Rockwell Automation 57C422B User Manual

2-Axis Servo Module

M/N 57C422B

Instruction Manual

J-3642-7

The information in this manual is subject to change without notice.

WARNING

THIS UNIT AND ITS ASSOCIATED EQUIPMENT MUST BE INSTALLED, ADJUSTED AND MAINTAINED BY QUALIFIED PERSONNEL WHO ARE FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF ALL EQUIPMENT IN THE SYSTEM AND THE POTENTIAL HAZARDS INVOLVED. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY

WARNING

INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION. POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE MODULE OR ITS CONNECTING CABLES. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY.

CAUTION

THIS MODULE CONTAINS STATIC-SENSITIVE COMPONENTS. CARELESS HANDLING CAN CAUSE SEVERE DAMAGE.

DO NOT TOUCH THE CONNECTORS ON THE BACK OF THE MODULE. WHEN NOT IN USE, THE MODULE SHOULD BE STORED IN AN ANTI-STATIC BAG. THE PLASTIC COVER SHOULD NOT BE REMOVED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE MATERIAL.

WARNING

RELIANCE STRONGLY RECOMMENDS THE USE OF AN EXTERNAL, HARDWIRED EMERGENCY STOP CIRCUIT THAT WILL DISABLE THE SYSTEM IN CASE OF IMPROPER OPERATION. UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY OR DAMAGE TO EQUIPMENT

Rellance® and AutoMax@ are trademarks of Reliance Electric Company or its

subsidiaries.

Rellance™ is a registered trademark of Reliance Electric Company or its subsidiaries.

1.0 Introduction......................................................................1-1

2.0 Mechanical/Electrical Description..................................2-1

2.1 Mechanical Description............................................2-1

2.2 Electrical Description ...............................................2-3

3.0 Installation........................................................................3-1

3.1 Wiring.......................................................................3-1

3.2 Initial Installation ......................................................3-1

3.3 Module Replacement.............................................3-11

4.0 Programming....................................................................4-1

4.1 Configuration ...........................................................4-2

4.2 Register 0: Encoder Setup.......................................4-3

4.3 Register 1: Drive Setup............................................4-4

4.4 Register 2: Switch Setup .........................................4-5

4.5 Register 3: Proportional Gain ..................................4-7

4.6 Register 4: Integral Gain..........................................4-7

4.7 Register 5: Velocity Gain.........................................4-7

4.8 Register 6: Feedforward Gain..................................4-8

4.9 Register 7: Deadband Compensation......................4-8

4.10 Register 8: Maximum Position Error........................4-9

4.11 Register 9: Maximum Velocity Error........................4-9

4.12 Register 10: In-Position Tolerance ........................4-10

4.13 Registers 11, 12: Positive Overtravel Limit............4-10

4.14 Registers 13, 14: Negative Overtravel Limit ..........4-11

4.15 Registers 15,16: Low Speed

Homing Reference.................................................4-11

4.16 Registers 17,18: Command Position .....................4-12

4.17 Registers 19, 20: Command Velocity ............. .......4-13

4.18 Registers 21, 22: Command Acceleration .............4-13

4.19 Registers 23, 24: Command Deceleration.............4-14

4.20 Registers 25, 26: Gear Ratio.......................... .......4-15

4.21 Register 27: User LEDs.........................................4-15

4.22 Register 28: Direct Drive Reference

Command..............................................................4-16

Note: Register descriptions for equivalent X and Y axis

registers are exactly the same. Although sections of Chapter 4 are titled by X axis register number, the equivalent Y register is given in the figure that accompanies each register description.

