. The default value of this parameter is 0%.

It is not unusual for an axis to have enough static friction–called "sticktion"–that, even with a significant position error, the axis refuses to budge. Friction Compensation is used to break "sticktion" in the presence of a non-zero position error.

The Friction Compensation value should be slightly less than the value that would break the "sticktion". A larger value will cause the axis to "dither" (i.e. move rapidly back and forth about the commanded position).

This value is not applicable for Ultra3000 drives. This window is defined as: command position - window attribute to command position + window attribute

While the command velocity is zero and the actual position is within this window, the Friction Compensation (or Deadband Compensation, for Hydraulics) is applied proportionally to the position error. While the command velocity is non-zero, the full Friction Compensation is applied.

The parameters on this tab become read-only when the controller is online if the controller is set to Hard Run mode, or if a Feedback On condition exists.

Table lists the configurable features available on the Offset tab.

72 Publication 1756-UM525A-EN-P - June 2003

Feature: Definition:

Backlash Compensation: Reversal Offset

Use this feature to compensate for positional inaccuracy introduced by mechanical backlash. For example, power-train type applications require a high level of accuracy and repeatability during machining operations. Lost motion is often generated by a number of mechanical components that may introduce inaccuracies and that are subject to wear over their lifetime. Hence, when an axis is commanded to reverse direction, mechanical lost motion in the machine may result in a small amount of actuator motion without axis motion. As a result, the feedback device may indicate movement even though the axis has not physically moved.

The Reversal Offset specifies a directional offset that is added to the motion planner’s command position as it is applied to the associated axis loop to compensate for mechanical lost motion. When the commanded velocity changes sign (a reversal), the ControlLogix controller adds, or subtracts, the Reversal Offset value from the current commanded position; the axis immediately moves the motor to the other side of the lost motion window and engages the load. The application of this directional offset is completely transparent and does not affect the value of the Command Position attribute.

If a value of zero is applied to the Reversal Offset, the feature is effectively disabled. Once enabled by a non-zero value, and the load is engaged by a reversal of the commanded motion, changing the Reversal Offset can cause the axis to shift as the offset correction is applied to the command position.

Backlash Compensation: Stabilization Window

Eliminates backlash-induced instability while maintaining full system bandwidth. This algorithm value should be commensurate with the amount of backlash in the mechanical system.

Using the 1756-HYD02 Module Features Chapter 4

Mechanical backlash is a common problem in applications that use mechanical gearboxes. Until the input gear is turned to the point where its proximal tooth contacts an adjacent tooth of the output gear, the reflected inertia of the output is not felt at the actuator (i.e. when the gear teeth are not engaged, the system inertia is reduced to the motor inertia).

If the axis loop is tuned for peak performance with the load applied, the axis will be at best under-damped and at worst unstable in the condition where the gear teeth are not engaged. In the worst case scenario, the motor axis and the input gear oscillates wildly between the limits imposed by the output gear teeth. The net effect is a loud buzzing sound when the axis is at rest. If this situation persists the gearbox will wear out prematurely. To prevent this condition, the conventional approach is to de-tune the loop so that the axis is stable without the gearbox load applied. Unfortunately, system performance suffers.

The key to this algorithm is a tapered Torque Scaling profile, that is a function of the position error of the axis loop. The reason for the tapered profile, as opposed to a step profile, is that when the position error exceeds the backlash distance a step profile would create a very large discontinuity in the torque output. This repulsing torque tends to slam the axis back against the opposite gear tooth and perpetuate the buzzing effect. The tapered profile is only run when the acceleration command to the axis loop is zero, i.e. when we are not commanding any acceleration or deceleration that would engage the teeth of the gearbox.

Properly configured with a suitable value for the Backlash Stabilization Window, this algorithm entirely eliminates the gearbox buzz without sacrificing any axis performance. The Backlash Stabilization parameter determines the width of the window over which backlash stabilization is applied. In general, this value should be set to the measured backlash distance. A Backlash Stabilization Window value of zero effectively disables the feature. (Patent Pending)

Velocity Offset Provides a dynamic velocity correction to the output of the position loop, in position units per second.

Because the position loop output value is updated synchronously every Coarse Update Period, the Velocity Offset can be tied into custom outer control loop algorithms using Function Block programming. Position loop is still closed and compensates for velocity offset values by changing position error. Position error faults are possible.

