Rockwell Automation 999 User Manual

Download

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

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

Publication 999-122  January 1997

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

iii

Publication 999-122  January 1997

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

Publication 999-122  January 1997

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

Publication 999-122  January 1997

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

vii

Publication 999-122  January 1997

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.

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

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

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

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

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

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

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 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

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

Technical Overview

Chapter

Digital Control Loop

Each axis of the IMC-S/23x utilizes a powerful Nested Digital Servo Control Loop to provide servo positioning control and compensation of a servo actua tor. The servo actuator can be a DC motor, a brushless DC motor, an AC motor (with the appropriate drive electronics), or a hydraulic cylinder or motor.

The Nested Digital Serv o Control Lo op utilizes s tate-of-the- art digital hardware and sof tware to perfo rm the func tions nec essary to e stablis h a closed l oop servo system. The only external elements neede d to complete the servo loop are:

Actuator (Brushless DC Motor, Hydraulic Cylinder, etc.)

•

Servo Amplifier for Actuator

•

Digital Incremental Encoder (Quadrature type)

•

The digital approach t o motion cont rol has numerous adv antages o v er conventional analog servo control techniques. Digital feedback eliminate s the need for potentiometers in the control loop with their associated adjustmen t labor and dr ift. Furthe rmore, the Nested Di gital Servo Loop is microprocessor-based. Microprocessor design reduces the system parts count, increases system reliability, and greatly increases the flexibility of the control.

The Nested Digital Servo Loop synthesizes a velocity (rate) loop as well as the required position loop in software using only the position information provided by the encoder (or other feedback device). No analog tachometer is required to provide complete stabilization and positioning control of the motor and load. In addition, velocity feedforward is provided to reduce the intrinsic following error of the position loop when the motor is moving.

Publication 999-122 - Janua ry 1997

3-2 Technical Overview

A functional block diagram of the Nested Digital Servo Loop is shown below. The following sections discuss, in detail, each block in this diagram.

Encoders

The IMC-S/23x interfaces to rotary or linear quadrature-type incremental encoders to provide both position and velocity feedback. The most common type of such encoders are optical; they utilize a light source and an alternately clear and opaque disc or scale to generate their output.

When operating at a f ixed speed, quadrat ure-type incremental enco ders generate two squar e wave outputs , usually referred to as Channel A and Channel B, which are approx imately 90° out of phase with one a nother. Proper phasing of these two channels can be checked by driving the encoder at a fixed speed and displaying the two encoder outputs on a dual channel oscilloscope.

Encoders are available with a variety of different output driver configurations. The IMC-S/23x interfaces directly to differential line driver encoders providing TTL (5V) level signals. In addition, the encoder inputs ar e optically isolated and po wered from a separate po wer supply contained withi n the IMC-S/23x. Encoder loss circuitry dete cts when any of the encoder connections have broken.

Publication 999-122 - Janua ry 1997

Technical Overview 3-3

Often a third output channel is available from the encoder. This so-called "marker" output is also known as Channel Z, 0, or C. The marker output from an encoder is a pulse that occurs at one specific point on the encoder disc (rotary encoders) or slide (linear encoders). Therefore, the marker may be used to establish a precise absolute position reference. Note that for rotary encoders, the marker provides a position referenc e within one revolution of the encoder. F or multi-turn applications, othe r means must be us ed in conjunct ion with the mark er pulse to determine the absolute position. The IMC-S/23x can interface to encoders with marker pulse outputs of either active-high or active-low polarity.

Encoder Counter

The encoder counter circuitry is identical for all axes and consists of optically-isolated AM26LS32 input buffers, programmable decode logic, and 16-bit encoder counters contained within the CX2216.

Once buffered and isolated, the two TTL-level encoder signals (Channel A and B) are c onnecte d to the CX22 16 which de codes them using 4X quadrat ure logic (4 cou nts per e ncoder lin e). Afte r decoding, the count signals are sent to the encod er counter in the CX2216 , which keeps a record of the number of counts and the direction of encoder motion. The IMC-S/23x software extends the encoder counters to 32 bits giving a total position range of ±1,000,000,000 encoder counts.

A quadrature type enc oder generates four counts for every line on the encoder disc or s lide. The sequenc e in whi ch th e co unts a re gen era ted is determined by the direction that the encoder is moving, and the encoder counter increments or decrements accordingly.

The maximum encoder rate for any digital control is determined by many factors, i ncluding t he sample r ate of the c ontrol lo op, the siz e of the encoder counters , and pulse ra te limitati ons of the digit al circuit ry . The maximum encoder count rate, or

encoder bandwidth

, for the

IMC-S/23x , is 4.0 Megahert z. Every servo sample period, the microprocessor reads the encoder

counter for each axis and computes a count increment by subtracting the previ ous counter value from the present counter value . Thi s c ount increment repres ents the distanc e the axis has tr aveled i n the precedin g millisecond. This v alue is then us ed to update the 32- bit actual position.

Publication 999-122 - Janua ry 1997

3-4 Technical Overview

Software Feedback Calculations

Every servo sample period, the IMC-S/23x microprocessor also does a complete position feedback calculation for each axis by first computing the dif ference between the actual positi on and the command position. This quantity is called the Position Error. The intent of every closed loop position se rvo syst em is to driv e this position error to zero.

T o accompl ish this, the position erro r is mult iplied by a pro grammable P (Proportional) Gain term and used to generate a velocity command. In addition, when the axis is not moving, po sition error i s accumulated (integrated) and multiplied by the I (Integral) Gain term and added into the velocity command. This allows the IMC-S/23x to compensate for static disturbances that would otherwise keep the position error from becoming zero. Such static disturbances include static friction (so-called Sticktion) and gravity effects on vertical axes.

Integral Gain is also effective in reducing the tracking erro r between the master and slave axis when the electronic gearing feature is used. The integral term is deactivated, however, when performing commande d motion (moves an d jogs) to improve servo stability and decrease overshoot.

To create a stable position servo loop without using an analog tachometer, damping is provided by synthesizing a tachometer in software. This is accomplished by calculating the rate of change of encoder position to generate the actual velocity. The actual velocity is compared to (subtracted from) the command velocity to generate the velocity error. This velocity error is then multiplied by the programmable V (Velocity) Gain and used to dri ve the mot or to reduce the velocity error (an d thus t he positi on error al so) to zer o. W ith serv o drive s incorporatin g a true tachomet er loop, the so ftware v elocity loop is disabled.

After being mult iplied by the V gai n, the veloci ty error is range l imited and then se nt out to a 16-bit DAC (Digital-to-Anal og Converter to generate the ±10 volt or ±150 mA signal for use by the drives.

In use, the servo output ranges between ±10 volts or ±150 mA, depending on the settin g of the drive out put type switch. The maximum output can also be cla mped to less than the abo ve full scale v alues. This servo output limit is fully programmable.

In addition, deadband compensation is provided to compensate for friction effects when using current-loop servo amplifiers. Deadband compensation adds a programmable valu e to the magnitude of t he servo output signal (i.e. when the velocity error is positive, the DB compensation value is added, and when the velocity error is negative, the DB compensation value i s subtracted) .

Publication 999-122 - Janua ry 1997

Technical Overview 3-5

Finally, drive offset compensation is provided to allow compensating for the inevi table offset and drift in anal og servo amplifiers. Dri ve offset compensation adds a programmable valu e to the magnitude of t he servo output signal.

Each of the gain terms me ntioned abo v e has a u nique influe nce on th e closed loop dynamics of t he system. By adjust ing the P, I, and V gains, it is easy to tailor the syst em dynamics to meet specific needs. The three programmable control ga ins influence t he closed loop dynamics i n the following wa y:

Servo Amplifiers and Motors

Proportional Gain Integral Gain Vel ocity Gain

⇒ ⇒ ⇒

Elastic Stiffnes s Static Disturbance Compensation Damping

Each axis of the IM C-S/23x can inter face to a sta ndard serv o amplif ier operating in current (torque) or velocity (tach) mode which accepts a ±10V DC command. Servo ampli fiers are availabl e from Allen-Bradley as well as other manufactur ers to drive DC, brushless DC or AC motors in a wide range of powers. The IMC-S/23x can also interface to hydraulic serv o and proportional v alves which acce pt ±150 mA signals.

Publication 999-122 - Janua ry 1997

3-6 Technical Overview

High Level Motion Functions

Destination Position

Because servo action forces the actual position to track the command position, sophisticated indexing, jogging, and electronic gearing functions are easily implemented through software control of the command position. These high le vel motion functions are sho wn below and explained in the following paragraphs.

Trapezoidal, Backlash Compensation

Parabolic,

S-Curve,

Indexed

Ramp Up/Ramp Down Jogger

Time-Lock Cam

Master Axis Command Position

Master Axis Actual Position

Time

Position-Lock Cam

Master Position

Electronic Gearing

Interpolator 0

Interpolator 1

Command Position

Publication 999-122 - Janua ry 1997

Technical Overview 3-7

Indexing and Jogging

The indexer moves the axis using either a trapezoidal, parabolic, or S-Curve (controlled jerk) velocity profile. Axis velocity, acceleration, and deceleration are completely programmable. The trapezoida l profile is the most common type of mov e and resul ts in a smooth acc eleration to the desired sp eed and a smooth deceleration to th e desired destination position. Parabolic and S-curve profiles are provided for use where minimum stress on the mechanics is more important than minimum index time.

The jogger produces constant speed motion of the axis in either direction. The v elocity and the acceleration ra te are programmable. The indexer an d jogger also pro vide th e ability to cha nge speeds and inde x positions while the axis is mo v ing . The jogger also allows changes in the acceleration or deceleration ramp while jogging. Furthermore, electronic gearing may be combined with ind ex and jog motion to create complex motion profiles and synchronizations.

Backlash Compensation

Another high level motion function is Backlash Compensation. This technique–called Unidirectional Approach–overcomes mechanical backlash by alw ays approaching the dest ination position from the same direction. When ap proaching the destinat ion position from the opp osite direction, the axis moves past the destination position by a programmable Backlash Offset, reverses, and then moves back to the destination positi on. Since the axi s al ways approa ches th e desti nati on position from the same direction, the mechanical backlash is always taken up in the same direction ensuring accurate positioning.

Electronic Cam

The electronic cam f eature pr ovide s the IMC-S/ 23x with t he abilit y to execute coordinated motion profiles. This is accomplished by programming a table of position values which describe the desired profile, and then e xec uting the tab le as required. Ele ctronic ca ms may be defined in terms of axis pos ition(s) v ersus time (time-lo ck cams) or position of the slave axis versus position of the master axis (position-lock cams).

Electronic Gearing

Electronic gearing allo ws an y ax is to be progr ammed to t rack another axis at a specif ied ratio. By con vention, the axis that is tracking i s called the the master axis is equi v alent to the inpu t shaft, a nd the s lav e axis t o the output shaft in a mechanical transmission.

, while the axis that is bein g tracked is called the

slave

Publication 999-122 - Janua ry 1997

master

. Thus,

3-8 Technical Overview

Electronic gearing is accomplished by first reading the master axis’ actual position an d computing the distance increment fro m the previous reading. This increment is then multiplied by a programmable gear ratio and added to the slave axis’ command position. In this way the slave axis is forced to track the master axis according to the specified gear ratio. The slave axis may be programmed to move in the same or the opposite direction from the master axis.