4.23 Registers 29, 30: Sync Position ............................ 4-16

4.24 Register 31: Maximum Voltage Reference ........... 4-17

4.25 Register 32: Positive Linearization Constant ........ 4-18

4.26 Register 33: Negative Linearization Constant....... 4-18

4.27 Registers 34,35: Feedback Unwind Constan........ 4-19

4.28 Registers 36, 37: Gearing Unwind Constant......... 4-19

4.29 Register 38: Gearing Modes, Ratio Format,

Ramp Velocity Control .......................................... 4-20

4.30 Registers 39, 40: Backlash Compensation ........... 4-21

4.31 Register 41: Registration Input

Edge Detection...................................................... 4-22

4.32 Register 63: Auto-Acknowledge............................ 4-22

4.33 Register 64: Interrupt Reset.................................. 4-23

4.34 Register 65: Mode................................................. 4-23

4.35 Register 66: Command ......................................... 4-27

4.36 Register 67: Command ......................................... 4-32

4.37 Register 72: Status................................................ 4-34

4.38 Register 73: Fault.................................................. 4-37

4.39 Registers 74, 75: Current Feedback Position ....... 4-38

4.40 Registers 76, 77: Current Gearing Position .......... 4-39

4.41 Registers 78, 79: Current Velocity ........... ....... ...... 4-39

4.42 Register 80: Following Error.................................. 4-39

4.43 Register 81: Velocity Error .................................... 4-40

4.44 Register 82: Digital Input Status............................ 4-40

4.45 Register 83: Current Velocity Status

Update Period ....................................................... 4-41

4.46 Registers 84, 85: Feedback

Registration Position ............................................. 4-41

4.47 Registers 86, 87: Gearing

Registration Position ............................................. 4-41

4.48 Registers 99-103: Software Version Number........ 4-42

4.49 Interrupt Registers................................................. 4-42

4.49.1 Registers 68/69: Interrupt Enable.............. 4-43

4.49.2 Registers 104/105: Interrupt Source.......... 4-45

4.49.3 Register 4095: Interrupt Status and Control

(ISCR) Register ......................................... 4-47

4.49.4 Sample Application Task with Interrupt ..... 4-48

Note: Register descriptions for equivalent X and Y axis

registers are exactly the same. Although sections of Chapter 4 are titled by X axis register number, the equivalent Y register is given in the figure that accompanies each register description.

4.50 Cam Registers.......................................................4-49

4.50.1 Register 125: Master Axis

Position Increment .....................................4-53

4.50.2 Registers 126, 127: Master Reference

Position ......................................................4-53

4.50.3 Register 128: Number of Points

in Cam Table..............................................4-54

4.50.4 Register 129:Time Between Points in

Cam Table .................................................4-54

4.50.5 Register 130: Cam Mode ...........................4-54

4.50.6 Register 131: Loop Back

Point in Cam Table ....................................4-56

4.50.7 Cam Data Registers...................................4-57

5.0 Applying the Module........................................................5-1

5.1 Required System Information..................................5-1

5.2 Tuning......................................................................5-1

5.2.1 Auto-Tuning .................................................5-2

5.2.2 Manual Tuning .............................................5-2

5.3 Initialization..............................................................5-5

5.4 Homing ....................................................................5-6

5.5 Moving.....................................................................5-7

5.6 Electronic Gearing ...................................................5-8

5.7 Velocity.............. ...... ....... ...... ....... ...... ....... ...... .........5-9

5.8 Cam Mode.............................................................5-10

6.0 Restrictions ......................................................................6-1

6.1 Remote Racks.........................................................6-1

Note: Register descriptions for equivalent X and Y axis

registers are exactly the same. Although sections of Chapter 4 are titled by X axis register number, the equivalent Y register is given in the figure that accompanies each register description.

III

Appendix A

Technical Specifications ...................................................A-1

Appendix B

Module Block Diagram ......................................................B-1

Appendix C

Field Connections..............................................................C-1

Appendix D

Related Components.........................................................D-1

Appendix E

Appendix F

Enhancements................................................................... F-1

Appendix G

Compatibility with Earlier Versions .............. ...... ....... ...... .. G - 1

Appendix H

Configuration Task Sample...............................................H-1

Appendices

Appendix I

Digital Servo Loop Block Diagram...................................... I-1

List of Figures

Figure 2.1 - Module Faceplate......................................................2-2

Figure 2.2 - Encoder Input Circuit .................................................2-4

Figure 2.3 - Typical Registration Input Circuit...............................2-5

Figure 2.4 - Typical Digital Input Circuit ........................................2-5

Figure 3.1 - Rack Slot Numbers....................................................3-2

