Rockwell Automation 999 User Manual
Allen-Bradley
IMC S Class
Compact Motion
Installation
Controller
(Cat. No. 4100-999-122)
and Setup
Manual
Important User
Information
Because of the variety of uses for the products described in this
publication, those res ponsible for the application and use of thi s control
equipment must satisfy themselves that all necessary steps have been
taken to ass ure that each appli cation and use meets all performance and
safety requirem ents, inclu ding an y applicabl e laws, re gulatio ns, codes
and standards.
The illustrations, c harts, sample programs an d layout example s shown
in this guide ar e inte nded so le ly for purpos es of e xample . Si nce th ere
are many variables and requirements associated with any particular
installation, Allen-Bradley does not assume responsibility or liability
(to include intellec tual property liabil ity) for actual use based upon the
examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation, and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanica l devices that should be taken into cons ideration when
applying products such as those described in this publication.
Reproduction of the content s of this copyright ed publication, in whole
or in part, without writte n permission of Allen-Bradle y Company , Inc.,
is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
ATTENTION: Identifies information about practices
or circumstances that can lead to personal injury or
!
Attention statements help you to:
identify a hazard
•
avoid the hazar d
•
recognize the consequences
•
Important: Identifies information that is critical for successful
GML, ULTRA, IMC, SCAN bus, Flex I/O, DTAM, PanelView, and SLC are trademarks; PLC is a registered
trademark of Allen-Bradley Company, Inc.
death, property damage or economic loss.
application and understanding of the product.
Table of Contents
Preface
Who Should Use this Manual ........................ P-1
Purpose of this Manual .................................. P-1
Safety Precautions ..........................................P-1
Contents of this Manual .................................P-2
Related Documentation ...............................P-3
Product Receiving & Storage Responsibility. P-3
Allen-Bradley Support ...................................P-3
Local Product Support .................................P-4
Technical Product Assistance ...................... P-4
Chapter 1 – Safety
i
Read This Manual .......................................... 1-1
Chapter 2 – Introduction
IMC-S/23x Description.................................. 2-1
Features .......................................................... 2-2
Model Numbering System ............................. 2-4
Pre-Engineered Cable Assemblies ................. 2-4
Mechanical Specifications ............................. 2-5
Front Panel Layout ...................................... 2-5
Mounting and Clearance Dimensions .......... 2-6
General Specifications ................................... 2-6
Environmental Specifications....................... 2-7
Electrical Specifications ................................. 2-7
Encoder Input Specifications ......................... 2-7
Servo Output Specifications........................... 2-8
Dedicated Discrete I/O Specifications........... 2-8
Serial I/O Specifications ................................ 2-9
DH-485 Specifications ................................... 2-9
Flex I/O Compatibility Specifications ......... 2-10
Servo Performance Specifications ............... 2-10
Servo Gain Units ....................................... 2-11
Remote I/O Adapter Specifications ............. 2-11
AxisLink Specifications ............................... 2-13
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ii
Table of Contents
Chapter 3 – Technical Overview
Digital Control Loop ...................................... 3-1
Encoders ......................................................... 3-2
Encoder Counter ............................................ 3-3
Software Feedback Calculations.................... 3-4
Servo Amplifiers and Motors ......................... 3-5
High Level Motion Functions........................ 3-6
Indexing and Jogging ................................... 3-7
Backlash Compensation .............................. 3-7
Electronic Cam ............................................ 3-7
Electronic Gearing....................................... 3-7
Interpolation ................................................. 3-8
Velocity Feedforward .................................... 3-8
CPU Watchdog .............................................. 3-9
Software Overtravel Limits............................ 3-9
Serial Communication .................................... 3-9
DH-485 Communication .............................. 3-10
Axis-Specific Discrete I/O ........................... 3-10
Home Limit Switch Input .......................... 3-10
Overtravel Limit Switch Inputs................. 3-10
Drive Fault Output ..................................... 3-11
Drive Enable Output .................................. 3-11
Position Registration Inputs ....................... 3-11
Status LEDs .................................................. 3-11
General Purpose Discrete I/O ......................3-12
The Imaginary Axis ..................................... 3-12
Remote I/O (Optional)................................. 3-12
AxisLink (Optional)..................................... 3-12
Publication 999-122 January 1997
Chapter 4 – Installation and Hookup
Introduction.................................................... 4-1
Complying with European Union Directives . 4-3
EMC Directive ............................................. 4-3
Low Voltage Directive................................. 4-3
Installing the IMC-S/23x ............................... 4-6
Configuring the IMC-S/23x........................... 4-7
Configure the Serial Ports ............................ 4-8
Select the Registration Input Voltage ........ 4-11
Select the Encoder Power Voltage ............. 4-12
Select the Servo Output Format................. 4-14
Serial Communications Devices.................. 4-15
Table of Contents
Serial Communication Protocol ................. 4-15
Connecting RS-232 Devices ...................... 4-16
Connecting RS-422 Devices ...................... 4-18
Connecting Encoders ................................... 4-19
AB 1391B-ES & 1391-DES Drives .......... 4-20
AB 845F, 845H, & 845T Encoders ........... 4-20
AB 845K Encoders.................................... 4-21
AB 845P Encoders ..................................... 4-21
Other Encoders .......................................... 4-22