Publication 1756-UM525A-EN-P - June 2003 73

Chapter 4 Using the 1756-HYD02 Module Features

Feature: Definition:

Output Offset Corrects the problem of axis “offset”, by adding a fixed voltage value (not to exceed +/-10V) to the analog

output value. Use a value to achieve near zero axis velocity when the uncompensated analog output value is zero.

When interfacing to a valve on a hydraulic axis, it is necessary to compensate for the effect of drive offset. Cumulative offsets of the hydraulic module’s DAC output and the Axis Input result in a situation where a zero commanded analog output value causes the axis to “drift”. If the drift is excessive, it can play havoc on the Hookup Diagnostic and Tuning procedures, as well as result in a steady-state non-zero position error when the axis loop is closed.

Manual Adjust Click on this button to access the Offset tab of the Manual Tune dialog for online editing.

The Manual Tune button is disabled when RSLogix 5000 is in Wizard mode, and when you have not yet saved or applied your offline edits to the above parameters.

Fault Actions Tab

You must set the action if any of the faults listed in Table occurs. The possible options are:

•Shutdown

• Disable Drive

• Stop Motion

• Status Only - When this option is chosen for any fault condition, the fault does not cause the axis to stop its current motion. However, new motion is prevented from starting.

The table below lists the faults that may occur:

Fault Type: Definition:

Drive Fault Specifies the fault action to be taken when a drive fault condition is detected, for an axis with the Drive

Fault Input enabled (in the Servo tab of this dialog) that is configured as Servo (in the General tab of this

dialog). Feedback Noise Specifies the fault action to be taken when excessive feedback noise is detected. Feedback Specifies the fault action to be taken when feedback loss condition is detected.

ATT ENTI ON: If a feedback fault occurs, the 1756-HYD02 module cannot control the axis. We recommend

you use either the shutdown or disable drive option for this setting. If used, the stop motion and status only options may cause dangerous conditions when a feedback fault occurs.

Position Error Specifies the fault action to be taken when position error exceeds the position tolerance set for the axis, for

an axis configured as Servo (on the General tab). Soft Overtravel Specifies the fault action to be taken when a software overtravel error occurs, for an axis with Soft Travel

Limits enabled and configured (on the Limits tab) that is configured as Servo (on the General tab).

74 Publication 1756-UM525A-EN-P - June 2003

Using the 1756-HYD02 Module Features Chapter 4

Table describes the possible actions if any of the faults listed in Table occurs

Fault: Definition:

Shutdown If a fault action is set to Shutdown, when the associated fault occurs:

• servo action status is immediately disabled,

• the drive output is zeroed,

and

• the appropriate drive enable output is deactivated.

Furthermore, this fault action opens the OK contact associated with the hydraulic module that can be used to open the E-stop string to the hydraulic power unit.

Shutdown is the most severe action to a fault and it is usually reserved for faults that could endanger the machine or the operator if power is not removed as quickly and completely as possible.

Disable Drive If a fault action is set to Disable Drive, when the associated fault occurs:

• servo action status is immediately disabled,

• the drive output is zeroed,

and

• the appropriate drive enable output is deactivated.

Stop a Motion If a fault action is set to Stop Motion, when the associated fault occurs, the axis immediately starts

decelerating the axis command position to a stop at the configured Maximum Deceleration Rate without disabling servo action status or the hydraulic modules Drive Enable output.

This is the gentlest stopping mechanism in response to a fault. It is usually used for less severe faults. After the stop command fault action has stopped the axis, no further motion can be generated until the fault is first cleared.

Status Only If a fault action is set to Status Only, when the associated fault occurs, no action is taken. The application

program must handle any motion faults. In general, this setting should only be used in applications where the standard fault actions are not appropriate.

ATTENTION: Selecting the wrong fault action for your application can cause a dangerous condition. Keep

clear of moving machinery.

Publication 1756-UM525A-EN-P - June 2003 75

Chapter 4 Using the 1756-HYD02 Module Features

Tag Tab

Use this tab to change the name and description of the axis. When you are online, all of the parameters on this tab transition to a read-only state, and cannot be modified. If you go online before you save your changes, all pending changes revert to their previously-saved state.