Figure 3.2 - Typical Encoder Connections....................................3-3

Figure 3.3 - Typical Encoder Power Supply Connections.............3-4

Figure 3.4 - Typical Limit Switch Connections ..............................3-5

Figure 3.5 - Typical Registration Input Connections .....................3-5

Figure 3.6 - Typical Drive Reference / Voltage Reference

Connections with External P/S..................................3-6

Figure 3.7 - Typical E-stop Circuit with Watchdog Output ............3-7

Figure 3.8 - Typical Drive Fault Connections................................3-8

Figure 4.1 - Encoder Configuration Register.................................4-3

Figure 4.2 - Control Loop Configuration Register .........................4-4

Figure 4.3 - Home and Overtravel Configuration Register............4-5

Figure 4.4 - Proportional Gain Register ........................................4-7

Figure 4.5 - Integral Gain Register................................................4-7

Figure 4.6 - Velocity Gain Register ...............................................4-8

Figure 4.7 - Feedforward Gain Register........................................4-8

Figure 4.8 - Deadband Compensation Register............................4-8

Figure 4.9 - Maximum Position Error ............................................4-9

Figure 4.10 - Maximum Velocity Error Register..............................4-9

Figure 4.11 - In-Position Tolerance Register ................................4-10

Figure 4.12 - Positive Overtravel Limit Registers..........................4-10

Figure 4.13 - Negative Overtravel Limit Registers........................4-11

Figure 4.14 - Low Speed Homing Reference Register .................4-11

Figure 4.15 - Command Position Registers .................................4-12

Figure 4.16 - Command Velocity Registers ..................................4-13

Figure 4.17 - Command Acceleration Registers...........................4-14

Figure 4.18 - Command Deceleration Registers...........................4-14

Figure 4.19 - Gear Ratio Registers ...............................................4-15

Figure 4.20 - User-Controlled LED Register.................................4-16

Figure 4.21 - Drive Command Reference Register.......................4-16

Figure 4.22 - Sync Position Registers...........................................4-17

Figure 4.23 - Maximum Voltage Reference Output Register........4-18

Figure 4.24 - Positive Linearization Constant Register.................4-18

Figure 4.25 - Positive Linearization Constant Register.................4-19

Figure 4.26 - Feedback Unwind Constant Registers ...................4-19

Figure 4.27 - Gearing Unwind Constant Registers....................... 4-20

Figure 4.28 - Gearing Mode, Ratio Format, and Ramp

Velocity Control Register........................................ 4-20

Figure 4.29 - Backlash Compensation Registers ......................... 4-22

Figure 4.30 - Registration Edge Detection Register..................... 4-22

Figure 4.31 - Auto-Acknowledge Register.................................... 4-23

Figure 4.32 - Interrupt Reset Register.......................................... 4-23

Figure 4.33 - Mode Register......................................................... 4-24

Figure 4.34 - Command Register 66............................................ 4-28

Figure 4.35 - Command Register 67............................................ 4-33

Figure 4.36 - Status Register........................................................ 4-34

Figure 4.37 - Fault Register.......................................................... 4-37

Figure 4.38 - Current Feedback Position Registers ..................... 4-38

Figure 4.39 - Current Gearing Position Registers ........................ 4-39

Figure 4.40 - Current Velocity Registers ...................................... 4-39

Figure 4.41 - Following Error Register.......................................... 4-40

Figure 4.42 - Velocity Error Register............................................ 4-40

Figure 4.43 - Digital Input Status Register.................................... 4-40

Figure 4.44 - Current Velocity Status Update Period Register..... 4-41

Figure 4.45 - Feedback Registration Position Regiesters ............ 4-41

Figure 4.46 - Gearing Registration Position Registers................. 4-42

Figure 4.47 - Software Version Registers..................................... 4-42

Figure 4.48 - Interrupt Enable Masking Register (Status) ............ 4-44

Figure 4.49 - Interrupt Enable Masking Register (Fault) .............. 4-45

Figure 4.50 - Interrupt Source Register (Status) .......................... 4-46

Figure 4.51 - Interrupt Source Register (Fault)............................. 4-47

Figure 4.52 - Interrupt Status and Control Register...................... 4-47

Figure 4.53 - Master Axis Position Increment Register................ 4-53

Figure 4.54 - Master Regference Position.................................... 4-54

Figure 4.55 - Cam Profile Registers............................................. 4-56

Figure 4.56 - Cam Loop Back Register........................................ 4-57

Figure 4.57 - Time Cam Data Registers....................................... 4-58

Figure 4.58 - Position Cam Data Registers.................................. 4-58

CHAPTER 1

INTRODUCTION

The 2-Axis Servo Module, in conjunction with external motor drive systems and electronic encoders, provides two axes of closed loop point-to-point position, velocity, and acceleration control. In addition, electronic gearing and electronic cam allow the module to replace mechanical gear trains and cams electronically for improved performance with no wear, no backlash, and faster setup times. Two or more modules can be connected together to provide synchronized control of multiple axes.