Connecting Servo Amplifiers ....................... 4-22
AB 1391B-ES & 1391-DES Drives .......... 4-23
Other Servo Amplifiers ............................. 4-23
Connecting Hydraulic Valves...................... 4-24
Connecting Axis-Specific Discrete I/O........ 4-25
The Drive Enable Outputs ......................... 4-26
The Drive Fault Inputs............................... 4-26
Connecting Registration Sensors ................. 4-27
Using the Registration Inputs .................... 4-28
Connecting the CPU Watchdog................... 4-29
Connecting Flex I/O .....................................4-30
Connect the I/O Power Supply ..................... 4-30
Connect the AC Power ................................. 4-31
Connecting Remote I/O (Optional) .............. 4-32
Connecting AxisLink (Optional) ................. 4-33
AxisLink for Standard Operation .............. 4-34
AxisLink for Extended Length Operation. 4-35
Connecting DH-485 (Optional) ................... 4-36
Chapter 5 – Understanding IMC-S/23x Setups
The Setup Menus ........................................... 5-1
Application Setup Menu .............................. 5-1
Machine Setup Menu ................................... 5-1
Hookup Diagnostics Menu.......................... 5-1
Servo Setup Menu ....................................... 5-2
Using the Setup Menus .................................. 5-2
Passwords .................................................... 5-2
Toggling ....................................................... 5-2
Disabling Feedback ..................................... 5-3
Disabling DH-485 ........................................ 5-3
Loading Setup Values.................................. 5-4
Selecting a Setup Menu ............................... 5-4
Selecting an Axis ......................................... 5-4
Editing Parameter Values ............................. 5-5
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iv
Table of Contents
Application Setup Menu ................................ 5-5
Upload Inhibit .............................................. 5-6
Editing the AxisLink Configuration .............. 5-6
Editing the DH-485 Configuration ................ 5-6
Maximum Node Address............................. 5-7
Network Node Address ...............................5-7
Baud Rate .................................................... 5-7
Token Hold Factor ....................................... 5-7
Editing the Axis Setup Parameters................. 5-8
Axis Configuration...................................... 5-8
Virtual Axes ................................................. 5-8
The Imaginary Axis................................... 5-10
Rotary Axes ............................................... 5-10
Position Units ............................................ 5-10
Display Fields ............................................ 5-11
Averaged Velocity Timebase ..................... 5-11
Move and Jog Profiles ............................... 5-12
Trapezoidal ................................................ 5-12
S Curve ......................................................5-13
Parabolic .................................................... 5-13
Backlash Compensation ............................ 5-14
Editing the Axis Fault Action Configuration 5-14
Editing the Direct Command Mode Configuration 5-16
Editing the Operator Interface Configuration 5-17
Editing the Runtime Display Configuration 5-18
Editing the Serial Port Configuration ........... 5-20
Editing the RIO Configuration ..................... 5-21
RIO Adapter Channel ................................ 5-21
RIO Baud Rate ........................................... 5-22
RIO Rack Size ........................................... 5-22
RIO Rack Address ..................................... 5-23
RIO Starting Group ................................... 5-23
RunningApplication Program on Power-Up 5-23
Machine Setup Menu ................................... 5-24
Editing the Feedback Configuration ............ 5-25
Conversion Constant (K)........................... 5-25
Unwind ...................................................... 5-26
Unwind Reference Point............................ 5-26
Encoder Loss Detection............................. 5-27
Editing the Overtravel Configuration .......... 5-27
Overtravel Limit Switches ......................... 5-28
Software Travel Limits .............................. 5-28
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Table of Contents
Editing the Homing Configuration .............. 5-29
Home Position ........................................... 5-29
Active Homing .......................................... 5-30
Homing Without a Limit Switch or Marker 5-30
Homing to an Encoder Marker.................. 5-30
Homing to a Limit Switch......................... 5-31
Homing to a Limit Switch and Marker...... 5-32
Limit Switch Contacts ............................... 5-32
Absolute Homing....................................... 5-33
Absolute_MV ............................................ 5-34
Absolute_Serial ......................................... 5-35
Passive Homing ......................................... 5-35
Editing the Servo Configuration.................. 5-36
Dual Loop Control ..................................... 5-36
Servo Output Limiting ............................... 5-39
Drive Fault Input ....................................... 5-40
Editing the Positioning Configuration ......... 5-40
Position Lock Tolerance ............................ 5-40
Backlash Offset.......................................... 5-41
Approach Direction ................................... 5-41
Hookup Diagnostics Menu ........................... 5-42
Checking Motors and Encoders ................... 5-43
Testing Encoders .......................................... 5-45
Editing the Motor/Encoder Polarity ............. 5-47
Tuning Velocity Loop Servo Drives ............ 5-47
Adjusting Offset .........................................5-47
Digital Battery Box .................................... 5-48
Checking Encoder Markers.......................... 5-50
Align Absolute Transducers ......................... 5-51
Checking The Discrete I/O .......................... 5-53
Checking the Dedicated Discrete Inputs ... 5-53
Checking the Dedicated Discrete Outputs . 5-54
Checking Flex I/O Discrete Inputs ............ 5-54
Checking Flex I/O Discrete Outputs ......... 5-55
Checking Flex I/O Analog Inputs .............. 5-56
Checking Flex I/O Analog Outputs ........... 5-57
Servo Setup Menu........................................ 5-58
The Servo Loop Gains ................................. 5-58
Velocity Gain ............................................. 5-59