Electronic gearing ratios may be specified as a number between

0.00001:1 and 9.99999:1 . Alt er nat el y, the gear ratio may be specified as a pair of intege r values–a numera tor and denominator– r epresenting the exact ratio of slave axis feedback counts to master axis feedback counts. The ability to s pecify numerator/denominator gear rati os makes it possible to perform electronic gearing using an irrational gear ratio such as 1/3 with no accumulated error.

By combining the jog and electronic gearing capabilities of the IMC-S/23x, the slav e axis may be smoothly accelerated and dec elerated into and out of electronic gearing motion. This merged motion capability is equivalent to a software clutch.

Velocity Feedforward

Interpolation

T wo independent interpolators for all axes allow any two or three axes to be moved as a group along a linear , circular , or helical path. Motions from the two interpolators may be combined with each other or with other types of motio n. Motion segments may be blended to one another to accomplish continuous path motion as long as they are tangent at their intersection.

The IMC-S/23x is capable of pro viding velocity fe edforward to reduce following error. Following error is the servo position error that is present when the axis is moving at a commanded speed. Without velocity fe edforward, a fo llowing err or necessary to pr oduce suff icient output to drive the motor at the comman ded speed will always exist. Many applicatio ns require that the following error be near zero over the entire speed range of the motor . Velocity feedfor ward may be used to satisfy this requirement.

Velocity feedforward is provided by pre-computing the command velocity as the rate of change with respect to time of the command position. The command velocity is then scaled by the F Gain (Feedforward Gai n) and added to the v elocity command. By adjusti ng the F Gain it is poss ib le to produce, from the feedforward term alone, the required ve locity command to d riv e the motor at the de sired speed. Thus, only a little position error is needed to " fine tune" the motor spe ed and position.

Publication 999-122 - Janua ry 1997

Technical Overview 3-9

Velocity feedforward is v ery usef ul in el ectroni c gearing a pplicat ions, since no position error between the master and slave axes exists with mechanical gears. Using velocity feedforward also allows the position loop integrator (I Gain) to respond more quickly to changes in speed.

CPU Watchdog

Software Overtravel Limits

Serial Communication

The IMC-S/23x pro vides a CPU Watchdog that monitors the he alth of the motion control microprocessor. In the event of a processor malfunction or other f ault, the CPU watchdog is im mediately disabled. T o reset the Watchdog, the IMC-S/23x must be reset, either by cy cling power, or by pressing the Reset button on the front panel.

An LED labeled "System OK" is provided on the IMC-S/23x front panel to visually monitor the state of the CPU watchdog. This green LED is lit under normal operation, and goe s out when the watchdog is deactivated. A relay driven by the CPU watchdog provides normally open and normally closed contacts on the Watchdog connector for wiring into the machine’s E-Stop string or other fail-safe circuit.

The IMC-S/23x can be configured to range check the command position of each axi s to ensure that the axis is oper ating within its limits. These software travel limit values are fully programmable. When an overtravel condition occurs, the IMC-S/23x either disables the feedback loop and disables the amplifier, or decelerates the axis to a stop. In either case, further motion in the offending direction is inhibited.

Serial communicat ion with the IMC-S/23x is v ia either an RS-232C or RS-422 serial link to one of two ports. If configured for RS-232C, operation up to 19.2K baud is possible, while ports configured for RS-422 can operate at up to 128K baud. A PC/AT-compatible 9-pin D-type connector is pr ovided for each serial po rt on the fron t panel. In general, the GML software development system for application programming is connected to serial port A while a serial operator interface device or runtime display is connected to serial port B.

The IMC-S/23x can be configured to operate in Multidrop Mode allowing up to eight con trols to share a single RS-422 communicati ons link. This is ac complished by using two special non- echoed commands to activate individual units to respond to commands issued by the operator interf ace device or host computer . Each IMC-S/23x is assigned its own uniq ue address via a recesse d front-panel rotary sel ector switch.

Publication 999-122 - Janua ry 1997

3-10 Technical Overview

DH-485 Communication

Axis-Specific Discrete I/O

The IMC-S/23x communicates with other devices over DH-485 by reading and writing data i nto and out of data file s. Data from local fil es (in the motion controller) is transferred to and from remote files (in other devices ). In the motion contr oller , up to 13 dif ferent local f iles of five different types can be used. Each type of file contains a different number of elements and is equivalent to a different SLC file type as shown belo w.

IMC S Class DH-485 Local File Types

S Class

File Type

Binary Integer Floating ASCII BCD

Elements Element

W ords/Bits 16-bit Values Floating Point Values Characte rs BDC Values

Numbers

0 - 1023 0 - 1023 0 - 511 0 - 2047 0 - 1023

Equivalent to SLC File T y pe

B N F A D

Each axis of the IMC-S/23x has associated with it four optically-isolated inputs which provide a direct interface for a home switch, overtravel (positive and negative) switches, and a drive fault signal (usually an output from the amplifier). In addition, a relaycontact drive enable output is provided for each axis to enable and disable the amplifier under program control. The four discrete inputs are completely de-bounced and can be connected directly to limit switches which operate on 24V DC. Inputs can be from mechanical limit switches, proximity switches, or PLC outputs.

Each axis of the IMC- S/23x can be individuall y programmed to operate with or without t hese discre te inputs e nabled. If enabled, each discr ete input can be individually programmed to operate with normally open (NO) or normally closed (NC) limit switch contacts.

Home Limit Switch Input

Home limit switches are used in conjunction with two of the four programmable homing sequences. When a homing sequence is enabled, the IMC-S/23x executes it under program control. See the Setup section of this manual fo r a complete de scription of the avai lable homing sequences.

Overtravel Limit Switch Inputs

Overtravel limit switches can be used to enforce the mechanical safe travel limits during machine operation. Assuming that the overtravel function is enabled, the IMC-S/23x may be programmed to either provide a status, disable the feedback loop, and deactivate the drive enable output of the affected axis, or stop motion and decelerate the axis to a stop when an overtravel limit switch is tripped.

Publication 999-122 - Janua ry 1997

Technical Overview 3-11

Drive Fault Output

The driv e fault inputs may be connected to the fault outputs (if provided ) on the amplifiers for each axis. This al lows the IMC-S/23x to re act to a fault in the amplifiers themselves . Lik e t he othe r disc re te inp uts, th e drive fault input may be enabled and disabled from the application program, and may be configured to operate with active-high or active-low drive fault outputs. When a drive fault input is activated, assuming the function is enabled, the IMC-S/23x stops all motion on the particular a xis and de acti v ates t he approp riate dri v e enabl e output .

Drive Enable Output

The driv e enable outp ut for each axis al lows t he IMC-S/23x to di sable the axis amplif iers in the e vent of a motion f ault. Since it uses a fl oating normally-open rel ay contact, the dri ve enable outp ut can be connected to amplifier s ha ving ei ther ac tive-high or acti v e -lo w ena ble o r disab le inputs.

Status LEDs

Position Registration Inputs

Special, high-speed, optically-isolated inputs on the IMC-S/23x (one per axis) provi de a direct interface for position registration s ensors. The position registration inputs are unfiltered to minimize propagation delay for speed-critical position registration applications and can be directly connected to sensors (or enco der markers) oper ating on 5V or 24V DC.

When a position registration input is activated, assuming the position registration feature is enabled, the current actual position of the axis is immediately latched in hardware into a special registration latch. The latched registration position is then available within the application program for calculations.

Three general purp ose status LEDs are provided on the front panel of the IMC-S/23x. Labeled St atus 0, 1, 2, thes e LEDs are used to indicate the results of the power-up diagnostics performed whenever power is applied to the IMC-S/23x. If the IMC-S/23x passes its power-up diagnostics, all th ree status LEDs are turn ed off and the CPU w atchdog LED (System OK) is turned on. At this point, the three status LEDs may be used by the application program for any desired purpose.

If all three status LEDs are not off after power -up, the IMC-S/23x d id not pass its power-up diagnostics, and the CPU watchdog is not activ ated. In this case, the code sho wn on the three status LEDs indicate s the specific tes t wh ic h fa il ed.

Publication 999-122 - Janua ry 1997

3-12 Technical Overview

General Purpose Discrete I/O

The IMC-S/23x provide s a direct connection to Allen-Bradley Flex I/ O for use as general-purpose I/O. The Flex I/O modules which may be used with S Class motion controllers a r e shown in the table below.

IMC S Class Compatible Flex I/O Modules

Catalog Number

1794-IB16 1794-IA8 1794-IE8 1794-OB16 1794-OA8 1794-OE4 1794-IE4XOE2

16 24V DC Discrete Inputs 8 115V AC Discrete Inputs 8 Analog Inputs 16 24V DC Discrete Outputs 8 115V AC Discrete Outputs 4 Analog Outputs 4 Current/Voltage Analog Inputs 2 Current/Voltage Analog Outputs

Description For Additional

Information

See...

1794-2.1 1794-2.1 1794-2.1 1794-2.1 1794-2.1 1794-2.1 1794-2.1

Up to eight separate modules, selected from the table above, may be connected to the motion controller in any order. For specific information on connecting I/ O devices to each of the Flex I/O modul es, see the appropriate Flex I/O publications listed above.

The Imaginary Axis

Remote I/O (Optional)

AxisLink (Optional)

The IMC-S/23x also provide s an imaginary axis i n addition to the tw o or four physical axes on each controller. The imaginary axis is an internal (softw are) axis whi ch ha s no serv o loo p and no conne ction to a drive, encoder, or discrete I/O. It is used only as a master axis for physical axes to syn chr oni ze th em when no physical or virtual axis is available. As such, it can be thought of as a built-in virtual axis not requiring AxisLink. The "output" of the imaginary is its c ommand position–it has no ac tual position. All of the high-le vel motion functions discussed earlier are available for the imaginary a xis.

IMC-S/23x-R and IMC-S/23x-RL models include an Allen-Bradley Remote I/O Adapter. This option allows certain aspects of the unit to be controlled and monitored from an Allen-Bradley PLC using a Remote I/O scanner. The IMC-S/23x appears to the PLC as a quad-density intelligent module in a Remote I/O rack. Both discrete and block transfer functions are available.

IMC-S/23x-L and IMC-S/23x-RL models include AxisLink, which allows axes on other IMC S Class controllers and ALECs (AxisLink Encoder Converter modules) to be used as mast er axes for electronic gearing and cams. In addit ion, 16 discrete outputs per motion co ntroller are av ail ab le t o othe r moti on controllers via AxisLink for sequencing and program synchronization.

Publication 999-122 - Janua ry 1997

Installation and Hookup

Chapter

Introduction

The IMC-S/234 provides four p hysical axes c alled Axis 0, 1, 2, and 3. The IMC-S/232 provides two physical axes (Axis 0 and Axis 1), and therefore only two servo amplifiers are required for this unit. Connections for e ach axis are made to separ ate but identica l connectors on the top and bottom panels of the unit.

Pre-engineered cabl e assemblies are used for all connections to external devices ex cep t the mai n A C po wer and the 24 V DC I/O power, which use pluggable terminal blocks. See Pre- Engineered Ca ble Assembli es in the Introdu ction section of this manual fo r information on the available assemblies. This section only describes connecting the IMC-S/23x using the pre-engineered cable assemblies. If you are making your own cable assemblies, refer to Appendix A for cable wiring information.

ATTENTION:

connections to the IMC-S/23x while po wer is connected!

Before attempting to use the IMC-S/23x, configuration switches inside the unit must be set as required and the following connected:

Doing so risks damage to the IMC-S/23x, external components, and your health!