Typically, this module is used for velocity control, point-to-point positioning control, electronic line shaft applications, and electronic cams requiring position synchronization. See Appendix I for a software block diagram of the module.

This manual describes the functions and specifications of the module. It also includes a detailed overview of installation and servicing procedures, as well as examples of programming methods. See Appendix F for a list of enhancements to the current version of the module.

Related publications that may be of interest:

• J-3675 AutoMax ENHANCED BASIC LANGUAGE

• J-3676 AutoMax CONTROL BLOCK LANGUAGE

• J-3677 AutoMax LADDER LOGIC LANGUAGE

• J-36 84 RESO URCE AutoMa x PROGRAMMIN G

• J-3675 AutoMax PROGRAMMING EXECUTIVE

INTRODUCTION

INSTRUCTION MANUAL

EXECUTIVE INSTRUCTION MANUAL VERSION 2.0

INSTRUCTION MANUAL VERSION 3.0

1-1

• IEEE-518 GUIDE FOR THE INSTALLATION OF ELECTRICAL EQUIPMENT TO MINIMIZE ELECTRICAL NOISE INPUTS TO CONTROLLERS FROM EXTERNAL SOURCES

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2-Axis Servo Module M/N 57C422B

CHAPTER 2

MECHANICAL /

ELECTRICAL

DESCRIPTION

The following is a description of the faceplate LEDs, field termination connectors and electrical characteristics of the field connections.

2.1 Mechanical Description

The 2-Axis Servo module is a printed circuit board assembly that plugs into the backplane of the DCS 5000/AutoMax rack. It consists of the printed circuit board, a faceplate, and a protective enclosure. The faceplate contains tabs at the top and bottom to simplify removing the card from the rack. Assembly dimensions are listed in Appendix A.

The faceplate of the module contains a 37-pin D-shell connector socket and eight LED status indicators for each axis. It also contains three LEDs that can be controlled from the application software. Refer to figure 2.1.

MECHANICAL / ELECTRICA L DESCRIPTION

2-1

Figure 2.1 – Module Faceplate

2-2

2-Axis Servo Module M/N 57C422B

Signals are brought into the module via a multi-conductor cable (M/N 57C377). One end of this cable attaches to the faceplate connector, while the other end of the cable attaches to a terminal board for easy wiring.

On the back of the module are two edge connectors that attach to the system backplane.

2.2 Electrical Description

The module contains an 80186 microprocessor, local RAM, and EPROM for the axis software. It also contains a dual port memory organized as 4k x 16 for transferring data to/from the module and the application software. Refer to the block diagram in Appendix B.

This module also contains a watchdog timer that is used to detect a processor failure. The processor is required to keep resetting the watchdog before it expires. If the watchdog expires, the processor will be halted, the green LED on the faceplate of the module will be turned off, and dual port memory will be locked so that the module can no longer be accessed by application software.

M/N 57C422A and later versions of the module support level-sensitive hardware interrupts. Interrupts are used to trigger execution of some part of an application task and are implemented using BASIC language hardware EVENT statements. See Section 4.49 for more information.

Each of the two axes contain the necessary circuitry for two encoders. One encoder is used to provide feedback to the axis. The other encoder can be used when gearing or cam mode is selected to provide a reference for that same axis. Each encoder input channel has the necessary circuitry for

an “A” channel, "B" channel, and "Z" channel. The encoder input circuit is designed for 5 volt differential signals. A single external power supply is required to power all of the encoders connected to the module. Refer to figure 2.2 for a typical encoder input circuit.

MECHANICAL / ELECTRICA L DESCRIPTION

2-3

Figure 2.2 – Encoder Input Circuit

Each axis contains two registration inputs which are connected to faceplate LEDs. One input is used with the feedback encoder; the other is used with the gearing reference. These registration inputs are typically used to strobe the feedback and/or the reference position into a group of registers for use by application software which can synchronize the axis to an external event. The input may be 15-24 VDC only and there is a transport delay of approximately 25 microseconds from the time that a registration input is asserted until the isolated signal changes state. Refer to figure 2.3 for a typical input circuit. In critical applications, hard-wire your overtravel L/S into the emergency stop circuit so that the drive will be disabled regardless of the state of the control.