Proportional Gain ...................................... 5-59
Integral Gain .............................................. 5-59
Feedforward Gain ...................................... 5-60
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vi
Table of Contents
Self-Tuning the Servo Gains ........................ 5-60
Using the Position Error Integrator ........... 5-66
Using Velocity Feedforward ...................... 5-66
Tuning Faults ............................................... 5-67
Aborted by Escape! ...................................5-67
Encoder Fault! ........................................... 5-67
Hit Hardware Overtravel Limit! ................ 5-67
Position Error Tolerance Exceeded! .......... 5-68
Drive Fault Detected! ................................ 5-68
Manually Tuning the Loop Gains 5-68
Setting the Drive Offset & Deadband Comp 5-69
Setting the Velocity Gain ........................... 5-69
Setting the Proportional Gain .................... 5-70
Setting the Integral Gain ............................ 5-71
Setting the Feedforward Gain .................... 5-72
Setting the Position Error Tolerance.......... 5-72
Saving Setup Values .................................... 5-73
Setup Menu Reference ................................. 5-74
Chapter 6 – Setting Up Your IMC-S/23x Using GML
Chapter Objectives ......................................... 6-1
General Startup Precautions ........................... 6-1
Setting Up Your Compact.............................. 6-2
Before You Begin ........................................ 6-2
Preparing the System................................... 6-2
Getting Started ............................................. 6-3
Defining Preferences ................................. 6-3
Defining Your Controller and Its Options .... 6-4
Defining Your Axes................................... 6-5
Applying Power........................................... 6-6
Establishing Communication....................... 6-6
Downloading Your Diagram..................... 6-7
Testing Motor Connections & Defining Dir 6-7
Testing the Encoder Marker...................... 6-8
Tuning a Velocity Loop ............................. 6-8
Tuning Servo Parameters.......................... 6-9
Saving Your Parameters .......................... 6-10
Publication 999-122 January 1997
Chapter 7 – Troubleshooting
Chapter Objectives......................................... 7-1
Understanding How to Detect a Problem ...... 7-1
Replacing Modules ........................................ 7-2
Before You Begin ........................................7-2
Table of Contents
Removing a CPU Module............................ 7-2
Installing a Replacement CPU Module ....... 7-3
Removing a Power Supply Module ............. 7-3
Installing a Replacement Power Supply ..... 7-4
Understanding Status LEDs ........................... 7-5
Understanding the System OKLED .............. 7-5
Understanding System Faults ......................... 7-6
Finding Faults.............................................. 7-6
Viewing Instantaneous Status.................... 7-6
Viewing Continuous Status ....................... 7-7
Troubleshooting General System Problems... 7-8
Appendix A – Cable Information
Introduction ................................................... A-1
4100-CCF1 or 4100-CCF3......................... A-2
4100-CCS15F ............................................. A-2
4100-CCA15F ............................................ A-3
4100-CCW15F ............................................ A-4
4100-RCS3T ............................................... A-4
4100-CCAQB ............................................. A-5
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viii
Table of Contents
Publication 999-122 January 1997
Preface
P-1
Preface
Read this preface to familiarize yourself with the rest of the manual.
This preface covers the following topics:
who should use this manual
•
the purpose of this manual
•
general safety precautions
•
receiving and storage information
•
Allen-Bradley support
•
Who Should Use this
Manual
Purpose of this Manual
Safety Precautions
Use this manual if you are responsible for designing, installing,
programming, or troubleshooting the Allen-Bradley IMC S Class
Compact.
If you do not have a bas ic understandi ng of the Compact, contact your
local Allen-Bradley representative for information on available training
courses before using this product.
This manual is a installa tion and set up guide for the Compact. It gi ves
you an over view of the Compact an d describes the procedures yo u use
to install, set up, use, and troubleshoot the Compact.
The following general precautions apply to the Compact:
ATTENTION:
and associated machinery shoul d pl an or im pl ement the
!
installation, startup, and subsequent maintenance of the
system. Failure to comply can result in personal injury
and/or equipment damage.
Only those familiar with the Compact
ATTENTION:
devices. To avoid hazar d of electrical shock, ver ify that
all voltage on the capacitors has been discha rged before
attempting to service, repair, or remove this unit. You
should only attempt the procedures in this manual if you
are qualified to do so and familiar with solid-state
control equipment and the safety procedures in
publication NFPA 70E.
ATTENTION:
for local safety and electrical codes.
This product contains stored energy
The system integrator is r esponsible
Publication 999-122 - January 1997
P-2 Preface
Contents of this Manual
ATTENTION:
An incorrectly applied or installed
Compact can result in componen t damage or a reduction
!
in product life. Wiring or application errors, such as
undersizing the mot or, incorrect or in adequate AC supply ,
or excessive ambient temperatures can result in
malfunction of the product.
ATTENTION:
This product contains ESD
(Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required
when installing, testing, servicing, or repairing this
assembly. Component damage can result if ESD
control procedures are not followed. If you are not
familiar with static control procedures, refer to
Allen-Bradley publication 8000-4.5.2, Guarding
Against Electrosta tic Dama ge or a ny other applic able
ESD Protection Handbook.
Chapter Title Contents
Describes the purpose, background, and scope
Preface
1 Safety Lists safety information regarding the Compact.
2 Introduction Provides a feature overview of the Compact.
3 Technical Overview Provides a technical overview of the Compact.
4
5
6
7 Troubleshooting
Appendix A Cable Information
Installation and
Hookup
Understanding the
IMC-S23x Setup
Setting Up your
Compact
of this manual. Also specifies the audience for
whom this manual is intended.