Do not attemp t to make any electrical

AC mains power 24V DC power Servo drives and feedback encoders RS-232 or RS-422 terminal or computer

The following sections explain the setup of the internal configuration switches and the specific connections required.

Publication 999-122 - January 1997

4-2 Installation and Hookup

As shown below, the servo drive and feedback devices attach to the bottom panel of the IMC S Class Compact while the axis-specific (dedicated ) I/O devices atta ch to the top panel. Power input terminal blocks are on the right side of the unit.

Publication 999-122 - January 1997

Installation and Hookup 4-3

Complying with European Union Directives

The information contained in this documen t pertains to the following Allen-Bradley products:

4100-234-RL

•

4100-234-R

•

4100-234-L

•

4100-234

•

4100-232-RL

•

4100-232-R

•

4100-232-L

•

4100-232

•

If these products are installed within the European Union or EEA regions and have the CE mark, the following regulations apply.

EMC Directive

These apparatuses are tested to meet Council Directive 89/336 Electromagnet ic Compatibility (E MC) in accordance with Article 10 (1). The following standards apply in whole:

EN 50081-2 EMC-Generic Emission Standard, Part 2-Industrial

•

Environment EN 50082-2 EMC-Generic Immunity Standard, Part 2-Industrial

•

Environment

The products described in this document are intended for use in an industrial environment and are not intended for use in a residential, commercial or light industrial environments.

Low Voltage Directive

These apparatuses are tested to meet Council Directi ve 73/23/EEC Low Voltage Directive. The following standards apply in whole or in part:

EN 60204-1 Safety of Machinery-Electrical Equipment of

•

Machines, Part 1-Specification for General Requirements

Publication 999-122 - January 1997

4-4 Installation and Hookup

To meet CE requirements, the following additions are required:

Y ou must mount the Bul letin 4100 Compact in a n IP 54 rated metal

•

enclosure on a metal panel. You must bond all equipment.

•

You must use the specified Allen-Bradley cables.

•

The IMC-S/23x is de signed to f unction with out maintenance when

•

operated in the environment specified in this manual. Under normal conditions, the IMC-S/23x should not require any

•

periodic maintenance. However, if conditions are less than ideal and any superf icial dust has accumulat ed on the controller ov er time, remove it car efully . Also, it is recommended to periodic ally inspect all cables for abrasion and all connectors for proper seating.

Refer to Figure 5.1 for grounding and wiring information.

Publication 999-122 - January 1997

Installation and Hookup 4-5

Figure 5.1 Suggested Bulletin 4100 Compact Motion Control System Configurati on for Meeting CE Requiremen ts

Publication 999-122 - January 1997

A/C and I/O fuse types: 3A Dual Element Time Delay (Slow Blow) (1/4 in. by 1 1/4 in.).

Important: Input power is to be wired in accordance with local

regulations.

4-6 Installation and Hookup

Installing the IMC-S/23x

The IMC-S/23x should be mounted to a panel inside an electrical cabinet or enclosure. For best performance, it should be mounted as close as practical to the servo drives with which it is being used. This minimizes the length of cable required to interconnect the units, thus minimizing the risk of electrical noise pickup. See the Introduction section of this manual for mounting and clearance dimensions.

The recommended panel layout for using the IMC-S/23x with Allen-Bradley 1391B-ES or 1391-DES AC servo drives is shown below. Panel layouts for use with other serv o dri v es should be si milar. Be sure to keep the power and signal wires segregated in separate wireways for maximum noise immunity.

Publication 999-122 - January 1997

Each axis of the IMC-S/23x connects to a 1391 drive via a 4100-CCA QB pre-en gineer ed cable ass embly. Both ends of this cable assembly are terminated in the appropriate mating connectors for the motion controller and the drive. The 4100-CCAQB cable assembly replaces both the 4100-CCSxxF and the 4100-CCAxxF when used wit h a 1391B-ES or 1391-DES s ervo driv e. Axis-spe cifi c dedicated I/O not required by the servo drive (home input, overtravel inputs, drive fault input, and regist ration input) are av ailable via 15 foot (4.5 met er) flying leads for termi nation t o user devices or a user -suppl ied ter minal b lock.

Installation and Hookup 4-7

Configuring the IMC-S/23x

Before applying power to the IMC-S/23x or connecting external devices, the unit must be configured for your application. The IMC-S/23x is configured via switches on the motion controller and power supply modules inside the unit, as shown in the table below.

IMC-S/23x Configuration Switches

To Configure... Use This

Serial Ports Axis 0 and 1 Regist. Inputs Axis 2 and 3 Regist. Inputs

(IMC-S/234

models only) Encoder Power Voltage

Axis 0 and 1 Servo Output Axis 2 and 3 Servo Output

ATTENTION:

Switch...

SW1 SW2 SW1

SW5 SW3 SW4

Do not use a pencil to change

On This Module

Motion Controller Motion Controller Motion Controller Expander Board

Power Supply Power Supply Power Supply

configuration s witch settings. The graphite may permeate

the switch, causing it to malfunction.

To verify or change any of the configura ti on swit ch se tt ing s, open the front panel of the IMC-S/ 23x by loosening the capti ve thumbscre ws on the top and bottom of the front panel and swing the panel out of the way to the left. Remove either the motion controller module (the leftmost module with the black sub-pan el) or the po wer supply module (the rightmost module) b y remo vi ng the t op and bot tom screws. Slide the module out of t he rack carefully and place it fa ce up on a static-s afe work surface . Configure the switches for your application a s explaine d following and then replace the module in the IMC-S/23x.

Publication 999-122 - January 1997

4-8 Installation and Hookup

Configure the Serial Ports

Serial port A may be independen tly conf igure d for RS-232 or RS- 422 operation and serial port B may be independently configured for RS-232C, RS-422, or DH-485 operatio n via switch SW1 on the motion controller module inside the IMC-S/23x. If RS-422 or DH-485 is selected, the port may al so be configured to use or not us e a termination resistor .

The serial port configuration switch layout is shown below. In IMC-S/23x-RL models, the switches are between the AxisLink and RIO boards (on the main board).

The leftmost switch selects RS-232 (down) or RS-422 (up) communications for serial port A. If RS-422 communications are selected, the next switch to the right determines whether the port is terminated (up) or not (down) with a 220 W resistor. If RS-232 communications are sel ected, the port should not be termin ated (second switch down). The next pair of switches provide the same selections for serial port B. The rightmost pair of switches determines whether port B is used for RS-232/RS-422 communicat ion (do wn) or DH-485 communication (up) and whether the DH-485 port is terminated (up) or not (down) with a 220 W resisto r . As shi pped from the f actory, both ports are configured for RS-232C operation, as shown in the figure above.

Publication 999-122 - January 1997

Installation and Hookup 4-9

To configure either serial port for RS-422 communications, carefully move the first (port A) or second (port B) pair of switches to their up positions using a pen, small screwdriver, etc. For example, the figure below shows serial port A configured for RS-232 and serial port B configured for RS-422.

RS-422 Term

Ω

220

RS-422

DH-485 Term

Ω

RS-422

220

DH-485

220

Port A

RS-232

RS-232/422

No RS-422 Term

Port B

No DH-485 Term

In Multidrop applications, only the first and last IMC-S/23x on the RS-422 line should be terminated. All intermediate IMC-S/23x controllers shoul d not have their mu ltidr op seri al por t te rminat ed. F or example, the figure below shows serial port A configured for RS-232 and serial port B configured for RS-422 without termination.

RS-422 Term

DH-485 Term

Ω

220

RS-422

DH-485

220

Port B

Port A

Ω

220

RS-422

Publication 999-122 - January 1997

RS-232

RS-232/422

No RS-422 Term

No DH-485 Term

4-10 Installation and Hookup

RS-422

RS-232

220 W RS-422 T erm.

RS-422

DH-485

220 W RS-422 T erm.

220 W DH-485 T erm.

No 220 Ω RS-422 Term.

RS-232

RS-232/422

No DH-485 Term.

SW1

Port B

T o configure seri al port B for DH-485 communications, ca refully move the rightmost pair of switches to their up positions using a pen, small screwdriver, etc. For example, the figure below shows serial port A configured for RS-232 and serial port B configured for DH-485.

Refer to the Allen-Br adley publ ication "Da ta Highway/Data Highway Plus/DH-485 Cable Install ation Manual" (1770-6 .2.2) for informa tion on proper DH-485 cable termi nat ion. If termination is not requi red in your application, move the rightmost switch to its down position and replace the motion controller module.

Publication 999-122 - January 1997

Installation and Hookup 4-11

Select the Registration Input Voltag e

Each axis of the IMC-S/23x ma y be individually confi gured to interface directly with ei ther 5V or 2 4V DC regi stration s ensors via swi tches on the motion controller module. SW2 on the main board selects the registration input voltage for axes 0 and 1, and SW1 on the expander board selects the registration input voltage for axes 2 and 3. The IMC-S/23x is ship ped from the f actory configu red for 24V re gistration sensors for all axes (all switches up), as shown below.

To use 5V registration sensors with any axis, carefully move the appropriate switc h to its down posi tion using a pen, small sc rewdri ver , etc. For example, the figure below shows axis 1 configured for 24V registration sensors and all other axes configured for 5V sensors.

Publication 999-122 - January 1997

4-12 Installation and Hookup

Power Supply Module

+12V +5V

Axes Axes 0 &1 2 & 3

Select the Encoder Power Voltage

The IMC-S/23x may be configured to provide either 5V or 12V DC power (at 1 Ampere total maximum) for the axis feedback encoder s via switch SW5 on the power supply module. SW5-1 selects the encoder power v oltage for axes 0 and 1, and SW5-2 for ax es 2 and 3. Regar dless of the encoder power voltage selected, however, the encoder outputs must be 5V (TTL) level signals. The IMC-S/23x is shipped from the factory configured for 5V encoder power for all axes (both switches down), as shown below.

To select 12V encod er power volta ge for either axes 0 and 1 or axes 2 and 3, carefully mov e SW5-1 or SW-2 (respectively) to i ts up pos ition using a pen, small screwdrive r, etc. For e xample, the figure below shows axes 0 and 1 configured for 12V encoder power and axes 2 and 3 configured for 5V encoder power.

SW5

+12V

+5V

Axes 0 & 1

Axes

2 & 3

Publication 999-122 - January 1997

Installation and Hookup 4-13

If you are using an Alle n-Bradle y 845 ser ies increment al encoder , use the table below to determine the proper encoder power voltage switch setting.

IMC-S/23x Encoder Voltage Switch

Settings for Allen-Bradley Encoders

Allen-Bradley Encoder Model SW5

845F-SJxZ14-xxYx... 845F-SJxZ24-xxYx...

845H-SJxx14xxYx... 845H-SJxx24xxYx...

845K-SAxZ14-xxY3 845K-SAxZ24-xxY3

845P-SHC14-xx3 Down (5V) 845T-xx12Exx...

845T-xx13Exx... 845T-xx42Exx... 845T-xx43Exx...

Down (5V) Up (12V)

Down (5V) Down (5V) Up (12V) Up (12V)

Encoders in a given family not shown in the table above are not compatible with the IMC-S/23x and should not be used.