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2-Axis Servo Module M/N 57C422B

Figure 2.3 – Typical Registration Input Circuit

Each axis on the module contains digital inputs for the home L/S, drive fault, positive overtravel L/S, and negative overtravel L/S. These inputs are connected to faceplate LEDs. Each of the inputs has a 30 Hz filter and may be 24 volts A-C or D-C. Refer to figure 2.4 for a typical input circuit.

Figure 2.4 – Typical Digital Input Circuit

Each axis contains a watchdog output which can be used by the module to disable the drive if the module falls. The watchdog output is a normally open relay contact. See figure 3-7.

MECHANICAL / ELECTRICA L DESCRIPTION

2-5

In order to provide a current or velocity reference to the servo drive panel, each axis on the module contains a voltage output. The voltage output has a range of + requires an externally mounted +

12 or +15 volt power

10 Volts and

supply. The voltage output is separately isolated for each channel. Refer to figure 3.6 for a typical output circuit and isolated power supply connections

2-6

2-Axis Servo Module M/N 57C422B

CHAPTER 3

INSTALLATION

This section describes how to install and remove the module and its cable assembly.

WARNING

THE MACHINERY BUILDER AND/OR USER ARE RESPONSIBLE FOR INSURING THAT ALL DRIVE TRAIN MECHANISMS, THE DRIVEN MACHINE, AND PROCESS MATERIAL ARE CAPABLE OF SAFE OPERATION AT THE MAXIMUM SPEED AT WHICH THE MACHINE WILL OPERATE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY

3.1 Wiring

DANGER

THE USER IS RESPONSIBLE FOR CONFORMING WITH THE NATIONAL ELECTRICAL CODE AND ALL OTHER APPLICABLE LOCAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

To reduce the possibility of electrical noise interfering with the proper operation of the control system, exercise care when installing the wiring from the system to the external devices. For detailed recommendations refer to IEEE 518.

3.2 Initial Installation

Use the following procedure to install the module: Step 1. Turn off power to the system. All power to the rack

as well as all power to the wiring leading to the module, servo, and encoders must be off.

INSTALLATION

3-1

DANGER

EQUIPMENT IS AT LINE VOLTAGE WHEN A-C POWER IS CONNECTED TO THE DRIVE. ALL UNGROUNDED CONDUCTORS OF THE A-C POWER LINE MUST BE DISCONNECTED BEFORE IT IS SAFE TO TOUCH ANY INTERNAL PARTS OF THIS EQUIPMENT. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

Step 2. Take the module out of its shipping container.

Take the module out of the anti-static bag it came in, being careful not to touch the connectors on the back of the module.

Step 3. Insert the module into the desired slot in the rack.

Refer to figure 3.1.

Figure 3.1 – Rack Slot Numbers

Step 4. Mount the terminal strips (M/N 57C377) on a

panel. The terminal strips should be mounted to permit easy access to the screw terminals. Make certain that the terminal strips are close enough to the rack so that the cable will reach between the terminal strips and the module.

Step 5. Verify that the feedback encoder has been

mounted on the back of the servo motor. Make certain that the mechanical coupling between the motor and encoder is securely fastened. If the encoder is not mounted directly on the motor, satisfactory performance may not be achievable.

3-2

2-Axis Servo Module M/N 57C422B

Fasten the field wires from the encoder to the terminal strip. Typical field connections are shown in figure 3.2. If you are not using the marker pulse in your application, you can leave the "Z" and "Z inputs disconnected.

Figure 3.2 – Typical Encoder Connections

Use twisted pair cabling, connected as shown in figure 3.2, for the cabling between the encode r and the terminal strip. If you use cabling with less than 2 twists/inch, it should be shielded. Note that the shield should only be connected at one end.

Step 6. Mount the external 5 volt power supply for the

INSTALLATION

If a feedback encoder is connected to the gearing reference of another axis, jumper the connections on the terminal strip.

encoders. The current rating must be sufficient for all of the encoders that will be powered from the supply as well, as the module. Check the specifications of the encoder you will be using.