Provides information that allows you to install and
hook up your Compact.
Provides information that allows you to
understand the setup procedures for the
Compact.
Provides setup procedures for the Compact.
Explains how to interpret and correct problems
with your Compact.
Provides information about the cables used with
the Compact.
Publication 999-122 - January 1997
Preface P-3
Related Documentation
The following documents contain additional information concerning
related Allen-Bradley products. To obtain a copy, contact your local
Allen-Bradley office or distributor.
For Read This Document Document Number
A description and specifications for the Compact Compact Motion Controller Product Data 4100-2.3
A user guide for GML programming to be used with the Compact. GML Programming Manual GML-DOC-S
An overview of the Flex I/O products Flex I/O Product Profile 1794-1.14
Specifications for the Flex I/O products Flex I/O Product Data 1794-2.1
Published by the
An article on wire sizes and types for grounding electrical equipment National Electrical Code
A complete listing of current Allen-Bradley documentation, including
ordering instructions. Also indicates whether the documents are
available on CD-ROM or in multi-languages
A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial Automation Glossary AG-7.1
Schematics related to the Compact. Schematics 4100-5.0.01
Allen-Bradley Publication Index SD499
National Fire
Protection Association
of Boston, MA.
Compact Prod uc t
Receiving and Storage
Responsibility
Allen-Bradle y Support
You, the customer, are responsible for thoroughly inspecting the
equipment before accepting the shipment from the freight company.
Check the item(s) you r eceive aga inst your purchase or der. If any items
are obviously damaged, it is your responsibility to refuse delivery until
the freight agent ha s n oted the damage on the freight bil l. Shoul d you
discover an y concealed damage during unpacking, you are responsible
for notifying t he freight agent. Lea ve t he shipping container i ntact and
request that the freight agent make a vi sual inspection of the equipment.
Leave the pro duct in its shi pping contai ner prior to instal lation. If you
are not going to use the equipment for a period of time, store it:
in a clean, dry location
•
within an ambient temperat ure range of -40 to 70 ° C (-40 to 158° F)
•
within a relative humidity range of 5% to 95%, non-condensing
•
in an area where it cannot be exposed to a corrosive atmosphere
•
in a non-construction area
•
Allen-Bradley offers support services worldwide, with over 75
Sales/Support Of fices, 512 auth orized Distrib utors and 260 authorized
Systems Integrators located throughout the United States alone, plus
Allen-Bradley representatives in every major country in the world.
Publication 999-122 - January 1997
P-4 Preface
Local Product Support
Contact your local Allen-Bradley representative for:
sales and order support
•
product technical training
•
warranty support
•
support service agreemen ts
•
Technical Product Assistance
If you need to contact Allen-Bradley for technical assistance, please
review the information in the
your local Allen-Bradley representative. For the quickest possible
response, we recommend that you have the catalog numbers of your
products av ailable when you call . The Rockwell Automation T echnical
Support number is (
603) 443-5419
Troubleshooting
.
chapter first. Then call
Publication 999-122 - January 1997
Safety
Chapter
1
Read This Manual
Read and understand this instruction manual. It pr ovides the nece ssary
information to allo w you to install, connect, and se t up your IMCñS/23x
for safe, reliable operation.
ATTENTION: DANGEROUS MACHINERY!
Operation and maintenance of automatic equipment
!
!
involves potential hazards. Control Operators, Setup
Personnel, and Programmers should each take
precautions to avoid injury.
Injury and entanglement may occur if hands and limbs
come in contact wit h moving machinery . KEEP HANDS
CLEAR of dangerous moving machinery. Loose fitting
clothing or ties ca n become entangled in the machinery.
These items should not be worn while operating,
servicing, or programming the machine.
ATTENTION: HIGH VOLTAGES!
Electric shock can ki ll. Be sure the con troller is safely
installed in accordance with the Installation and
Hookup Section of this manual. Avoid contact with
electrical wires and cabling while power is on. The
electrical cabinet should be opened only by trained
service personnel.
ATTENTION: STATIC CONTROL!
The internal modules of the IMC S Class Compact motion
!
controller contain staticñsensitive electronic
components. Remove and handle the internal modules
only at a staticñsafeguarded work area. Failure to do so
may result in a dra st ica lly shortened life of your moti on
controller.
A disposable wristñstrap for grounding yourself is
included with this product. Please follow the directions
for use of this strap when removing and handling the
motion controller s internal modules.
Publication 999-122 - January 1997
1-2 Safety
Publication 999-122 - January 1997
Introduction
Chapter
2
IMC-S/23x Description
The IMC-S/23x is a compact, rugged, microprocessor-based two- or
four-axis servo motion controller. By including the logic and field
power supplies, t he IMC-S/23x pro vides a comp letely programmabl e,
stand-alone motion and logic controller suitable for a wide variety of
industrial applications.
The IMC-S/23x, in conjunction with external drive systems and
feedback encoders, provides two or four axes of closed-loop
point-to-point positioning with profile (trapezoidal, parabolic, or
S-curve), velocity, acceleration, and deceleration control as well as
multi-axis linear, circular, or helical interpolation. The electronic
gearing feature allows any axis to be slaved to another at a
programmable ratio. The electronic cam feature allows coordinated
motion profiles which are functions of ti me or position of another axis.