The table below lists the features available on the Tag tab. Some of these features cannot be changed on this screen however.

Fault Type: Definition:

Name Displays the name of the current tag. Description Displays the description of the current tag, if any is available. Tag Type Indicates the current tag type.

• Base

• Alias

• Consumed

Data Type Displays the data type associated with the current tag. Scope Displays the scope of the current tag. For axis tags, the scope must be controller scope. Style Displays the default style in which to display the value of the tag. Note that style is only applicable to an

atomic tag; a structure tag does not have a display style.

Chapter Summary and What’s Next

In this chapter, you read about the 1756-HYD02 module’s features.

Chapter 5 describes

Troubleshooting the 1756-HYD02 Module

76 Publication 1756-UM525A-EN-P - June 2003

Chapter

Troubleshooting the 1756-HYD02 Module

What This Chapter Contains

Using the Status Indicators

This chapter describes how to troubleshoot the 1756-HYD02 module.

The ControlLogix Hydraulic Servo module uses a single bi-colored LED to indicate module OK status and bi-colored LED indicators to show individual feedback (FDBK) and drive (DRIVE) status for both axes.

During power-up, the module completes an indicator test. The OK indicator turns red for 1 second and then turns to flashing green if the module passes all its self tests.

The module’s status indicators are shown below.

For more information about: See page:

Using the Status Indicators 77 Using the OK Indicator 78 Using the FDBK Indicator 79 Using the DRIVE Indicator 80 Using RSLogix 5000 to Troubleshoot the

Module

43454

77Publication 1756-UM525A-EN-P - June 2003 77

Chapter 5 Troubleshooting the 1756-HYD02 Module

Using the OK Indicator

The module’s OK indicator is shown below.

OK indicator

The table below explains the OK indicator.

OK Indicator Displays

If the OK indicator displays:

Off The module is not operating. • Apply chassis power.

Flashing green light

The module status is: Take this action:

• Verify the module is completely inserted into the chassis and backplane.

The module has passed internal diagnostics, but it is not communicating axis data over the backplane.

• Configure the module to begin communications.

• If you have configured the module, check the slot

number in the 1756-HYD02 Properties dialog box.

43454

Steady green light

Flashing red light One of the following:

Steady red light One of the following:

One of the following:

· Axis data is being exchanged with the module.

· The module is in the normal operating state.

• A major recoverable failure has occurred.

• A communication fault, timer fault, or NVS update is

in progress.

• The OK contact has opened.

• A potential non- recoverable fault has occurred.

• The OK contact has opened.

None

If a Non-Volatile Storage (NVS) update is in progress, complete the NVS update.

If an NVS update is not in progress, follow these steps:

1. Check the Servo Fault word for the source of the error.

2. Clear the servo fault condition using the Motion Axis Fault Reset instruction.

3. Resume normal operation.

4. If the flashing persists, reconfigure the module.

Follow these steps:

1. Reboot the module.

2. If the solid red persists, replace the module.

78 Publication 1756-UM525A-EN-P - June 2003

Troubleshooting the 1756-HYD02 Module Chapter 5

Using the FDBK Indicator

The module’s FDBK indicators are shown in Figure . Make sure that any transducer used with the 1756-HYD02 module uses an external interrogation signal.

Feedback indicators

43454

The table below explains the FDBK indicators.

FDBK Indicator Displays

If the FDBK indicator displays:

Off The axis is not used. If you are using this axis, make sure the module is

The module status is: Take this action:

configured and an axis tag has been associated with the module.

Flashing green light

Steady green light

Flashing red light The axis servo loop error tolerance has been exceeded. Follow these steps:

Steady red light An axis LDT feedback fault has occurred. Follow these steps:

The axis is in the normal servo loop inactive state. None. The servo axis state can be changed by executing

motion instructions.

The axis is in the normal servo loop active state. None. The servo can may be changed by executing motion

instructions.

1. Correct the source of the problem.

2. Clear the servo fault condition using the Motion Axis Fault Reset instruction.

3. Resume normal operation.

1. Correct the source of the problem by checking the LDT and power connections.

2. Clear the servo fault condition using the Motion Axis Fault Reset instruction.

3. Resume normal operation.

Publication 1756-UM525A-EN-P - June 2003 79

Chapter 5 Troubleshooting the 1756-HYD02 Module

Using the DRIVE Indicator

The module’s DRIVE indicators are shown in Figure .