Fasten the field wires from the power supply to the terminal strip. Typical field connections are shown in figure 3.3

3-3

Figure 3.3 – Typical Encoder Power Supply Connection

Use twisted pair cabling, connected as shown in figure 3.3, for the cabling between the power supply and the terminal strip. If you use cabling with less than 2 twists/inch, it should be shielded. Note that the shield should only be connected at one end.

For best results, the power supply voltage should be adjusted to provide 5 volts at the furthest encoder.

Step 7. If your application requires them, mount the home

L/S, positive overtravel L/S, and negative overtravel L/S on your machine. Overtravel L/S should be normally closed devices. Fasten the field wires from the limit switches to the terminal strip. Typical field connections are shown in figure

3.4.

3-4

2-Axis Servo Module M/N 57C422B

Figure 3.4 – Typical Limit Switch Connections

Step 8. Mount the registration sensors on your machine if

your application requires them. Fasten the field wires from the sensors to the terminal strip. Use extra care in routing these wires because these signals are not filtered on the module. Typical field connections are shown in figure 3.5.

Figure 3.5 – Typical Registration Input Connections

Step 9. Install the servo amplifier according to the

manufacturer’s instructions. Select the proper mode of operation for the servo amplifier (current or velocity). Select current mode for most applications because all tuning can then be done

INSTALLATION

3-5

in the software. If your application has unusually high bandwidth requirements or your servo amplifier functions as a velocity regulator only, use the velocity mode.

Step 10. Fasten the field wires from the drive reference and

power supply to the terminal strip. Typical field connections are shown in figure 3.6 and 3.7.

Figure 3.6 – Typical Drive Reference/Voltage Reference

Connections with External P/S

Step 11. Connect the watchdog outputs on the terminal

strip into the drive enable circuit. This signal is used to disable the servo if a problem develops in the module. It must be installed in combination with a hardwired E-stop circuit as well as a pair of contacts that are controlled from a digital output from DCS or AutoMax software. Typical field connections are shown in figure 3.7.

3-6

2-Axis Servo Module M/N 57C422B

Figure 3.7 – Typical E-stop Circuit with Watchdog Output

The hardwired E-STOP ensures that you can disconnect the drive under all conditions. The contacts controlled by a DCS or AutoMax digital output allow you to disable the drive in the event of a processor failure or when faults are detected by the application software.

WARNING

Step 12. Fasten the field wires from the drive fault inputs to

the terminal strip. This signal is used to notify the module that a problem has developed in the servo. It must be connected if available. Typical field connections are shown in figure 3.8. Be sure to use the proper connections for your servo amplifier.

INSTALLATION

3-7

Figure 3.8 – Typical Drive Fault Connections

DANGER

ADJUSTMENTS ARE MADE WITH THE POWER ON. EXERCISE EXTREME CAUTION AS HAZARDOUS VOLTAGE EXISTS. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

Step 13. Verify power supply connections by performing

the following operations: a. Make certain that all connectors from the

module and the encoders are disconnected. b. Turn on power to the system. c. Verify that you can read 5 volts on the proper

terminal strip and encoder connectors

(terminals 1 and 2). d. Verify that you can read ±12 volts or ±15 volts

on the proper terminal strip connectors

(terminals 21, 22, 23). e. Turn off power and reattach the connectors to

the module.

Step 14. Verify power supply connections at the encoder by

performing the following operations: a. Make certain that all connectors at the

encoders are disconnected. b. Turn on power to the system.

3-8

2-Axis Servo Module M/N 57C422B

c. Verify that you can read 5 volts on the proper

pins of the encoder connector (at the encoder).

d. Turn off power and attach the connectors to

the encoders.

Step 15. Verify wiring connections by performing the

following operations: a. Turn on power to the system. b. Toggle all of the following digital inputs that you

are using in your application: the home L/S, positive overtravel L/S, negative overtravel L/S, drive fault, feedback registration, and gearing registration. The appropriate LED on the faceplate of the module should change state as the input is toggled. Because the signal may be very brief, it may be necessary to use an oscilloscope to verity that it is present.

Step 16. Verify the installation by connecting the

programming terminal to the system and running the Programming Executive Software. Note that if you are using a version 3.0 Programming Executive and working with the sample application program disk shipped with the Programming Executive software, you will need to do a rack import operation for the files in the 57C422 subdirectory first. See J-3684 for more information and disregard steps a and b below.