Sophisticated phase shift, auto-registration, and auto-correction
capabilities allow many complex motions and synchronizations to be
easily programmed. General-purpose discrete I/O, analog inputs,
analog outputs, et c. are provided by dire ct connection of Allen-Bradl ey
Flex I/O modules. Up to eight Fle x I/O modules–pro viding a total of
128 discrete I/O poi nts –may be connected directly to the IMC-S/23x.
Analog inputs and outputs can be substituted for discrete I/O blocks
for increased I/O flexibility.
Application programming of the IMC-S/23x for any application is
accomplished with GML, the exclusive Graphical Motion Control
Language from Allen-Bradley. Using GML, over 100 different
commands are available to completely customize operation of the
IMC-S/23x for your specific application. Complete application
programs are downloaded to the IMC-S/23x via a field-configurable
RS-232C or RS-422 port where they are store d in non-volati le memory
(write-protected battery-backed RAM).
A prompted, English-language machine setup procedure, complete
hookup diagnostics, an d improved Automatic Servo Setup routines for
self-tuning the se rvo paramet ers make setti ng up the IMC-S/23x q uick
and easy.
Publication 999-122 - January 1997
2-2 Introduction
Features
A dedicated serial port–which can be field-configured for RS-232,
RS-422, or Allen-Bradley DH-485 communications–is prov ided for the
man-machine interface (MMI). Connection of the MMI device is via
an AT-compatible DB-9 connector (RS-232 or RS-422) or RJ-45
connector (DH-485), both locate d on the f ront pan el. If DH-485 is not
used, a multi-unit addressing scheme (Multidrop) allows up to eight
IMC-S/23x motion controll ers to share a single RS-422 communication
channel in sophisticated multi-axis systems. The address of each unit
is set by a recessed front panel rotary switch.
The Remote I/O option allows the IMC-S/23x to communicate directly
with an A-B PLC® via Remote I/O using both discrete and block
transfers. The AxisLink option allows axes on other IMC S Class
controllers or ALECs (AxisLink Encoder Converter modules) to be
used as master axes for electronic gearing and cams. This ability
provides real-time coordination for distributed, multi-axis systems in
electronic gearing, cam, lineshaft, and synchronization applications.
Powerful graphical software development system (GML) makes
•
application programming easy and fun.
State-of-the-art Intel i960 RISC microprocessor.
•
Fast application program execution (most commands executed in
•
less than 1 µs) ensures highest machine performance and
productivity.
Completely digital–no potentiometers or other adjustments
•
required; wi ll not drift with time temperature or humidity.
Multitasking operating sy stem allows simult aneous execution of up
•
to 10 tasks for efficient utilization.
Electronic gearing for synchronization of any axis to another at a
•
programmable ratio. Ratio may be specified as a floating-point
number of integer fraction (1/3, 3/10 etc.).
Electronic cam for co ordinated motion profil es on one or more axes.
•
Profiles may be position versus time or slave axis position versus
master axi s position.
Sophistic ated phase shift and advance/r etard capabilities for
•
electronic gears and cams allows complex motions to be easily
programmed.
Auto-registr ation and auto-corr ection make high-spe ed registratio n
•
applications easy.
Exclusive Imaginary Axi s provi des addit ional command-onl y axis
•
for precise generat ion of master motion in master-sl ave applications
or correction moves in registration and synchronization
applications.
Concurrent, independent, or synchronous motion on all axes.
•
Interpolated motion on up to three axes.
Publication 999-122 - January 1997
Introduction 2-3
Wide position, speed, acceleration, and deceleration ranges for
•
precise control.
Separately programmable acceleration and deceleration rates for
•
maximum versatility.
Trapezoidal, parabolic, and S-curve velocity profiles.
•
Rotary mode with electronic unwind allows unlimited position
•
range for rotary axes.
Merge motion functi on allows seamless trans ition between all types
•
of motion.
Most motion parameter s (including master axis for electr onic gears
•
and cams) can be changed on-the-fly with no delays.
Powerful floa ting-poi nt math ca pabilitie s includi ng trans cendental
•
functions (sin, cos, log, etc.).
Sophisticated Nested Digital Servo Control Loop with automatic
•
servo setup for quick and easy servo tuning.
Isolation of all e xternal connections fr om the microproces sor logic
•
for reliable performance.
4 MHz maximum feedback count rate allo ws high s peed opera tion
•
without sacrificing resolution.
Encoder loss detection protects operators and machinery from
•
damage in the event of encoder feedback failure.
Isolated 16-bit DA Cs for smooth motion. Software offset correction
•
eliminates drift with analog servo drives.
Field-configurable servo outputs allow independent selection of
•
±10V or ±150 µΑ signal format for each axis.
Programmable position lock and posit ion error toler ances for serv o
•
fault protection.
Programmable directional software travel limits for enhanced
•
overtravel protection.
Vel ocity Feedforward to reduce following error.
•
Four optically isolated limit switch inputs for a home switch,
•
positive and negative overtravel switches, and a drive fault signal
for each axis.
Relay-contact drive enable output for each axis.
•
Optically isolated high-speed position registration input for each
•
axis for position synchronization and registration applications.
CPU Watchdog with front-panel LED indicator for fail-safe
•
protection.