Publication 999-122 - January 1997

4-14 Installation and Hookup

Power Supply

Module

Axis Axis

Voltage Current

SW4

Axis Axis

Select the Servo Output Format

Each axis of the IMC- S/23x may be indivi dually confi gured to provid e either a ±10V (voltage) or ±150 mA (current) servo output signal via switches on the power supply module. SW3 selects the servo output format for axes 0 and 1, and SW4 for ax es 2 an d 3. The IMC-S /23x is shipped from the fac tory confi gured for ±10V serv o output for al l axes (all switch es up), as shown be low.

If you are using hydraulic servo or proportional valves with any axis, carefully move the appropriate switch to i ts down position usin g a pen, small screwdriver, etc. For example, the figure below shows axis 1 configured for ±150 mA (current) servo output and all other axes configured for ±10V (voltage) servo output.

Voltage Current

Axis

SW3

Axis

SW4

Axis

Publication 999-122 - January 1997

Installation and Hookup 4-15

Serial Communications Devices

The IMC-S/23x provides two optically-isolated serial ports called Serial Port A and Serial Port B. These ports ar e accessible th rough the 9-pin AT-compatible DB-9 connectors on the front panel. Both front panel connectors are pinned out identical ly, so c onnection to either p ort is the same.

ATTENTION:

Do not connect anything to Serial

Port B if you are using DH-485.

Serial port A is used for communicating with the GML development system and serial port B is used for a serial operator interface device for setup and actual machine operation if DH-485 is not used. When DH-485 is used, serial port B on the motion controller is used for DH-485 communication and the normal built-in operator interface functions of the IMC S Class are unavailable. When DH-485 is used, do not make an y c onne ct ion s t o s eri al po rt B on the motion controller.

Serial Communication Protocol

When configured for RS-2 32 or RS-422, both serial ports communicate using the standard ASCII chara cter codes at a user selectable baud rate . As shipped from the f actory , both seri al ports are conf igured for a baud rate of 9600. Configure serial communications devices for the serial protocol defined below for proper operation with the IMC-S/23x:

IMC-S/23x Default Serial Communication Protocol

Parameter Value

Baud Rate Start Bits Stop Bits Word Length Parity

XON/XOFF

9600 (others may also be specified) 1 1 8 (7 Data Bits plus Parity) Ignored (May be Even, Odd, Mark, or Space) ON

Publication 999-122 - January 1997

4-16 Installation and Hookup

Connecting RS-232 Devices

When an IMC-S/23x serial port is configured for RS-232 operation (see Configuring the IMC-S/23x earlier in this section), RS-232C compatible serial communi cations devices may be connected t o it using readily-available RS-232C cables. To prevent damage to the IMC-S/23x or the serial device, make sure that the serial port is configured for RS-232 operation before connecting RS-232 compatible devices.

ATTENTION:

Configure the serial port for RS-232

operation before connec ting RS-232 compatible de vices.

The pinout of each serial port is identical and shown for reference in the table below.

IMC-S/23x RS-232 Serial Port Pinout

DB-9 Pin Signal Description

1 2 3 4 5 6 7 8 9

Note that the har dware handshaking signa ls (RTS/ CTS and DSR/DTR) for both serial ports are jumpered inside the IMC-S/23x. This allows the use of standard RS-232C c abl es wi th serial devices which req uir e hardware handshaking.

TxD RxD

DTR Com DSR RTS CTS

N/C

Do Not Connect Transmitted Data Received Data Data Terminal Ready Signal Common Data Set Ready Ready To Send Clear To Send No Connection

Publication 999-122 - January 1997

Installation and Hookup 4-17

If you are making an RS- 232C cable, only four conductors a re required. Construct the cable as shown below, making sure to use the correct mating connector for your PC or terminal. The mating connector for the IMC-S/23x is a s tandar d male 9 -pin D-ty pe (A MP P/N 2 05204-1) .

Most serial communication devices (PCs, PC compatibles, and terminals) use one of two types of RS-232C connector. These are the standard DB-25 (25-pin) connector and the smaller DB-9 (9-pin) connector introduced on AT-compatible PCs. The pinouts for the DB-25 and DB-9 and the DB-9 to DB-9 connectors are given in the tables below.

Typical RS-232C Connector Pinout

Signal DB-25 Pin DB-9 Pin

Com RxD

TxD

Shield

Typical RS-232C Connector Pinout

Signal DB-9 Pin DB-9 Pin

Com RxD

TxD

7 3 2 1

5 2 3

N/C

5 2 3

Publication 999-122 - January 1997

4-18 Installation and Hookup

Connecting RS-422 Devices

When an IMC-S/23x serial port is configured for RS-422 operation (see Configuring t he IMC-S/23x earlier in this sec tion), RS-422 compatible serial communications de vices may be connected to it using pre-made RS-232C/RS-422 cables. To prevent damage to the IMC-S/ 23x or the serial device, make sure that the serial port is configured for RS-422 operation before connecting RS-422 compatible devices.

ATTENTION:

Configure the serial port for RS-422

operation before connec ting RS-422 compatible de vices.

The pinout of each serial port is identical and shown for reference in the table below.

IMC-S/23x RS-422 Serial Port Pinout

DB-9 Pin Signal Description

1 2 3 4 5 6 7 8 9

If your application ulti mate ly requi res the use of mult iple IMC-S/ 23x controllers on the same RS-422 communications link (multidrop), connect each one to a serial communicat ions device (PC, ter minal, etc.) for setup individuall y before enabling multidrop. This assures that eac h IMC-S/23x is operating properly before being connected to the multidrop link. The Set up section of this manual descri bes the setup of multidrop systems.

TxD+

TxDRxDTxD+

Com TxD+ RxD+ RxD+

N/C

Transmitted Data (+) Transmitted Data (-) Received Data (-) Transmitted Data (+) Signal Common Transmitted Data (+) Received Data (+) Received Data (+) No Connection

Publication 999-122 - January 1997

Installation and Hookup 4-19

If you are making an RS-422 cable, five conductors are required. Construct the cable as shown below, making sure to use the correct mating connector for your PC or terminal. The mating connector for the IMC-S/23x is a stand ard male 9-pin D-type (AMP P/N 2 05204-1).

Be sure that the TxD+/- and RxD+/ - pair s are tw isted as sho w n abo v e for best noise immunity.

Connecting Enco d ers

The IMC-S/23x provides optically-isolated, differential line receiver (AM26LS32) encoder inputs for all axes. Differential-o utput line driver encoders must be used–single-ended encoders are not compatible.

ATTENTION:

12V encoder power before connecting encoders.

Set encoder po wer switches for 5V or

Encoder power is also pro vided by t he IMC-S/23x and can be selec ted as either 5V or 12V depending on the requirements of the encoder as explained in Select the Encoder Power Voltage earlier in this section. Regardless of the encoder power voltage selection, however, the encoder outputs must be 5V (TTL) level signals. The encoder power supply in the IMC-S/23x is capable of supplying a total of 1 Ampere to power all the encoders connected to the IMC-S/23x.

Publication 999-122 - January 1997

4-20 Installation and Hookup

Allen-Bradley 1391B-ES and 1391-DES Drives

If you are using 4100-CCAQB pre-engineered ca ble assemblies from Allen-Bradley to connect th e IMC-S/2 3x to All en-Bra dle y 1391B- ES or 1391-DES AC servo drives, select 5V encoder power (the factory setting) and refer to Appendix A for connection information.

Allen-Bradley 845F, 845H, and 845T Encoders

If you are using Allen-Bradley 845F, 845H-, or 845T incremental encoders (see Select the Encoder Power Voltage earlier in this section for compatible models), connect them to the IMC-S/23x using a separate 4100-CCSxxF pr e-engineered cable assembly for each axis as shown belo w.

Publication 999-122 - January 1997

Installation and Hookup 4-21

Allen-Bradley 845K Enc oders

If you are using Allen-Bradley 845K-SAxZx4-xxY3 incremental encoders, connect them to the IMC-S/23x using a separate 4100-CCSxxF pre-engineered cable assembly for each axis as shown belo w.

Note that a user- supplied terminal block (TB) or intermediate c onnector is required to c onnect the 845K’ s int egrated cable to the 4100-CCSxxF cable assembly.

Allen-Bradley 845P Encoders

If you are using Allen-Bradley 845P-SHC14-xx3 incremental encoders, connect them to the IMC-S/23x using a separate 4100-CCSxxF pre-engineered cable assembly for each axis as shown belo w.

Publication 999-122 - January 1997

4-22 Installation and Hookup

Note that a user- supplied terminal block (TB) or intermediate c onnector is required to conne ct the 845P’ s int egrated ca ble to the 4100-CCSx xF cable assembly.

Other Encoders

If you are not using Al len-Bradley 1391B-ES or 1391-DES ser vo drives or Allen-Bradley 845 en coders, connect each encoder to the IMC-S/23x using a separate 4100 -CCSxxF pre-engineered cable as sembly for each axis as shown below.

Connecting Servo Amplifiers

The IMC-S/23x can be used with any commercially available servo amplifier that accepts a ±10 volt analog input signal. Each axis must be connected to its o w n amplifier. Bef ore co nnecti ng serv o amplif i ers to the IMC-S/23x, connect each amplifier to its motor and set up the drive system as outlined in the amplifier manufacturer’s manual. Be sure that the dri ve syste m is operating cor rectly before con necting it to the IMC-S/23x.

ATTENTION:

for Voltage before connecting servo amplifiers.

Set the servo output format switches

Each axis of the IMC- S/23x may be indivi dually confi gured to provid e either a ±10V (voltage) or ±150 mA (current) servo output signal as explained in Select the Serv o Output Format earli er in this section. Fo r servo amplifiers, ensure that the appropriate axes are set for voltage output.

Publication 999-122 - January 1997

Installation and Hookup 4-23

Allen-Bradley 1391B-ES and 1391-DES Drives

If you are using 4100-CCAQB pre-engineered ca ble assemblies from Allen-Bradley to connect Allen-Bradley 1391B-ES or 1391-DES AC servo dri v es to the I MC-S/23x, select v olt age serv o out put format (the factory setting) and refer to Appendix A for connection information.

Other Servo Amplifiers

If you are not using Allen-Bradley 1391B-ES or 1391-DES servo drives, conn ect e ach s erv o a mplifier to the IMC-S/23x using the same 4100-CCSxxF pre-engineered cable assembly as used for that axis’ encoder, as shown below.

Publication 999-122 - January 1997

4-24 Installation and Hookup

Connecting Hydraulic Valves

The IMC-S/23x can also be used with any commercially available hydraulic servo or proportional valve that accepts a ±150 mA analog input signal. Each axis of the IMC-S/23x may be individually configured to provide either a ±10V (voltage) or ±150 mA (current) servo output signal as explained in Select the Servo Output Format earlier in this se ction. For hydraulic v alves, ensure that the appr opriate axes are set for curre nt output. Each axis must be conne cted to its o wn valve.

ATTENTION:

for Current before connecting hydraulic valves.

Set the servo output format switches

Connect each hydraulic valve to the IMC-S/23x using the same 4100-CCSxxF pre-engineered cable assembly as used for that axis’ encoder, as shown below.

For full ±15 0 mA cu rr ent output from the IMC-S/23x, the imped ance of the servo valve motor coil must be less than 56 W .

Publication 999-122 - January 1997

Installation and Hookup 4-25

Connecting Axis-Specific Discrete I/O

The IMC-S/23x prov ides h ome and o v ert ra v el l imit s witch inp uts an d a driv e fault input for e ach axis. These axis-s pecif ic discret e inputs are optically isola ted and f i lter ed to elimin ate swit ch bounc e. In additi on, the IMC-S/23x provides a normally open relay contact drive enable output for each axis.