INSTALLATION

a. Load the application disk that came with your

ReSource software.

b. Compile the BASIC tasks SETUPCNF.CNF

AXISSETUP.BAS, AXISSUB.BAS, and AXISINIT.BAS.

c. Load the configuration and BASIC tasks onto

the CPU.

d. Use the RUN ALL command to start all four

tasks.

3-9

e. Move the cable from the programming port on

the processor to the port labeled "LOCAL

COMM". f. Select the menu option labeled

"COMMUNICATIONS INTERFACE". g. Type C <CR> <CR>. h. The screen on the programming terminal

should now display the test and setup menu for

the module. You should progress sequentially

through the menu from item 1 through item 8

before attempting to use the module.

Note that when you have finished configuring and tuning your drives, you may save all of the data to a DOS disk file. By adding this file to AXISINIT.BAS, you can eliminate the need to re-configure your drive each time you use the test and setup software.

3-10

2-Axis Servo Module M/N 57C422B

3.3 Module Replacement

WARNING

Use the following procedure to replace a module: Step 1. Turn off power to the rack and all connections.

Step 2. Remove the connectors from the module. Step 3. Loosen the screws that hold the module in the

rack. Remove the module from the slot in the rack.

Step 4. Place the module in the anti-static bag IT came in,

being careful not to touch the connectors on the back of the module. Place the module in the cardboard shipping container.

Step 5. Take the new module out of its anti-static bag,

Step 6. Insert the module into the desired slot in the rack.

Step 7. Attach the field terminal connectors (M/N 57C377)

Step 8. Turn on power to the rack.

INSTALLATION

being careful not to touch the connectors on the back of the module.

Use a screwdriver to secure the module into the slot.

to the mating halves on the module. Make certain that the connectors are the proper ones for the module and for the specific axes.

3-11

3-12

2-Axis Servo Module M/N 57C422B

CHAPTER 4

PROGRAMMING

This section describes how the data is organized in the module and provides examples of how the module is accessed by the application software. For more detailed information on programming, refer to J-3675, J-3676, and J-3677.

The module contains a total of 4096 16-bit registers, one set of 2047 registers for each servo axis. The X axis uses registers 0-2046. The Y axis uses registers 2048-4094.

Note that there are 2 exceptions to this basic register organization scheme: registers 64 and 4095 (interrupt control) are used for both axes. In other words, the use of an interrupt on either axis will require you to perform some function In these two registers. See section 4.49 for more information on interrupts.

The following register reference conventions are used throughout this instruction manual. All register descriptions in the following sections are based on the X axis and are organized in numerical order, except for interrupt and cam registers, which are described in sections 4.49 and 4.50. The equivalent Y axis registers are given in parentheses in the figure that accompanies each register description. Appendix E is a numerical register summary with page number references.

Register numbers listed together separated by a comma (e.g., 11, 12) signify a double precision (32-bit) value. Register numbers listed together separated by a slash (e.g., 104/105) indicate that both registers have a similar function and should be considered together. This notation does not indicate a double precision value.

For ease of locating descriptions for individual bits within registers, bit names are underlined in the sections where the bits are described. Bit names are placed between quotation marks when they are only referred to. In some cases,

PROGRAMMING

4-1

registers with individual bit descriptions are shown with the bits broken up into groups of four for ease of interpretation in monitoring the registers in hexadecimal format.

At times register and bit references will be in the form of

"RA,bB," where "A” is the register number and "B" is the bit number.

4.1 Configuration

Before an application program can be written, it is necessary to configure the definitions of variables that must be accessible to all tasks in the rack. This section describes how to configure the module.

If you are using V3.0 or later of the Programming Executive software, you can configure the module using a special software "form" that allows you to fill in the names of the registers and bits. See the Programming Executive instruction manual for more information on configuration forms.

If you are using an earlier version of the programming executive, you will need to create a configuration task to configure the registers/bits on the module. See Appendix H, for more information on creating a configuration task.

4-2

2-Axis Servo Module M/N 57C422B

+ 92 hidden pages

Rockwell Automation 57C422B User Manual

Table Of Contents

2.1 Mechanical Description

2.2 Electrical Description

3.1 Wiring

3.2 Initial Installation

3.3 Module Replacement

4.1 Configuration