Publication 999-122 - January 1997
2-4 Introduction
AxisLink option allows real-time axis coordination between
•
controllers for distributed, multi-axis systems.
Non-volatile storage (write-locked battery-backed RAM) of
•
application program, setup parameter and default variable values.
Memory Lock keyswitch on front panel prevents accidental or
•
unauthorized changes to application program, default setup
parameters, and default variable values.
Model Numbering System
The IMC-S/23x is available as a two- or four-axis motion controller
with optional Remote I /O Adapter and AxisLin k. The complete model
number is specified as shown below:
IMC-S/
Platform
2 = Stand Alone
Packaging
3 = Compact Package
Number of Axes
2 =Two Axes
4 = Four Axes
2
3
-
Pre-Engineered Cable
Assemblies
Remote I/O Option
R = Remote I/O Adapter
AxisLink Option
L = AxisLink Multi-Axis Synchronization Link
Pre-engineered cable assemblie s are used for connec ting the Fl ex I/ O,
servo amplifiers, feedback devices, axis-specific (dedicated) I/O, and
the CPU watchdog. The table below shows the available cable
assemblies.
ATTENTION:
connections to the IMC-S/23x while the power is on!
!
Doing so risks damage to the IMC-S/23x, external
components, and your health!
Do not attempt to make any electrical
Publication 999-122 - January 1997
IMC S/23x Pre-Engineered Cable Assemblies
Catalog Number Used to Connect. . . Length
(ft) (m)
4100-CCF1
4100-CCF3
4100-CCS15F
4100-CCAQB
4100-CCA15F
4100-CCW15F
4100-RCS3T
or
Flex I/O
Servo and Feedback
1391B-ES or 1391-DES
Dedicated Discrete I/O
CPU Watchdog
REC Interface
10.3
31
15 4.5
-15 4.5
15 4.5
31
Introduction 2-5
Number
Required
1 per S Class
1 per Axis
1 per Axis
1 per Axis
1 per S Class
1 per Axis
Mechanical Specifications
Front Panel Layout
(IMC-S/23x-RL model shown.)
Publication 999-122 - January 1997
2-6 Introduction
Mounting and Clearance Dimensions
General Specifications
Motion Control
Microprocessor
Number of
Controlled Axes
Application
Storage
Data Storage
Number of User
Variables
Number of Electronic
Cam Poi n ts
Intel 80960SB @ 16 MHz.
2 (Axis 0 and Axis 1) IMC-S/232...models.
4 (Axis 0, 1, 2, and 3) IMC-S/234...models.
Write-lockable batt ery-backed RAM (Ran dom-Access Memory) with 10
year (minimum) battery life for application program (32K) and setup
parameter values.
Write-lockable batt ery-backed RAM (Ran dom-Access Memory) with 10
year (minimum) battery life for cam table and default user variable values.
2,000 user-definable; values stored as 64-bit floating-point numbers.
26,000 total.
Publication 999-122 - January 1997
Envir onmental Specifications
Storage
Temperature -40°C to 70°C (-40°F to 158°F).
Operating
Temperature 0°C to 50°C (32°F to 122°F).
Maximum
Humidity 95% non-condensing.
Electrical Specifications
AC Power Input 90 - 132 or 175 - 264 Volts AC,
AC Fuse 3A Dual Element Time Delay (Slow Blow) 1/4 x 11/4
I/O Power Input 18 - 36V DC,
I/O Fuse 3A Dual Element Time Delay (Slow Blow) 1/4 x 11/4
Introduction 2-7
47 - 63 Hz,
3 Amperes maximum.
3A maximum (24V nominal).
Encoder Input Specifications
Number of
Encoder Inputs
Type of
Encoder Input
Encoder
Interface IC AM26LS32 or equivalent.
Compatible
Encoder Types
Decode Modes 4X Quadrature, Step/Direction, Count Up/Count Down.
Maximum Encoder
Frequency
Input
Impedance 7 kΩ minimum (each input).
Encoder
Power
2 (Axis 0 and Axis 1) IMC-S/232...models.
4 (Axis 0, 1, 2, and 3) IMC-S/234...models.
Incremental AB quadrature; optically isolated, differential with marker
channel.
Differential, TTL-Level (5V DC) line driver outputs, with or without
marker; including the following Allen-Bradley devices:
845F-SJxZ14-xxYx...
845F-SJxZ24-xxYx...
845H-SJxx14xxYx...
845H-SJxx24xxYx...
845K-SAxZ14-xxY3
845K-SAxZ24-xxY3
845P-SHC14-xx3
845T-xx12Exx...
845T-xx13Exx...
845T-xx42Exx...
845T-xx43Exx...
4,000,000 counts per second (4 MHz). This is equivalent to a channel
frequency of 1 MHz in 4X quadrature decode mode.
5 or 12 Volts DC at 1 Ampere (tot al) a v a ilable f rom IMC-S/23x . Voltage
selection by internal sw itch.
Publication 999-122 - January 1997
2-8 Introduction
Servo Output Specifications
Number of
Servo Drive Outputs
Type of Output Isolated analog voltage or current; individually field-configurable via
Output Range ±10 Volts DC or ±150 µA (minimum).
Resolution 16 bits, 305 µV or 4.58 µA per bit.
Output Impedance 220Ω resistive for voltage output; 56Ω maximum load impedance for
Output Offset ±80 µV maximum. Compensated to 0 volts via soft ware setup pr ocedure.