Connect axis-specific I/O to the IMC-S/23x using a separate 4100-CCAxxF pre-engineere d cabl e assembl y for each a xis as shown below.

Publication 999-122 - January 1997

The I/O power supply connected to the IMC-S/23x (see Connect the I/O Power Supply later in this section) provides 24V DC at up to 3 Amperes total maximum for powering the axis-specific discrete I/O. This power is available on the Red and Black conductors in the 4100-CCAxxF cable assembly as shown above. Note that a usersupplied terminal block (TB) is generally required to connect the I/O devices to the 4100-CCAxxF cable assembly.

4-26 Installation and Hookup

The Drive Enable Outputs

Many servo amplifiers provide a drive enable/disable input which can be used by the IMC-S/23x to disable the drive whenever feedback is turned off. The drive enable outputs (one for each axis) of the IMC-S/23x provide a normally open relay contact capable of conducting up to 1 Ampere at up to 40V DC (24V DC nominal) for this purpose.

While the figure shown earlier uses the drive enable output to switch 24V DC into a drive enable relay coil, if your servo amplifiers provide an active-low TTL, CMOS, or 24V DC level drive enable input, each drive enable output may be conne cted directly to the appropriat e servo amplifier . If your servo amplif iers provid e a drive disable input , use the drive enable outp ut to switch 24V DC into a drive enable relay coil, and connect the normally cl osed contacts of the relay to the appr opriate servo amplifier.

The Drive Fault Inputs

Many servo amplifiers also provide a fault output which can be used by the IMC-S/23x to disab le fee dback an d ta ke th e ap propri ate ac tion if a fault in the driv e system occurs. The dri ve fault inputs (one for each axis) of the IMC-S/23x require 12 mA at 30V DC maximum (24V DC nominal) to provide this function.

If your servo amplifiers provide an open-collector, open-drain , or dry contact drive fault signal, connect each drive fault input to the servo appropriate amplifier as shown in the previous figure. If your servo amplifiers provide a 12V or 15V DC level drive fault signal, use it to drive a relay and connect the contacts from th is relay to the appropriate drive fault input.

Publication 999-122 - January 1997

Installation and Hookup 4-27

Connecting Registration Sensors

The IMC-S/23x provides a high-speed optically isolated registration input for each axi s. These re gistration inputs requ ire 2.5 mA at 5 V DC (each) to operate.

ATTENTION:

24V sensors before connecting registration devices.

Set the regist ration switches for 5V or

Each registration input may be individually configured to interface directly with ei ther 5V or 24V DC re gistra tion sens ors as expla ined in Configure the Registration Inputs earlier in this section. To prevent damage to either the IMC-S/23x or the re gistration senso rs, ensure that these switches are set pro perly before connecting regi st rat ion sensors.

If you are using current sourcing proximity switches, registration sensors, or active-high encoder markers, connect them to the IMC-S/23x using the same 4100-CCAxxF pre-engineered cable assembly used for that axis’ discrete I/O, as shown below.

Publication 999-122 - January 1997

If you are using current sinking proximity switches, registration sensors, or acti ve-low encoder markers, connect them to the IMC-S/23x using the same 4100 -CCAxxF pre-engineered c able assembly used f or that axis’ discrete I/O, as sh own b elow.

4-28 Installation and Hookup

ATTENTION:

24V sensors; do not use the gen eral purpose I/O po wer

Use a clean 5V po wer supply for 5V re gistration sensors or a clean 24V power supply for 24V sensors. Do not use the 24V DC power supply connected to the IMC-S/23x for the axis-specific discrete I/O.

supply .

Use a clean 24V power supply for

Using the Registration Inputs

The registration inputs on the IMC S Class are the most sensitive discrete inputs on the motion controller. Since they are used to latch axis position within 1 µs, the y employ a f aster optocoupl er and are not filtered for switch bounce like the home, overtravel, and drive fault inputs. In applications which use a similarly fast registration sensor, this is not usually a problem. However, in some applications, the fast response and lac k of filtering mean tha t extra precautions mu st be taken.

Since the registration inputs are–and have to be–sensitive because of their function, i t is best to trea t them not li ke discret e inputs b ut as you would treat a sensitiv e analog inpu t. The registr ation inputs are floating (not referenced to any common) and are thus similar to a differential servo amplifier or encoder input. As with a servo amplifier or encoder input, best results are obtain ed by using shielded twisted-pa ir cable for all registration wiring as shown previously.

The registration input current is 2.5 mA when the input is activated. While this is a reasonable current for most 5V devices (the marker channel on an encoder for instance), it is quite low for typical 24V devices, making them more susceptible to interference. For these devices, the on current can be raised by a 470 Ω shunt resistor across the registration inputs, as shown below.

This resistor increa ses the current dra wn from 24V registrati on sensors to over 50 mA. If you r re gistratio n sensor c an handle more on cur rent, you can use lower resistance values, but be sure to check the power dissipation of the res istor and size it acc ordingly. Install the resistor as close to the end of the 4100-CCAxxF cable assembly as possible.

Publication 999-122 - January 1997

Installation and Hookup 4-29

Connecting the CPU Watchdog

The IMC-S/23x provides a fail-safe CPU watchdog with relay-contact outputs for connecting into your machine’s start/stop string or other protectiv e circuit. Form-C (NO and NC) contac ts are provided to allo w external equipment to be disabled in the event of a control malfunction. The CPU watchdog relay is activated during normal operation and deactivates when there is a malfunction. A front-panel indicator (System OK) is illuminated whene ver t he CPU watchdog is acti v ated. The CPU watchdog r el ay con tac ts are UL/CSA rated for 1 Amper e at 30V DC.

Connect the CPU watchdog contacts into the start/stop string of your machine using the 4100-CCWxxF pre -engineered cable assembly . The CPU watchdog contacts may be used directly in 24V DC start/stop strings; a typical connection is shown below.

An external relay dri ven from the CPU watchdog contacts must be used when switching A C. A typi cal connectio n for an A C start/ stop string is shown belo w.

The connections sho wn in th e figures above are t ypical only . The y may be modified as required for your application if they cannot be used exactly as shown.

Publication 999-122 - January 1997

4-30 Installation and Hookup

Connecting Flex I/O

Flex I/O modules connect directly to the IMC-S/23x using a 4100-CCF1 or 4100-CCF3 pre-engineered cable assembly. Plug the mini-D connector end of the 4100-CCF1 or 4100-CCF3 into the connector marked Fle x I/O on the left of the top panel of t he IMC-S/23x and the other end into the f irst Flex I/O module as sho wn in the general connection figure at the beginning of this section.

The Flex I/O modules which may be used with S Class motion controllers are shown in the table below.

IMC S Class Compatible Flex I/O Modules

Catalog Number

1794-IB16 1794-IA8 1794-IE8 1794-OB16 1794-0A8 1794-OE4 1794-IE4XOE2

Description For Additional

Information See...

1794-2.1 1794-2.1 1794-2.1 1794-2.1 1794-2.1 1794-2.1 1794-2.1

Up to eight separate modules, selected from the table above, may be connected to the motion controller in any order. For specific information on connecti ng I/O devices and mounting Fle x I/O modules, see the appropriate Flex I/O publications listed above.

Connect the I/O Power Supply

The IMC-S/23x requires a source of 24V DC power for the axis-specific discrete I/O. The I/O power supply must be capable of supplying enough current for all of the axis-specif ic discrete I/O (up to a maximum of 3 amperes). Connect the I/O power supply to the 24V DC power input (two posi tion) terminal block o n the r ight si de of the IM C-S/23x as shown below.

Be sure to connect the co mmon of the I/O power sup ply to earth ground as shown.

Publication 999-122 - January 1997

Installation and Hookup 4-31

Connect the AC Power

The IMC-S/23x requires 3 Amperes (maximum) at 90 - 132 or 175 264 Volts AC (auto switching), 47 - 63 Hz, single-phase. This is compatible with the AC mains power in all countries. Connect AC power to the A C po wer input (four positio n) terminal block on t he right side of the IMC-S/23x as shown below.

ATTENTION:

to earth ground as shown above for proper operation.

The IMC-S/23x

be connected

must

The IMC-23x requires that the earth ground terminal be connected to earth ground fo r proper oper ation. The i nternal noise filte ring circuit ry does not work prop erly without this connection and erra tic or unreliable operation of the unit can result.

Publication 999-122 - January 1997

4-32 Installation and Hookup

RIO Adapter

Terminal Block

Install termination resistor

only

if this is the first or last physical module on the RIO cable . Us e 82Ω resistor only for 230k baud communications.

A-B 1770-CD (Belden 9463 or Equivalent)

Connecting Remote I/O (Optional)

IMC-S/23x-R and IMC-23x-RL models include a Remote I/O (RIO) Adapter for connection to an Allen-Bradley PL C. On these models, the RIO cable is connecte d using a 3-t erminal plug gable ter minal block t o either channel A or channel B of the Remote I/O Adapter front panel. The front panel of the Remote I/O Adapter is shown below.

ATTENTION:

Even though the RIO Adapter front

panel is identical to the AxisLink front panel, the two

options are not interchangeable. Do not mix RIO and AxisLink connections or neither system will work properly.

Publication 999-122 - January 1997

Remove the 3-terminal pluggable terminal block from the RIO adapter and connect the RIO cable to it as shown below. If this IMC-S/23x is the last physical modul e on the RIO cable, also connec t the appropriate terminating resistor as shown.

Installation and Hookup 4-33

Plug the terminal block into the channel (A or B) on the RIO adapter which you wish to u se for RIO co mmunications. E ither channel c an be used–the selection is made in the Application Setup Menu. See the Setup section of this manual for information on configuring RIO operation.

Connecting AxisLink (Optional)

IMC-S/23x-L and IMC-23x-RL models include AxisLink, which allows linkin g multiple IMC S Class controller s and ALECs (AxisLink Encoder Con verte r modules) together so that axe s on one co ntroller or ALEC can be used as master axes for ele ct ron ic geari ng and cams on other controllers . On these model s, the AxisLi nk cable is con nected to channel A of the AxisLink opti on using a 3-terminal pluggable term inal block on the AxisLink option front panel. The AxisLink option front panel is shown below.

Important: All nodes on the same AxisLink network should be

operated at the same ser vo update rate.

ALECs cannot currently operate in extended length mode.

ATTENTION: Even though the front panel of the AxisLink option is identical to the RIO Adapter front

panel, the tw o options a re not in terchangeable. Do not mix RIO and AxisLink connections or neit her system will work properly.

Publication 999-122 - January 1997

4-34 Installation and Hookup

ATTENTION: Even though AxisLink and RIO use the same cable, connections are not interchangeable.

Do not mix RIO and AxisLink connect ions or neith er link will work properly.

The AxisLink option can be operated in either of two configurations depending upon the cable length required between controllers. Refer to the AxisLink sp ecifications in this manua l for mor e inf ormati on o n the differences between the two configurations. The standard configuration is used for daisy-chain cabling with a maximum end-to-end distance of 1 to 25 meters (3 to 82 feet) and the extended configuration for daisy-chain cabling with a maximum end-to-end distance of 25 to 125 meters (82 to 410 fe et). To use th e AxisLink option in its extended configuration, the IMC-S/23x-L or IMC-S/23x-RL controller requires a firmware version of V3 .2 or later for extended length and V3.5 or later for e xtended node (extended node also requir es GML V3.9 or later). For both configurations, there is a 1 m (3 ft) minimum cable length betwee n AxisLink nodes. The Axi sLink option switch setting, termination resistors, and cabling are different for the two confi gurations an d must be cor rect fo r proper Ax isLink oper ation in the intended configuration.