Drive indicators

43454

The table below explains the DRIVE indicator.

DRIVE Indicator Displays

If the DRIVE indicator displays:

Off One of the following:

Flashing green light

Steady green light The axis drive is in the normal enabled state. None. The servo axis state can be changed by executing

Flashing red light The axis drive output is in the shutdown state. Follow these steps:

The module status is: Take this action:

If the axis is being used and is not a position-only axis type, make sure the module is configured, an axis tag has

• The axis is not used.

• The axis is a position-only axis type.

The axis drive is in the normal disabled state. None. The servo axis state can be changed by executing

been associated with the module, and the axis type is servo.

motion instructions.

1. Check for faults that may have generated this state.

2. Execute the Shutdown Reset motion instruction.

3. Resume normal operation.

Steady red light The axis drive is faulted. Follow these steps:

1. Check the drive status.

2. Clear the Drive Fault condition at the drive.

3. Clear the servo fault condition using the Motion Axis Fault Reset instruction.

4. Resume normal operation.

5. Check the configuration for the Drive Fault.

• If configured to be normally open and there is no voltage, this is the normal condition.

• If configured to be normally closed and 24V is applied, this is the normal condition.

80 Publication 1756-UM525A-EN-P - June 2003

Troubleshooting the 1756-HYD02 Module Chapter 5

Using RSLogix 5000 to Troubleshoot the Module

You can also use the RSLogix 5000 programming software to detect and diagnose problems with the ControlLogix Hydraulic Servo module. The software alerts you to fault and other conditions in the following ways:

· Warning Signal in Controller Organizer

· Fault Message in Status Line

· Notification in Axis Structure

Warning Signal in Controller Organizer

The warning signal appears in the module listing as shown below.

Publication 1756-UM525A-EN-P - June 2003 81

Chapter 5 Troubleshooting the 1756-HYD02 Module

Fault Message in Status Line

The module status line appears in the lower left corner of each configuration tab. It provides a brief explanation of the module status and reports Faulted when a fault has occurred on the module.

Explanation of the module fault

The number one (1) indicates a fault

Notification in Axis Structure

Use the Tag Monitor to view controller tags. A fault has occurred for any point that lists the number one (1) in the Fault line.

Chapter Summary and

In this chapter, you read about Troubleshooting the 1756-HYD02 Module. Appendix A lists the module

Specifications

What’s Next

82 Publication 1756-UM525A-EN-P - June 2003

Appendix

Specifications

Number of axes 2 axes maximum Servo loop

Typ e

Gain resolution Absolute position range

Rate Module location 1756 ControlLogix chassis Module keying Electronic Power dissipation 5.5W maximum Thermal dissipation 18.77 BTU/hr. Backplane current 5.1V dc @ 700mA and 24V dc @ 2.5mA

Proportional, integral and differential (PID) with Feed-Forwards and Directional scaling 32- bit floating point 230,000 LDT counts 500Hz to 4kHz (Selectable)

LDT input

Typ e

Sample rate

Resolution

Electrical interface

Input impedance

Output load Registration inputs

Typ e

24V dc input voltage

Maximum on

Minimum on

Maximum off

5V dc input voltage

Maximum on

Minimum on

Maximum off

Input impedance

24V dc input

5V dc input

Response time (position latched)

(1)

PWM, Start/Stop rising or falling edge 120MHz (8.33ns)

Less than 0.001 inch with single recirculation Isolated 5V differential (RS-422 signal) 215 Ohm differential 100 Ohm minimum

Optically isolated, current sinking input +24V dc nominal

26. 4V dc

18. 5V dc

3.5V dc +5V dc nominal

5.5V dc

3.7V dc

1.5V dc

1.2 kΩ

9.5 kΩ 1 servo update period - Servo update period is the period at which the position and/or velocity feedback is sampled and a new servo loop is closed to generate a new servo output. The time of this period is a user-defined setting from 250μs to 2000μs.