Dedicated Discrete I/O
Specifications
Number of
Dedicated Discrete
Inputs
Dedicated
Discrete Input
Functions
Input Type Optically isolated.
Operating
Voltage
Input ON
Current
Impedance
Input Response
Number of
Dedicated
Discrete Outputs
Dedicated Discrete
Output Function
Output Type Normally-open relay contacts (Drive Enable);
Operating
Voltage
Output
Current
Input
Time
2 (Axis 0 and Axis 1) IMC-S/232...models.
4 (Axis 0, 1, 2, and 3) IMC-S/234...models.
internal switch for each axis.
current output.
10 (5 each for Axis 0 and 1) IMC-S/232...models.
20 (5 each for Axis 0, 1, 2, and 3) IMC-S/234...models
Home Limit Switch,
Positive Overtravel Limit S witch,
Negative Overtravel Limit Switch,
Drive (Amplifier) Fault,
Position Registration.
24 Volts DC nominal; 28V DC maximum.
24 Volts DC nominal; 28V DC maximum or 5 Volts DC nominal;
10V DC maximum for position registration inputs.
12 µΑ per input (nominal);
2.5 µΑ for position registration inputs.
2 kΩ (resistive) per input;
8.8 kΩ (resistive) for 24V position registration inputs.
5 µs maximum;
1 µs maximum for pos ition registration i nputs.
4 (2 each for Axis 0 and 1)IMC-S/232...models.
8 (2 each for Axis 0, 1, 2, and 3)IMC-S/234...models.
Drive (Amplifier) Enable.
Absolute Position Strobe.
Optically isolated, floating, solid-state relay (Position Strobe).
0.010 - 40 Volts DC; 24V DC nominal for drive enable outputs,
5.10± 0.10 Volts DC for position strobe outputs.
1 Ampere per output maximum for drive enable outputs;
10 µΑ per output maximum for position strobe outputs.
Publication 999-122 - January 1997
Serial I/O Specifications
Number of
Serial Channels 2 (Serial Port A and Serial Port B).
Channel Type Optically isolated RS-232C or RS-422; each channel individually
Information Code ASCII (American Standard Code for Info rmation Interchange).
Baud Rate User-selectable up to 128k Baud (RS-422).
Number of
Start Bits 1.
Number of
Stop Bits 1.
Word Length 8 bits total; 7 data bits plus 1 parity bit.
Parity Space parity transmitte d;
Duplex Full or half (user-selectable).
Data
Synchronization XON (Control-Q)/XOFF (Control-S).
Front-Panel
Connectors IBM-PC /AT compatible 9-pin D-type female.
RS-422
Termination User-selectable 220Ω resistor via internal switch.
Introduction 2-9
configurable via internal s witch.
User-selectable up to 115.2k Baud (RS-232C).
Receive parity ignored (may be Mark, Space, Even, or Odd).
DH-485 Specifications
Number of
DH-485 Channels 1; replaces Serial port B when used.
Channel Type Optically isolated half-duplex RS-485.
Baud Rate 9,600 or 19.2k Baud (user-selectable).
Front-Panel
Connectors Two RJ-45 jacks (+24V is not provided).
RS-485
Termination User-selectable 220Ω resistor via internal switch.
Node Address User-selectable between 0 and 31 inclusive.
Node Type Token-passing master.
Accessible Data
Files
1 Binary file (B3) for up to 16,384 bits
1 Integer file (N7) for up to 1,024 16-bit values
1 Floating-point file (F8) for up to 512 32-bit values
1 ASCII string file (A) for up to 2, 048 characters
9 user-configurable files; each can be individually configured as any of
the above types or as a BCD file for floating point simulation (required
for certain A-B MMI devices).
Publication 999-122 - January 1997
2-10 Introduction
Flex I/O Compatibility
Specifications
Maximum Number of
Flex I/O Modules 8.
Compatible
Modules
S Class Interface Direct-no 1794-ASB or other adapter required.
Servo Performance
Specifications
Servo Loop
Sample and Update
Maximum Feedback
Frequency 4 MHz (4,000,000 feedback counts per second).
Absolute
Position Range
Absolute Position
Resolution
Speed Range 0.00001 feedback counts per servo update to 4,000,000 feedbac k counts
Speed Resolution 15 position unit digits or
Acceleration/
Deceleration Range
Acceleration/Deceleration
Resolution
Electronic Gearing
Gear Ratio Range 0.00001:1 to 9.99999:1 (slave counts : master counts).
Electronic Gearing
Gear Ratio Resolution 8 position unit digits or 32 feedback count bits.
Servo Gain Resolution 32 bit floating point.
Servo Output Limit
Servo Output Limit
Resolution 305 µ (voltage output); 4.58µΑ (current output).
1794-IB16 16 24V DC Discrete Inputs
1794-IA8 8 115V AC Discrete Inputs
1794-IE8 8 Current/Voltage Analog Inputs
1794-OB16 16 24V DC Discrete Outputs
1794-OA8 8 115V AC Discrete Outputs
1794-OE4 4 Current/Voltage Analog Outputs
1794-IE4XOE2 4 Current/Voltage Analog Inputs
2 Current/Voltage Analog Outputs
Rate 250 Hz to 2 kHz for each of 2 or 4 axes.
± 1,000,000,000 feedback counts for Linear AxisAxi s:Lin earli near ax es ;
R for rotary a xes.