Important: T o use exte nded length mode, you need firmware V3.2 or

later. To use extended node, you need V3.5 or later.

AxisLink Settings for Standard AxisLink Operation

Switch 1 (SW1) on the AxisLink board must be set to the non-EXTENDED setting (toward the edge of the board).

Jumper 6 (J6), labele d STD on the b oard, must b e in place a cross bot h J6 pins if using onboard ca ble ter mination. Jumper 5 ( J5) on t he board should not be connected.

XTEND

STD

EXTENDED

SW1

Publication 999-122 - January 1997

Installation and Hookup 4-35

AxisLink Settings for Extended Length AxisLink Operation

Switch 1 (SW1) on the AxisLink board must be set to the EXTENDED setting (away from the edge of the board).

Jumper 5 (J5), labeled XTEND on the board, must be in place across both J5 pins if using onboard cable termination. Jumper 6 (J6) on the board should not be connected.

XTEND

STD

EXTENDED

SW1

If you are not using the onboard termination resistors, both jumper 5 (J5) and 6 (J6) should not be in place across the pins on the board.

To connect the AxisLink option, remove the 3 terminal pluggable terminal block from the AxisLink connector and connect the AxisLink cable to it as shown below. If this IMC-S/23x is either the first or the last physical module on the AxisLink cable and the onboard cable termination resistors are not used, also connect a terminating resistor.

Standard Configuration Diagram

AxisLink Terminal

Block

*150

Install termination resistor

is the first or last physical module on

and

the AxisLink termination resistors are not used.

if the onboard cable

only

if this

Standard AxisLink Cable

A-B 1770-CD (Belden 9463 or Equivalent)

Publication 999-122 - January 1997

4-36 Installation and Hookup

AxisLink Terminal

Block

Yellow

300

Shield

Black

Extended Configuration Diagram

Extended AxisLink Cable

Install termination resistor

is the first or last physical module on the AxisLink termination resistors are not used.

and

if the onboard cable

Connecting DH-485 (Optional)

only

if this

Belden 9182, Carol C8014 or equivalent.

Plug the terminal block back into channel A on the front panel of the AxisLink option.

If you are using the standard or extended length AxisLink configurations, select the desired AxisLink address (0 - 7) for this motion controller usi ng the Address select or switch on the fron t panel. Only positions 0 - 7 o n this switch may be used as AxisLink addr esses– do not select positions 8 or 9.

ATTENTION:

Do not select position 8 or 9 on the

Address selector switch.

If serial port B has been c onf igur ed for DH-485 communic ations (s ee Configure the Serial Ports earlier in this section), plug a 1747-Cxx DH-485 cable into either of the DH-485 connectors (RJ-45) on the IMC-S/23x front panel. The two DH-485 connectors are internally wired in parallel, so either one may be used. The second connector is provided to permit easy "daisy-chaining" of multiple devices on the DH-485 network. Connect the other end of the 1747-Cxx DH-485 cable into a PanelView 550 operator terminal or 1747-AIC DH-485 link coupler for connection to a DH-485 network.

Publication 999-122 - January 1997

The IMC S Class does not provide 24V DC power on the DH-485 connectors for powering external equipment. Refer to the Allen-Bradley publication "Data Highway/Data Highway Plus/DH-485 Cable Installation Manual" (1770-6.2.2) for more information on DH-485 cabling and the user man uals for other DH-485 devices for information on powering them.

Installation and Hookup 4-37

ATTENTION:

Port B of the IMC-S/23x if you are using DH-485

When DH-485 is used, serial port B on the motion controller is used for DH-485 communication a nd the nor mal b uilt -in operator interf ace functions of the IMC S Class are unavailable. When DH-485 is used, do not make an y c onne ct ions to serial port B on the mot ion con tr ol ler.

communications.

Do not connect anything to Serial

Publication 999-122 - January 1997

4-38 Installation and Hookup

Publication 999-122 - January 1997

Chapter

Understanding IMC-S/23x Setups

This chapter shows you how to program your IMC-S/23x using the view mode window of the on-line manager in GML. If you are using the GML Definitions menu and function blocks to program your IMC-S/23x, refer to this chapter for additional information on programming features.

The Setup Menus

A user-friendl y setup and diagnostic menu is built i nto the IMC-S/23x. This menu–which is itself subdivided into four separate submenus– greatly simplifies setting up the IMC-S/23x for a specific application or a specific machine. The four submenus are as follows:

Application Setup Menu

•

Machine Setup Menu

•

Hookup Diagnostic Menu

•

Servo Setup Menu

•

The setup menus cannot be acces sed unless the contr oller’ s memory is unlocked via the front panel keyswitch. Make sure that the Memory keyswitch in i s the (unloc ked) posit ion before proc eeding with s ystem setup. All parameter values entered in the setup menus are stored in this lockable memory.

Application Setup Menu

The Application Setup Menu contains parameters that define the configuration of the IMC-S/23x.

Machine Setup Menu

The Machine Setup Menu contains parameters which configure the IMC-S/23x for the specific machine being controlled.

Hookup Diagnostics Menu

The Hookup Diagnostics Menu is us ed to check and verify conn ections to external devices. Tests are included for checking encoders, drives and motors, and discrete and dedicated I/O. This menu also provides tests to automatically determine correct feedback polarity for proper closed-loop servo operation.

Publication 999-122 - Janua ry 1997

5-2 Understanding IMC-S/23x Setups

Servo Setup Menu

The Servo Set up Menu is used to tune the servo loop gains and dynamic parameters. It provides access to the automatic setup and self-tuning routines, and also al lows manual tuning of all ser vo parameters. Each of these menus can be used at any time for diagnostic purposes.

All of the setup parameters a vail able in the set up menus can als o be set using the Defi nit i ons men u and t he Onl ine Manager in GML. See the GML Programming Manual for IMC S Class Motion Controllers (GML-DOC-S ) for more information on using the Definitions menu.

Using the Setup Menus

The user-fri endly setup menus are acc essed via the Online Man ager in GML connected to serial port A.

After the terminal is connected, apply power to the IMC-S/23x and the Standard Operator Inte rface appears i n the Display window in the Online Manager window. Refer to the Online Manager in the GML Programming manual for more information.

Passwords

To protect against unauthorized setup parameter changes, the IMC-S/23x requires a password before allowing access to the setup menus.

T o get to the Setu p menu, type .S and press ENTER . The Setup menu appears.

The setup password is an ASCII character string selected by the application programmer fo r each specific applicati on. As shipped from the factory, the password is application. If you type the password incorrec tly, an In correct Password appears on the IMC-S/23x. Enter the setup menus again as described above and enter the correct password.

, but may be dif ferent for you r specifi c

SET

Publication 999-122 - Janua ry 1997

Toggling

The technique used to sele ct the desired answer to questions in the setup menus is called

SP A CE BAR

or answer to the question.

Toggle Choices are always English-language answers to

TIP:

questions and are displayed in all CAPITAL letters.

toggling

on a terminal or PC, which displays the next legal option

. Toggling is accomplished by pressing the

Understandin g IMC-S/2 3x Setups 5-3

Setup Password? OK to Disable Axis # Feedback? YES

OK to Disable Axis # Feedback? NO Setups Require Feedback Off!

Feedback Off OK to Disable DH-485 Communication?

OK to Disable DH-485 Communication? NO Setups Require DH-485 Communications Off!

For example, the only legal answers to many questions are

, and thus these two c hoices are alternatel y displaye d each time the

SP A CE B AR

is pressed. When there are mo re than two answer s to the

YES

and

question, toggling s hows all the a vailable choi ces sequentially , starti ng with the currently selected choice. To answer the question, toggle to the desired choice and press

ENTER

Disabling Feedback

When the co rrect password has been entered, if feedback is currently enabled on any axis, the following appears in the Display Window in the Online Manage r window for all ax es on which f eedback is en abled:

After ensuring th at disabling axis feedback will not injure yourself or the machine, press

ENTER

Answering NO to this question immediately generates the following message

RETURN

and exits the Se tup menu with feedback still ac tive.

Disabling DH-485

After disabling feedback on all axes, if DH-485 communications are used, the IMC-S/23x asks

After ensuring that disabling the motion controller on the DH-485 network will not injure yourself or the machine, press

ENTER

Answering NO to this question immediately generates the following message

and exits the Setup menu with DH-485 still active.

Publication 999-122 - Janua ry 1997

5-4 Understanding IMC-S/23x Setups

OK to Disable DH-485 Communication? YES Load Setups from App Module? NO

Select: AXIS 0

Another AXIS? NO

Loading Setup Values

Next, the IMC-S/23x asks

Toggle to parameters. Answer NO to this question to edit or review the current

working

may have been modified by the application program and thus be different from the power-up values.

and press

YES

values of the setup paramet ers. The working p arameter v alues

ENTER

to load the power-up values for all

Selecting a Setup Menu

After entering the setup menus as described above, selection of a specific se tup menu is accomplish ed by advancing to the desired menu by pressing and pressing pressing and type

ENTER

until the desired menu appears, toggling to

again. If you go past the menu yo u want, continue

or press the

again.

(Escape) key to exit the Setup me nu

ESC

YES

Selecting an Axis

After selecting a setup menu , you must select the axis to configure. The IMC-S/23x displays

The IMC-S/232 provides two physical axes cal l ed Axi s 0 and Axis 1, while the IMC-S/244 p rovides four physic al axes (Axis 0, 1, 2, an d 3). All contro llers also provid e one imaginary axis . Controllers with AxisLink (IMC-S/23x-L and IMC-S/23x-RL models) provide two additional virtual ax es (Virtual Axis 0 and 1) for use as remote master axes. Toggle to the desired axis and press

After you hav e completed an y of the setup menus for the select ed axis, the IMC-S/23x asks:

Toggle to

Publication 999-122 - Janua ry 1997

ATTENTION:

of the setup menus for

all

Make sure to set

axes in your system!

all

the paramete rs in

all

to configure another axis.

YES

ENTER

Understandin g IMC-S/2 3x Setups 5-5

Parameter Name = Current Value

Editing Parameter Values

In the setup menus, questions are asked that can be answered by toggling as described above. In addition, numeric values for setup parameters are requested. The desired values are entered by a process called

editing

Each setup parameter which requires a numeric value is displayed sequentially as shown below:

Editable parameter values are always numbers preceded by =.

TIP:

Application Setup Menu

T o retain the current v alue for th e displayed param eter , press

ENTER

To change (edit) the value, type in the new value, followed by

ENTER

. When entering new parameter values, the decimal point (.)

and the minus (-) keys may be use d i n addition to the digits 0 through

. If you make a mis tak e while enter ing the n e w v alue , pr ess t he

(delete) ke y to erase the entire val ue or the

(backspace) ke y on a

BSP

DEL

terminal to erase just the previous character. If an illegal para met er value (too big, too small, of the wrong sign, or

containing too many di gits) is entered, the ter minal or PC beeps to alert you of the error a nd the value is changed to the clos est legal v alue when you press pressing

ENTER

DEL

. You can then en ter another value directly by

(delete) or

(backspace). Press

BSP

ENTER

again to

accept the displayed value.