All other inputs

Typ e

Input voltage

Maximum on

Minimum on

Maximum off

Input impedance

Publication 1756-UM525A-EN-P - June 2003 83

Optically isolated, current sinking input +24V dc nominal

26. 4V dc

17. 0V dc

8.5V dc

7.5 kΩ

Appendix A Specifications

Servo output

Type Voltage range Voltage resolution Load Maximum offset Gain error

Analog voltage ±10V dc 16 bits

5.6 kOhms resistive minimum 25 mV ±4%

All other outputs

Type Operating voltage Maximum Operating current

Solid-state isolated relay contacts +24V dc nominal

26. 4V dc 75 mA

Isolation Voltage

User to System 30V continuous RTB keying User-defined Field wiring arm

36-position RTB (1756-TBCH or -TBS6H)

RTB screw torque (cage clamp)

4.4 inch-pounds (0.4Nm) maximum

(2)

Conductors

Wire size

#22 to #14 AWG (0.324 to 2.08 sq. mm) stranded 3/ 64 inch (1.2 mm) insulation maximum

Glossary

Broadcast

Data transmissions to all address or functions

Bumpless reconfiguration

A reconfiguration in which the real time data connection to the module is not closed and reopened. Communications are never interrupted and configuration data is applied to the module immediately. This works best in a single owner-controller system.

Compatible match

An electronic keying protection mode that requires that the physical module and the module configured in the software to match according to vendor and catalog number. In this case, the minor revision of the module must greater than or equal to that of the configured slot.

Connection

The communication mechanism from the controller to another module in the control system.

ControlBus

The backplane used by the 1756 chassis.

ControlLogix chassis

Hardware assembly that houses devices such as ControlLogix Hydraulic Servo modules, ControlLogix controllers and power supplies.

ControlLogix controller

Controller used in the ControlLogix system that uses programmable memory for storage of data to implement specific functions such as I/O control, logic, timing and data file manipulation. The ControlLogix controller owns and communicates with the ControlLogix Hydraulic Servo module to control hydraulic applications.

ControlLogix power supply

An electrical circuit that filters, conditions and supplies appropriate voltages for system components and circuitry.

Publication 1756-UM525A-EN-P - June 2003 87

Glossary

Disable keying

An electronic keying protection mode that requires no attributes of the physical module and the module configured in the software to match

Download

The process of transferring the contents of a project on the workstation into the controller

Electronic keying

A feature where modules can be requested to perform an electronic check to make sure that the physical module is consistent with what was configured by the software

Exact match

An electronic keying protection mode that requires the physical module and the module configured in the software to match according to vendor, catalog number, major revision and minor revision

Field side

Interface between user field wiring and I/O module

Inhibit

A ControlLogix process that allows you to configure the Hydraulic Servo module but prevent it from communicating with the owner-controller. In this case, the controller behaves as if the module does not exist at all

Interface module (IFM)

A module that uses prewired cable to connect wiring to an I/O module

Linear displacement transducer (LDT)

Feedback device connected to the ControlLogix Hydraulic Servo module that provides axis position data. Any LDT used with the ControlLogix Hydraulic Servo module should use an external interrogation signal.

88 Publication 1756-UM525A-EN-P - June 2003

Glossary

Major revision

A module revision that is updated any time there is a functional change to the module

Minor revision

A module revision that is updated any time there is a change to the module that does not affect its function or interface

Owner-controller

The controller that creates and stores the primary configuration and communication connection to a module

Position loop

Part of motion control firmware responsible for:

· comparing measured position with command position to determine a position error

and

· generating a signal to an actuator to reduce any position error that may occur.

Program Mode

In this mode the following events occur:

· Controller program is not executing.

· Inputs are still actively producing data.

· Outputs are not actively controlled and go to their configured program

mode

Removal and insertion under power (RIUP)

ControlLogix feature that allows a user to install or remove a module or RTB while power is applied

Removable Terminal Block (RTB)

Field wiring connector for I/O modules

RSLogix 5000

Programming software used to configure and troubleshoot the ControlLogix Hydraulic Servo module.

Publication 1756-UM525A-EN-P - June 2003 89

Glossary

Run mode

In this mode, the following events occur:

· Controller program is executing

· Inputs are actively producing data.

· Outputs are actively controlled

Service

A system feature that is performed on user demand, such as fuse reset or diagnostic latch reset

Status indicators

Indicators on the front of the ControlLogix Hydraulic Servo module that display the general status of the module and specific status of individual feedback and drive conditions for the axes connected to the module.

System side

Backplane side of the interface to the I/O module

Tag

A named area of the controller’s memory where data is stored

90 Publication 1756-UM525A-EN-P - June 2003

Index

Numerics

1756-SYNCH module

Using with the 1756-HYD02 module

Agency approvals 11 Axes properties

Configuring in RSLogix 5000

tion

52 60

Conversion tab

Conversion constant Positioning mode

Dynamics tab

Maximum acceleration Maximum deceleration Maximum velocity

Fault actions tab

Drive fault Feedback Feedback noise Position error Soft overtravel

Feedback tab

Absolute feedback offset Calibration constant LDT type Length Recirculations Scaling

Gains tab

Feedforward gains-acceleration Feedforward gains-velocity Integrator hold Manual tune Position gains-differential Position gains-integral

Position gains-proportional General tab Homing tab

Active home sequence group-direc-

Limit switch

Mode

Offset

Position

Return speed

Sequence

Speed

Hookup tab

Limits tab

Motion planner tab

Offset tab

Output tab

Servo tab

Tag tab Tune tab

Units tab

Feedback polarity Output polarity Test increment

62 62 62

Output limit Position error tolerance Position lock tolerance Soft travel limits Soft travel limits-maximum negative

Soft travel limits-maximum positive

Master delay compensation Master position filter bandwidth Output cam execution targets Program stop action

Backlash compensation-reversal off-

set

Backlash compensation-stabilization

window

Friction/deadband compensa-

tion-friction compensation

Friction/deadband compensa-

tion-window Output offset Velocity offset

Direction scaling ratio Low-pass output filter bandwidth Velocity scaling

Direct drive ramp rate Drive fault input External drive configuration Loop configuration Real time information

Direction Speed Travel limit

Average velocity timebase Position units

Publication 1756-UM525A-EN-P - June 2003 91

Index

Cage clamp RTB 16 Class I Division 2 compliance Configurable features of the 1756-HYD02

module

Axes features General module features

Configuration

Configuring the axes features Dynamic reconfiguration Editing configuration Overview of the process Reconfiguring parameters in program

Reconfiguring parameters in run mode Using RSLogix 5000

mode

52-76

38-39

31-40

42-51

Documentation

For other ControlLogix products used with

the 1756-HYD02 module

Dynamic reconfiguration

Electronic keying 34, 44-?? Electrostatic discharge (ESD)

Preventing

Extended-depth housing for RTBs

Cabinet size considerations

Inhibiting the module 35 Interface module (IFM)

10, 16

Keying

Electronic Mechanical 15

34, 44-??

Linear displacement transducer (LDT) 9

Connecting the LDT to the 1756-HYD02

21-22

module

Mechanical keying 15 Module identification information

Retrieving

OK contact wiring 20

Physical features of the 1756-HYD02

module

Preventing electrostatic discharge (ESD)

10-11

Fault reporting 43

Registration sensor wiring 19 Removable terminal block (RTB)

Home limit switch input wiring 20

92 Publication 1756-UM525A-EN-P - June 2003

Assembling Cage clamp Installation Mechanically keying the RTB Removal Spring clamp Types available with the 1756-HYD02

23 16

26-27

module

Index

Removal and insertion under power

(RIUP)

12, 14

mode

81-82

31-40

52 60

RSLogix 5000

Configuring the axes features Conversion tab Dynamics tab Electronic keying Fault actions tab Feedback tab Gains tab General tab Homing tab Hookup tab Limits tab Motion planner tab Offset tab Output tab Reconfiguring parameters in program

Reconfiguring parameters in run mode Servo tab Tag tab Tune tab Units tab Using the software in troubleshooting

Servo update period 42 Specifications

83-85

Spring clamp RTB Status indicators

Drive indicator Feedback (FDBK) indicator OK indicator

17 11, 77-80 80

Troubleshooting 77-82

Fault reporting Status indicators

Drive indicator Feedback (FDBK) indicator OK indicator

Using RSLogix 5000

11, 77-80

81-82

Wiring connections 16-22

Choosing the extended-depth housing Connecting LDTs to the 1756-HYD02

21-22

module

Example diagram of 1756-HYD02 wiring

18 Home limit switch input OK contacts Recommendations for wiring RTBs Registration sensors Using the cage clamp RTB Using the spring clamp RTB

Publication 1756-UM525A-EN-P - June 2003 93

Index

94 Publication 1756-UM525A-EN-P - June 2003

How Are We Doing?