15 position unit digits or
32 feedback count bits, whichever is less.
per second.
15 feedback count bits, whichever is less.
0.00001 feedback counts per servo update2 to 4,000,000,000 feedback
counts per second2.
15 position unit digits or
15 feedback count bits, whichever is less.
Range 0 to 100%.
Publication 999-122 - January 1997
Servo Gain Units
IMC-S/23x Servo Gain Units
Gain Description Units
P
I
V
F
Proportional Gain
Integral Gain
Velocity Gain
Feedforward Gain
Deadband Compensation
Offset Compensation
Introduction 2-11
Counts per Millisecond
Count of Error
Counts per Millisec ond2
Count of Error
Millivol ts
Count per Mi llisecond
Counts per Millisecond
Count per Mi llisecond
Volts
Volts
Remote I/O Adapter
Specifications
Baud Rate
Rack Address
Rack Width
I/O Group Address
IMC-S/23x-R and IMC-S/23x-RL models only.
57.6K, 115.2K or 230.4K (User-selectable).
User-selectable between 0 and 31 decimal.
User-selectab le in quarter-rack increment s (1/4, 1/2, 3/4, Full).
User selectable as shown below:
IMC-S/23x Remote I/O Adapter Addressing
Type of Transfer I/O Group
Block
Discrete
Discrete
Discrete
Discrete
Discrete
Discrete
Discrete
Starting I/O Group 0246 024 02 0
Rack Width
0246
1357
1/4 1/2 3/4 Full
024
135
246
357
02
13
24
35
46
57
0
1
2
3
4
5
6
7
Publication 999-122 - January 1997
2-12 Introduction
Number of
Discrete I/O Bits
12 dedicated inputs,
12 dedicated outputs,
User-defined as shown below:
IMC-S/23x Remote I/O Adapter
Number of User-Defined Discrete I/O Bits
Rack Width Inputs Outputs
1/4
1/2
3/4
Full
Maximum Block
Transf er Length 64 words (128 bytes).
Block Transfer
Data Types
User Variable values,
Axis Data Parameter value,
Axis Data Bit state,
Master Cam Posi tion Point values,
Master Cam Time Point values,
Slave Cam Position Point values,
Axis or System Variable value.
Block Transfer
Data Formats
32-bit (double-word) 2s complement integer,
16-bit (single-word) 2s complement integer,
32-bit (8-digit) signed BCD,
32-bit IEEE floating-point,
Word-swapped 32-bit (double-word) 2s complement integer,
Word-swapped 32-bit (8-digit) signed BCD,
Word-swapped 32-bit IEEE floating-point.
36
68
100
4
4
36
68
100
Publication 999-122 - January 1997
Introduction 2-13
AxisLink Specifications
Baud Rate Standard and extended
Cable Type Standard and extended
Cable Length Standard and extended
Number of
Motion Controll ers
Addressing Standard and extended
Number of Virtual
Master Axes
Type of Virtual
Master Axes
Slave Axes Standard and extended
IMC-S/23x-L and IMC-S/23x-RL models only.
1 megabit per second.
node configurations
Extended length
500 kilobit per second.
configuration
Allen-Bradley 1770-CD RIO cable (Belden 9463 or
node configurations
Extended length
equivalent).
Belden 9182, Carol C8014 or equivalent.
configuration
25 meters (82 feet) maximum total. Minimum of 1
node configurations
Extended length
configuration
Standard and extended
meter (3 feet) between controllers.
125 meters (410 feet) maximum total. Minimum of 1
meter (3 feet) between controllers.
8 maximum for a total of 32 possible axes.
length configurations
Extended node
16 maximum for a total of 64 possible axes.
configuration
User-selectable address via rotary selector switch on
length configurations
Extended node
front panel.
User-selectable address via GML.
configuration
Standard configuration 4 maximum total; 1 per motion controller maximum.
Any axis on any motion controller can be a virtual
master axis to any ot her motion controller . Each motion
controller can de fine a total of tw o separate axes on an y
other motion control lers as virtual master axes, b ut only
one can be active at any time. A tot al of f our di fferent
axes can be active as virtual master axes at any time.
Extended length and
extended node
configurations
2 maximum total; 1 per motion controller maximum.
Any axis on any motion controller can be a virtual
master axis to any ot her motion controller . Each motion
controller can de fine a total of tw o separate axes on an y
other motion control lers as virtual master axes, b ut only
one can be active at any time. A total of two different
axes can be active as virtual master axes at any time.
All configurations 2: Command and Actual. Each virtual mast er axis may
be defined to report its command or actual position.
31 maximum total per virtual master axis (3 local + 4
length configurations
Extended node
configuration
x 7 other motion controllers = 31).
63 maximum total per virtual master axis (3 local + 4
x 15 other motion controllers = 63).
Publication 999-122 - January 1997
2-14 Introduction
Number of
Discrete I/O
Discrete I/O
Response
All configurations 112 inputs maximum total and 16 user-definable
outputs per motion controller. Any motion controller
can read the 16 discrete outputs of any other motion
controller, giving a maximum total of 7 x 16 = 112
discrete inputs per motion controller. For extended
node configuration, discrete I/O can still only be
obtained from a maximum of 7 other controllers (112
inputs maximum total), n ot from all 15 other controllers
available in a 16 node maximum extended node
configuration.
All configurations ≤1 millisecond.
Publication 999-122 - January 1997
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