The Application Setup Menu is password-protected to prevent unauthorized alteration of application-specific setup parameters. A list of all the application setup menu parameters is includ ed at the end of this section for reference.

Like the setup password, the application password is an ASCII character string selected by the application programmer for each specific application. As shipped from the factory, the application password is

, but may be different for your specific application.

APP

If you type the password incorrectly, the IMC-S/23x exits the Setup menu. Enter the setup menu again as described above and enter the correct password.

Publication 999-122 - Janua ry 1997

5-6 Understanding IMC-S/23x Setups

Inhibit Program Upload? NO

Edit AxisLink Config? NO

Edit AxisLink Config? YES

AxisLink? NO

Edit DH-485 Config? NO

Upload Inhibit

After entering the Applications Setup Menu, the IMC-S/23x asks:

If you desire to prevent the uploading of the Application Program from memory , togg le to Application program from being viewed or uploaded.

YES

and press

ENTER

. This will prev ent the

Editing the AxisLink Configuration

Note:

If a hardware initialization is done with the keyswitch unlocke d and

Upload Inhibit

set to

, the Application program will

YES

be erased from the memory.

For IMC-S/23x-L and IMC-S/23x-RL models only, after the correct password has been entered, the IMC-S/23x asks

Toggle to

YES

and press

ENTER

to configure AxisLink for your

application. Next the IMC-S/23x asks

Toggle to

YES

and press

ENTER

if you plan to use AxisLink in yo ur application. If you do not need to use AxisLink, toggle to NO and press

ENTER

Editing the DH-485 Configuration

Publication 999-122 - Janua ry 1997

If the IMC-S/23x is configured for DH-485 communication (see Configuring the I MC-S/23x in the Installation and Hookup section of this manual), th e motion controll er next asks

Toggle to

YES

and press

ENTER

to configure the motion controller

for operation on the DH-485 network.

Next the IMC-S/23x asks

Edit DH-485 Config? YES

DH-485? NO

Address Must be < than Max. Address! Network Node Address?

Understandin g IMC-S/2 3x Setups 5-7

Toggle to

YES

and press

ENTER

if you plan to use DH-485 in your

application. To temporarily disable DH-485, toggle to NO and press

ENTER

. To permanently disable DH-485, the hardware must be re-configured (see Configuring the IMC-S/23x in the Installation and Hookup section of this manual).

Maximum Node Address

Enter the highest address of any device on the DH-485 network for the maximum node address. T his is the highest address which will be polled as de vices pass the token among masters on the DH-485 networ k. The smaller the maximum node address, the faster the throughput on the DH-485 network, since no time is spent polling devices which do not exist.

Network Node Address

Enter the desired address of the motion controller on the DH-485 network for the network node address. The specified address must be less than or equal to the specified maximum node address. If not, the message

is displayed and you must enter a new network node address.

Baud Rate

Toggle to the baud rate of the DH-485 network to which the motion controller is connected. Both 19,200 and 9,600 baud are available. Unless necessary for some other device, always use 19,200 baud for fastest communication.

Token Hold Factor

Toggle to the hold factor you want (1, 2, 3, or 4). Selecting the default of 4 gives the IMC-S/23x the largest time slice for sending and receiving.

Publication 999-122 - Janua ry 1997

5-8 Understanding IMC-S/23x Setups

Edit Axis Setup Parameters? NO

Select: VIRTUAL AXIS 0 A Virtual Axis is MASTER ONLY

Editing the Axis Setup Parameters

When the correct password has been entered, the IMC-S/23x asks

T oggle to

YES

, press

ENTER

, and select the desi red axis as ex plained

above to configure the axes for your application.

Axis Configuration

Each physical axis in the IMC-S/23x may be independently enabled or disabled

(NOT CONFIGURED)

In addition, an enabled axis may be configured as either a full closed-loop servo axis

(MASTER ONLY)

axis and press

ENTER

(SERVO)

. T oggle to the desired conf iguration for the selected

When an axis (physical or virtual) is configured for the encoder input for that axis may be used as the master encoder for electronic gearing or cams, and questions relating to closed-loop operation are not as ked in th e foll owi ng setup menus. When an axis i s configured as a full closed-loop

as required by your application.

or for position monitoring only

MASTER ONLY

SERVO

axis, all questions are asked.

Virtual Axes

Virtual axes provided by AxisLink are automatically configured for position monitori ng only

(MASTER ONLY)

is displayed when a virt ual axis is sele cted. Functionally, AxisLink virtual axes are identical to extra encoder inputs on the motion controller . All set up parameters av ailable fo r physical axes are also available for virtual axes unless mentioned otherwise.

. The followi ng messag e

MASTER ONLY

Publication 999-122 - Janua ry 1997

Understandin g IMC-S/2 3x Setups 5-9

Controller Address? # *** Cannot Select This Controller!

Axis on Controller #: IMAGINARY Axis Type is COMMAND

To configure a virtual axis, first select the address of the controller or ALEC (AxisLink Encoder Converter module) and the physical or imaginary a xis on that controller which is to be used for this virtual axis. When AxisLinking to an ALEC, al ways s elect controller or ALEC address from the front panel Address selector switch of the appropr iate controlle r or ALEC. If you selec t the address of the controller you are setting up, the message

is displayed and you must sel ec t an other address. The axis associated with an AxisLink virtua l axis ALEC.

be on another motion c ontrol ler or

must

AXIS0

. Read the

ATTENTION:

the physical axis is configured as MASTER ONLY.

Do not select command axis type if

AxisLink virtual axes may be configured to provide either the actual or command position of the ass ociated physical axis. Sel ect the desired axis type for this virtual ax is. If the associated physical axis is configured as position is alwa ys pro vided, re gardl ess of the s elected a xis type. I f the virtual axis is AxisLinked to the imaginary axis in another motion controller, message

is displayed, sin ce the imag inary ax is does n ot ha ve an actual positi on. The direction of motion of virtual axes may also be defined to be the

same as or opposite from the associated physical axis. In most cases, answer virtual axis directions are the same as the physical axis directions. If

OPPOSITE

direction results in virtua l axis motion in t he vice versa.

MASTER ONLY

COMMAND

to the

SAME

is selected, motion of the physical axis in the positive

axis type is automatically selected and th e

Relative Direction?

on its reside nt motion cont roller , ac tual

question so that the

negative

direction, and

Publication 999-122 - Janua ry 1997

5-10 Understanding IMC-S/23x Setups

Select: IMAGINARY Axis Type is COMMAND

Position Units = Inches Position Unit = Inch

The Imaginary Axis

The imaginary axis can only generate command position and is automaticall y conf igured for command only operat ion. The f ollo wing message

is displayed when the imaginary axis is selected. Functionally, the imaginary a xis is identical to a physical ser vo axis, except that it h as no servo loop or physical connections. A conversion constant and unwind value (if the imaginary axis is configured as rotary) must be entered for the imaginary axis in the machine setup m enu, and values for its maximum velocity, acceleration, and deceleration in the servo setup menu.

Rotary Axes

All configured axes may be defined as either linear or rotary axes. To define an axis as linear (the usual case), answer NO to the

Axis?

question. To define an axis as rotary, answer

YES

Rotary

Rotary axes use a feature called electronic unwind to provide infinite position range by electronically "unwinding" the axis position whenever the axis moves through a complete physical revolution. Rotary axes request an unwind value in the machine setup menu.

Position Units

The IMC-S/23x allows user-defined engineering units rather than feedback counts to be used for measuring and programming all motion-related v alues (position, velocity , etc.). These posit ion units can be different for each axis and should be chosen for maximum ease of use in your application. For example, linear axes might use position units of Inches, Meters, or mm while rotary axes might use units of Revs or Degrees.

The Positio n U nits and Posit ion Unit parameters are the ASCI I text strings used in the machine and servo setup menus to request values for motion-r elated paramete rs. Enter the singular form of the unit as the Position Unit and the plural form for Position Units. A maximum of eight characters may be used to specify each string.

Publication 999-122 - Janua ry 1997

For example, to use units of inches for an axis, enter

Understandin g IMC-S/2 3x Setups 5- 11

Position Display Field Length = 6

Number of Decimal Digits = 3

Velocity Display Field Length = 6

Number of Decimal Digits = 3

Accel Display Field Length = 4

Number of Decimal Digits = 0

Display Fields

The runtime display a s well as t he machine and servo setup menus use fixed length fields to display and enter all motion-related values (position, velocity, etc.). Enter the desired total number of characters (not including the decimal point or sign) to be used for displaying position, velocity, and acceleration as the appropriate Field Length value. Speci fy the locatio n of the decimal poi nt (if necess ary) for each type of parameter by entering the appropriate number o f Decimal Digits (digits to the right of the decimal point). Up to 10 total digits may be used for the position dis play , 13 for the v elocity displa y , and 15 for the acceleration displ ay. MASTE R ONL Y axes do not r equest acceleration display values.

For example, on a linear SERVO axis with position units of Inches, specifying

provides a position display with thr ee digits on either side of the decimal point, allowing values between ±999.999 inches to be displayed or entered in the machine and servo setup menus for this axis.

The Number of Decimal Digits must be greater than or equal to zero and less than or equal to Display Field Length.

Averaged Velocity Timebase

Specify the desired time in seconds to be used for calculating the displayed velocity of the axis. This value should be large enough to filter out the small changes in velocity which would otherwise result in an unstable and hard to read velocity display, but small enough to track signif icant changes in axi s speed. T ypically , a v alue between 0. 25 and 0.5 seconds works well for most applications.

Publication 999-122 - Janua ry 1997

5-12 Understanding IMC-S/23x Setups

Move and Jog Profiles

The IMC-S/23x provides t hree types of moti on profi les for mov es and jogs on physical

TRAPEZOIDAL

SERVO

(linear acceleration and d eceleration), (controlled jerk), and press

ENTER

axes and the imaginary axis . These are the

S-CURVE

PARABOLIC

. T oggle to the desired selection and

A guide to the effects of these three motion profiles on various application requirements is given below:

IMC-S/23x Velocity Profile Effects

Velocity

Profile

Trapezoida l S-Curve Parabolic

Acc/Dec

Time

Fastest 2X slower 2X slower

Motor

Stress

Worst Better Best

Mechanical

Stress

Worst Best Better

Trapezoidal

The trapezoidal velocity profile is the most commonly used profile since it provides the most flexibility in motion programming and the fastest acceleration and deceleration times.

Publication 999-122 - Janua ry 1997

Understandin g IMC-S/2 3x Setups 5- 13

S Curve

S Curve velocity profiles are most often used when the stress on the mechanical system and load needs to be minimized. The S Curve profile, however, sacrifices acceleration and deceleration time compared to the Trapezoidal. I n addition, the speed (velocity) of S Curve motion cannot be changed once the motion is started except to zero and the same acceleration and deceleration must be used.

Parabolic

A parabolic velocity profile is most often used to optimize the motor selection since i t conf orms most closely to the torqu e/s pee d cur ve for most motors. The parabolic profile, however, sacrifices acceleration and deceleration t ime compared to the trapezoid al profi le. In additi on, the speed (velocity) of parabolic motion cannot be changed once the motion is started except to zero and the same acceleration and deceleration rate must be used.

Publication 999-122 - Janua ry 1997

5-14 Understanding IMC-S/23x Setups

Another Axis? NO

Edit Axis Fault Action Configs? NO

Select: AXIS # *** This Axis is NOT CONFIGURED!