Your comments on our technical publications will help us serve you better in the future. Thank you for taking the time to provide us feedback.

You can complete this form and mail (or fax) it back to us or email us at RADocumentComments@ra.rockwell.com.

Pub. Title/Type ControlLogix Hydraulic Servo Module

Cat. No.

1756-HYD02

Pub. No. 1756-UM525A-EN-P Pub. Date June 2003 Part No. 957678-84

Please complete the sections below. Where applicable, rank the feature (1=needs improvement, 2=satisfactory, and 3=outstanding).

Overall Usefulness 1 2 3 How can we make this publication more useful for you?

Completeness

(all necessary information

is provided)

Technical Accuracy

(all provided information

is correct)

1 2 3 Can we add more information to help you?

procedure/step illustration feature example guideline other explanation definition

1 2 3 Can we be more accurate?

text illustration

(all provided information is

Clarity

easy to understand)

Other Comments You can add additional comments on the back of this form.

Your Name

Your Title/Function Would you like us to contact you regarding your comments?

Location/Phone

Return this form to: Rockwell Automation Technical Communications, 1 Allen-Bradley Dr., Mayfield Hts., OH 44124-9705

Publication CIG-CO521D-EN-P- July 2007

1 2 3 How can we make things clearer?

___No, there is no need to contact me ___Yes, please call me ___Yes, please email me at _______________________ ___Yes, please contact me via _____________________

Fax: 440-646-3525 Email: RADocumentComments@ra.rockwell.com

Other Comments

PLEASE FASTEN HERE (DO NOT STAPLE)

PLEASE FOLD HERE

BUSINESS REPLY MAIL

FIRST-CLASS MAIL PERMIT NO. 18235 CLEVELAND OH

POSTAGE WILL BE PAID BY THE ADDRESSEE

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED STATES

PLEASE REMOVE

1 ALLEN-BRADLEY DR MAYFIELD HEIGHTS OH 44124-9705

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products. At manuals, a knowledge base of FAQs, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit

http://support.rockwellautomation.com

, you can find technical

Installation Assistance

If you experience a problem within the first 24 hours of installation, please review the information that's contained in this manual. You can also contact a special Customer Support number for initial help in getting your product up and running.

United States 1.440.646.3434

Monday – Friday, 8am – 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues.

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States Contact your distributor. You must provide a Customer Support case

number (call the phone number above to obtain one) to your distributor in order to complete the return process.

Outside United States

Please contact your local Rockwell Automation representative for the return procedure.

Publication 1756-UM525A-EN-P - June 2003 98 PN 957678-84

Rockwell Automation 1756-HYD02 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Preface

Using This Manual

The Purpose of This Manual

Related Documentation

What is the 1756-HYD02 Module?

What the Module Does

Using A ControlLogix Hydraulic Servo Module in the ControlLogix System

Certifying Agency Approvals

Preventing Electrostatic Discharge

Removal and Insertion Under Power

Chapter Summary and What’s Next

Installing the 1756-HYD02 Module

What This Chapter Contains

Installing the Module

Keying the Removable Terminal Block

Connecting Wiring

Wiring the 1756-HYD02 Module

Choosing the Extended-Depth Housing

Installing the Removable Terminal Block

Removing the Removable Terminal Block

Removing the Module from the Chassis

Chapter Summary and What’s Next

Configuring the 1756-HYD02 Module

Using RSLogix 5000 Configuration Software

Overview of the Configuration Process

Creating a New Module

Configuring General Module Features

Configuring the Axes Features

Downloading New Configuration Data

Editing Configuration

Reconfiguring Module Parameters in Run Mode

Reconfiguring Module Parameters in Program Mode

Chapter Summary and What’s Next

Using the 1756-HYD02 Module Features

What This Chapter Contains

Using General Module Features

Using Axes Features

Chapter Summary and What’s Next

Troubleshooting the 1756-HYD02 Module

What This Chapter Contains

Using the Status Indicators

Using the OK Indicator

Using the FDBK Indicator

Using the DRIVE Indicator

Using RSLogix 5000 to Troubleshoot the Module

Specifications

Glossary

Index

Numerics