Select: AXIS # *** This Axis is MASTER ONLY!

Select: IMAGINARY *** This Axis is IMAGINARY ONLY!

Backlash Compensation

Editing the Axis Fault Action Configuration

The Backlash Compensation feature can be used on physical

SERVO

axes to compensate for the mechanical backlash found in many mechanical transmissions. In most applications, backlash compensation is not required, and thus should be disabled. Toggle to NO and press

ENTER

UNIDIR APPROACH

to disable backlash compensation.

backlash compensatio n ensures tha t all mo v es– regardless of pr ogrammed motion direction–approach the fin al position from the

direction. The Approa ch Direction parameter determines

same

from which direction the axis approaches the programmed destination position, while the Backla sh Offset parameter determines the amount of "overshoot" necessary to take up the backlash when approaching from the opposite direction. Both of these parameters are entered in the machine setup menu under positioning configuration.

LOAD REVERSAL

backlash compensation adds or subtracts a programmable offset to moves whenever the axis changes direction. The Backlash Offset parameter is entered in the machine setup menu under positioning configuration.

After completing the axis s etup parameters, the IMC-S/23x asks

Toggle to

YES

, press

ENTER

, and select the desired

SERVO

axis as explained ab ove t o conf igure t he fault actions f or each p hysical ax is in your application. If the axis you have selected is not configured, the message

is displayed and you must select another axis. If the axis you have selected is configured as a

MASTER ONLY

axis, the message

is displayed and you must select another axis. If you select the imaginary axis , the message

Publication 999-122 - Janua ry 1997

Understandin g IMC-S/2 3x Setups 5- 15

Hard Overtravel Action? KILL DRIVE Soft Overtravel Action? STOP MOTION Pos Error Fault Action? KILL DRIVE Drive Fault Action? KILL DRIVE Encoder Noise Fault Action? STATUS ONLY Encoder Loss Fault Action? KILL DRIVE

is displayed and you must select another axis.

ATTENTION:

KILL DRIVE

Danger of axis runaway exists if

is not selected as the fault action.

Each

SERVO

the various motion faults in different ways. If a fault action is set to

STOP MOTION

decelerates to a stop without disabling feedback or the drive enable output. A fault action of fault. It is usu all y used for less sev ere faults, since it is re latively easy to recover from a

KILL DRIVE

immediately disabled, the servo amplifier output is zeroed, and the appropriate drive enable output is deactivated. most severe reaction to a fault and it is usually used for faults which could endanger the machine or t he operator if po wer is not remov ed as quickly as possible.

If a fault action is set to by the application program. In general, this setting shou ld in applications whe re neither th e standard

DRIVE

axis of the IMC-S/23x can be configured to respond to

, then when the fault occurs, the axis immediately

STOP MOTION

is selected, when the fault occurs, axis feedback is

STATUS ONLY

actions are appropriate.

fault action.

is the gentlest reaction to a

KILL DRIVE

, motion faults must be handl ed

STOP MOTION

only

nor

is the

be used

KILL

The recommended setting of the fault action con figuration par ameters– suitable for most applications–is shown below:

Publication 999-122 - Janua ry 1997

5-16 Understanding IMC-S/23x Setups

Another Axis? NO

Edit Direct Command Mode Config? NO

Linefeed Insertion? YES Carriage Return Insertion? YES Duplex? FULL Multidrop? NO

Editing the Direct Command Mode Configuration

After completing the axis fault action configuration, the IMC-S/23x asks

Toggle to

YES

and press

ENTER

to configure direc t comman d mode

for your application. Direct Command Mode is a mode of operation where iCODE (the

native language of the IMC-S/23x) commands can be sent directly to the IMC-S/23x via serial port A. It is used by the Online Manager in GML for communicating wit h the motion controller durin g application program development and debugging.

The recommended setti ng of the direct command mode configuration parameters for use with GML is shown below:

If the direct command mode display is double-spaced, turn off

TIP:

Linefeed Insertion.

If you are using a du mb terminal or other terminal emulation s oftw are on a computer which automatically inserts Line Feed characters whenever a Carriage Return character is received, answer NO to the

Linefeed Insertion?

question to turn off the extra line feed normally generated by the IMC-S /23x. You can tell that your terminal is generating its own linefeeds if the direc t co mma nd mode display is double spaced.

Normally, the IMC-S/23x appends a Carriage Return character to the response string ge nerated by all commands sent to it in direct command mode which request data. If you are using direct command mode to communicate to a host computer, answer NO to the

Return Insertion?

question to turn off the sending of this

Carriage

Carriage Return character after all response strings. Normally, the IMC-S/23x echoes all commands sent to it in direct

command mode so that the y are displaye d on the screen. Thi s is known as

full duplex

operation. If you are using direct command mode to communicate to a hos t computer or a nother IMC-S/23 x in a multi drop configuration, answer

HALF

to the

Duplex?

question to set the IMC-S/23x direct command mod e to half duplex and eliminate the ex tra echoed characters.

Publication 999-122 - Janua ry 1997

Understandin g IMC-S/2 3x Setups 5- 17

Multidrop?

Edit Operator Interface Config? NO

Operator Interface Serial Port? B Linefeed Insertion? YES Carriage Return Insertion? YES

Editing the Operator Interface Configuration

ATTENTION:

RS-232 communications. See the Installation and

Multidrop is a communications scheme which allows multiple IMC-S/23x controllers to communi cate with a master controller or host computer over a single RS-422 serial link. Answer NO to the

Multidrop?

IMC-S/23x. Also answer NO to the IMC-S/23x is to be the master on the multidrop link.

If this IMC-S/23x is to be a slave on the multidrop link in your application, answer multidrop for seri al port A only Use the recommended settings of the direct command mode configuration pa rameters for GML (s hown earlier) with multid rop. After enabling multidrop, be sure to set the desired controller address using the front-panel selector switch.

After completing the direct command mode configuration, the IMC-S/23x asks

Hookup section of this manual to conf igure serial p ort A for RS-422 operation if you are using multidrop.

question for initial setup and commissioning of the

YES

It is not possible t o use multidrop with

question if this

question to enable

to the

Multidrop?

you have compl eted setting it up.

after

Toggle to for your application.

If you are Installation and Hookup section of this manual), the recommended setting of the operator interface configuration parameters for use with most serial devices is shown below:

and press

YES

using DH-485 (see Configuring the IMC-S/23x in the

not

ATTENTION:

interface for serial port A if you are using DH-485 communications.

ENTER

to configure the operator interface

Always configure the operator

Publication 999-122 - Janua ry 1997

5-18 Understanding IMC-S/23x Setups

Setup Pasword?

Edit Runtime Display Configuration? NO

Runtime Display? YES

Runtime Display Serial Port? B Display Refresh Time (SEC) = 0.50

The operator interface can be configured to operate off either serial port. If you are usi ng DH-485 or your app lication uses se rial port B for another function (such as the master controller in multidrop), answer A to the

Operator Interface Serial Port?

question to place the operator interface on serial port A. Since direct command mode always appears on serial port A, if you configure the operator interface for use on serial port A also, use the ESC (Escape) key to toggle between these two modes.

If the Operator Interface display is double-spaced, turn off

TIP:

Linefeed Insertion.

If you are using a dumb terminal or terminal emulation software on a computer which automati cally inserts Line Feed chara ct ers whenever a Carriage Return character is rece ived as an operator interf ace, answer

to the

Linefeed Insertion?

question to turn off the extra line feed normally generated by the IMC-S/23x. You can tell that your terminal is generating its own linefeeds if the operator interface display is double spaced.

Editing the Runtime Display Configuration

Do not answer NO to the

Carriage Return Insertion?

question otherwise erratic behavior of the operator interface may result.

The setup and application pa sswords may be changed from their default values by e nteri ng th e de sired thre e c haract er st ring in re spon se to the appropriate question. The passwords are not case-sensitive, so either upper or lower case characters may be used for the passwords. If you change the passw ords, do not forget them or you will be pre vented from re-entering the setup menus!

After completing the opera tor i nter fac e c onf igu ratio n, t he IMC-S /23x asks

T oggl e to

YES

and press

ENTER

to configure the runtime display for

your application. If you are

using DH-485 (see Configuring the IMC-S/23x in the

not

Installation and Hookup section of this manual), the recommended setting of the runtime display configuration parameters for use with most serial devices is shown below:

Publication 999-122 - Janua ry 1997

Understandin g IMC-S/2 3x Setups 5- 19

Runtime Display Serial Port? B

DH-485 Communications Uses Port B: Runtime Display Disabled!

If your application does not use or require a runtime display while operating, answer NO to the

Runtime Display?

question.

ATTENTION:

you are using DH-485 communications.

Always disable t he runtime display if

Like the operat or interf ace, th e runtime dis play can als o be conf igured to operate of f either serial port. If you are using DH- 485 and select port B, the runtime display is automatically disabled and the message

is displayed. If yo ur applicati on uses seria l port B for ano ther functi on (such as the master controller in Multidrop), answe r A to the

Display Serial Port?

serial port A. Since direc t command mode always uses se rial port A, if you configure th e runtime di splay for use on s erial port A a lso, use the

(Escape) key to toggle between the two modes.

ESC

The runtime displa y (if ena bled) is con tinuously upd ated as pa rt of the Standard Operator Interface as well as during execution of the application program. The rate at which the display is updated is determined by the Dis play Refresh parameter . For most reaso nably fast display de vices, the recommended v alue of 0.5 seconds should be used.

question to place the run time display on

Runtime

If your display de vice cannot respo nd to updates e very half second, t he screen may become garbled or the data may noticeably lag behind reality. In this case, increase the display re fresh time to all o w ti me fo r the display to catch up. Due to the response time of the human eye, display refresh times less than 0.2 seconds are rarely effective and generally result in an unreadable display–especially with quickly changing values.

Publication 999-122 - Janua ry 1997

5-20 Understanding IMC-S/23x Setups

Display Refresh Time (Sec) =

Edit Serial Port Configuration? NO

Channel A Baudrate? 9600 Channel B Baudrate? 9600

Editing the Serial Port Configuration

After completing the runtime display configuration, the IMC-S/23x asks

T oggle to

YES

and press

ENTER

to confi gure the s erial por ts for yo ur

application. If you are

using DH-485, the recommend ed setting of the serial p ort

not

configuration parameter s for use with GM L and most ser ial de vice s is shown below:

Either serial por t may be s et to any one of the follo win g baud rat es by toggling the appropriate parameter:

IMC S Class Serial Port Baud Rates

Baud Rate Recommended Use

300 1200 2400 4800 9600

19200 38400

57600 115200 128000

Minimum Baud Rate

Maximum RS-232C Baud Rate RS-422 only

Publication 999-122 - Janua ry 1997

If you are using a de vice which c annot communi cate a t 9600 b aud, set the baud rate for the appropriate serial port to a suitably lower value. If you are using DH-485, parameter s for serial port B are not r equested since DH-485 uses serial port B.

ATTENTION:

For reliable communi cations, do not

use baud rates higher than 9600 with RS-232C.

If you are using a serial device that can communicate faster than 9600 baud, the baud rate for the appropriate serial port may be set higher . I t is recommen ded, h o we v e r, not to use rates higher t han 9600 with serial ports co nfi gured for RS -232 operat ion. See th e Instal lation and Hookup section of t his manual for more information on c onfiguring the serial ports.

Rockwell Automation 999 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual