Rockwell Automation 999 User Manual

Allen-Bradley

IMC S Class

Compact Motion

Controller

(Cat. No. 4100-999-122)

Installation

and Setup

Manual

Important User

Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) 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 electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or in part, without written permission of Allen-Bradley 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

! death, property damage or economic loss.

Attention statements help you to:

∙identify a hazard

∙avoid the hazard

∙recognize the consequences

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

GML, ULTRA, IMC, SCAN bus, Flex I/O, DTAM, PanelView, and SLC are trademarks; PLC is a registered trademark of Allen-Bradley Company, Inc.

Table of Contents	E

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

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EE	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

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

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Table of Contents	EEE
Serial Communication Protocol .................	4-15
Connecting RS-232 Devices ......................	4-16
Connecting RS-422 Devices ......................	4-18
Connecting Encoders ...................................	4-19
AB 1391B-ES & 1391-DES Drives ..........	4-20
AB 845F, 845H, & 845T Encoders ...........	4-20
AB 845K Encoders ....................................	4-21
AB 845P Encoders .....................................	4-21
Other Encoders ..........................................	4-22
Connecting Servo Amplifiers .......................	4-22
AB 1391B-ES & 1391-DES Drives ..........	4-23
Other Servo Amplifiers .............................	4-23
Connecting Hydraulic Valves ......................	4-24
Connecting Axis-Specific Discrete I/O........	4-25
The Drive Enable Outputs .........................	4-26
The Drive Fault Inputs...............................	4-26
Connecting Registration Sensors .................	4-27
Using the Registration Inputs ....................	4-28
Connecting the CPU Watchdog ...................	4-29
Connecting Flex I/O .....................................	4-30
Connect the I/O Power Supply .....................	4-30
Connect the AC Power .................................	4-31
Connecting Remote I/O (Optional) ..............	4-32
Connecting AxisLink (Optional) .................	4-33
AxisLink for Standard Operation ..............	4-34
AxisLink for Extended Length Operation . 4-35
Connecting DH-485 (Optional) ...................	4-36
Chapter 5 – Understanding IMC-S/23x Setups
The Setup Menus ...........................................	5-1
Application Setup Menu ..............................	5-1
Machine Setup Menu ...................................	5-1
Hookup Diagnostics Menu ..........................	5-1
Servo Setup Menu .......................................	5-2
Using the Setup Menus ..................................	5-2
Passwords ....................................................	5-2
Toggling .......................................................	5-2
Disabling Feedback .....................................	5-3
Disabling DH-485 ........................................	5-3
Loading Setup Values ..................................	5-4
Selecting a Setup Menu ...............................	5-4
Selecting an Axis .........................................	5-4
Editing Parameter Values .............................	5-5

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EL	Table of Contents

Application Setup Menu ................................	5-5
Upload Inhibit ..............................................	5-6
Editing the AxisLink Configuration ..............	5-6
Editing the DH-485 Configuration ................	5-6
Maximum Node Address.............................	5-7
Network Node Address ...............................	5-7
Baud Rate ....................................................	5-7
Token Hold Factor .......................................	5-7
Editing the Axis Setup Parameters.................	5-8
Axis Configuration ......................................	5-8
Virtual Axes .................................................	5-8
The Imaginary Axis ...................................	5-10
Rotary Axes ...............................................	5-10
Position Units ............................................	5-10
Display Fields ............................................	5-11
Averaged Velocity Timebase .....................	5-11
Move and Jog Profiles ...............................	5-12
Trapezoidal ................................................	5-12
S Curve ......................................................	5-13
Parabolic ....................................................	5-13
Backlash Compensation ............................	5-14

Editing the Axis Fault Action Configuration 5-14 Editing the Direct Command Mode Configuration 5-16 Editing the Operator Interface Configuration 5-17

Editing the Runtime Display Configuration	5-18
Editing the Serial Port Configuration ...........	5-20
Editing the RIO Configuration .....................	5-21
RIO Adapter Channel ................................	5-21
RIO Baud Rate ...........................................	5-22
RIO Rack Size ...........................................	5-22
RIO Rack Address .....................................	5-23
RIO Starting Group ...................................	5-23

RunningApplication Program on Power-Up 5-23

Machine Setup Menu ...................................	5-24
Editing the Feedback Configuration ............	5-25
Conversion Constant (K) ...........................	5-25
Unwind ......................................................	5-26
Unwind Reference Point............................	5-26
Encoder Loss Detection.............................	5-27
Editing the Overtravel Configuration ..........	5-27
Overtravel Limit Switches .........................	5-28
Software Travel Limits ..............................	5-28

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Table of Contents	L
Editing the Homing Configuration ..............	5-29
Home Position ...........................................	5-29
Active Homing ..........................................	5-30
Homing Without a Limit Switch or Marker 5-30
Homing to an Encoder Marker ..................	5-30
Homing to a Limit Switch .........................	5-31
Homing to a Limit Switch and Marker......	5-32
Limit Switch Contacts ...............................	5-32
Absolute Homing.......................................	5-33
Absolute_MV ............................................	5-34
Absolute_Serial .........................................	5-35
Passive Homing .........................................	5-35
Editing the Servo Configuration ..................	5-36
Dual Loop Control .....................................	5-36
Servo Output Limiting ...............................	5-39
Drive Fault Input .......................................	5-40
Editing the Positioning Configuration .........	5-40
Position Lock Tolerance ............................	5-40
Backlash Offset..........................................	5-41
Approach Direction ...................................	5-41
Hookup Diagnostics Menu ...........................	5-42
Checking Motors and Encoders ...................	5-43
Testing Encoders ..........................................	5-45
Editing the Motor/Encoder Polarity .............	5-47
Tuning Velocity Loop Servo Drives ............	5-47
Adjusting Offset .........................................	5-47
Digital Battery Box ....................................	5-48
Checking Encoder Markers..........................	5-50
Align Absolute Transducers .........................	5-51
Checking The Discrete I/O ..........................	5-53

Checking the Dedicated Discrete Inputs	... 5-53
Checking the Dedicated Discrete Outputs . 5-54
Checking Flex I/O Discrete Inputs ............	5-54
Checking Flex I/O Discrete Outputs .........	5-55
Checking Flex I/O Analog Inputs ..............	5-56
Checking Flex I/O Analog Outputs ...........	5-57
Servo Setup Menu ........................................	5-58
The Servo Loop Gains .................................	5-58
Velocity Gain .............................................	5-59
Proportional Gain ......................................	5-59
Integral Gain ..............................................	5-59
Feedforward Gain ......................................	5-60

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LE	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
Chapter 7 – Troubleshooting
Chapter Objectives .........................................	7-1
Understanding How to Detect a Problem ......	7-1
Replacing Modules ........................................	7-2
Before You Begin ........................................	7-2

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Table of Contents	LEE
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 OK LED ..............	7-5
Understanding System Faults .........................	7-6
Finding Faults ..............................................	7-6
Viewing Instantaneous Status....................	7-6
Viewing Continuous Status .......................	7-7
Troubleshooting General System Problems...	7-8
Appendix A – Cable Information
Introduction ...................................................	A-1
4100-CCF1 or 4100-CCF3 .........................	A-2
4100-CCS15F .............................................	A-2
4100-CCA15F ............................................	A-3
4100-CCW15F ............................................	A-4
4100-RCS3T ...............................................	A-4
4100-CCAQB .............................................	A-5

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LEEE	Table of Contents

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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 basic understanding of the Compact, contact your local Allen-Bradley representative for information on available training courses before using this product.

This manual is a installation and setup guide for the Compact. It gives you an overview of the Compact and describes the procedures you use to install, set up, use, and troubleshoot the Compact.

The following general precautions apply to the Compact:

ATTENTION: Only those familiar with the Compact and associated machinery should plan or implement the ! installation, startup, and subsequent maintenance of the

system. Failure to comply can result in personal injury and/or equipment damage.

ATTENTION: This product contains stored energy devices. To avoid hazard of electrical shock, verify that all voltage on the capacitors has been discharged 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: The system integrator is responsible for local safety and electrical codes.

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P-2

Preface

ATTENTION: An incorrectly applied or installed Compact can result in component damage or a reduction

! in product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate 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 Electrostatic Damage or any other applicable ESD Protection Handbook.

Contents of this Manual

	Chapter	Title	Contents
			Describes the purpose, background, and scope
		Preface	of this manual. Also specifies the audience for
			whom this manual is intended.
	1	Safety	Lists safety information regarding the Compact.
	2	Introduction	Provides a feature overview of the Compact.
	3	Technical Overview	Provides a technical overview of the Compact.
	4	Installation and	Provides information that allows you to install and
		Hookup	hook up your Compact.
		Understanding the	Provides information that allows you to
	5		understand the setup procedures for the
		IMC-S23x Setup
			Compact.
	6	Setting Up your	Provides setup procedures for the Compact.
		Compact
	7	Troubleshooting	Explains how to interpret and correct problems
			with your Compact.
	Appendix A	Cable Information	Provides information about the cables used with
			the Compact.

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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	National Fire
			Protection Association
			of Boston, MA.
	A complete listing of current Allen-Bradley documentation, including
	ordering instructions. Also indicates whether the documents are	Allen-Bradley Publication Index	SD499
	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

Compact Product

Receiving and Storage

Responsibility

You, the customer, are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company. Check the item(s) you receive against your purchase order. If any items are obviously damaged, it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill. Should you discover any concealed damage during unpacking, you are responsible for notifying the freight agent. Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment.

Leave the product in its shipping container prior to installation. If you are not going to use the equipment for a period of time, store it:

∙in a clean, dry location

∙within an ambient temperature 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 Support

Allen-Bradley offers support services worldwide, with over 75 Sales/Support Offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen-Bradley representatives in every major country in the world.

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P-4

Preface

Local Product Support

Contact your local Allen-Bradley representative for:

∙sales and order support

∙product technical training

∙warranty support

∙support service agreements

Technical Product Assistance

If you need to contact Allen-Bradley for technical assistance, please review the information in the Troubleshooting chapter first. Then call your local Allen-Bradley representative. For the quickest possible response, we recommend that you have the catalog numbers of your products available when you call. The Rockwell Automation Technical Support number is [phone].

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Chapter 1

Safety

Read This Manual

Read and understand this instruction manual. It provides the necessary information to allow you to install, connect, and set 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 with moving machinery. KEEP HANDS CLEAR of dangerous moving machinery. Loose fitting clothing or ties can become entangled in the machinery. These items should not be worn while operating, servicing, or programming the machine.

ATTENTION: HIGH VOLTAGES!

Electric shock can kill. Be sure the controller 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 drastically shortened life of your motion 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 controllers internal modules.

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1-2 Safety

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Chapter 2

Introduction

IMC-S/23x Description

The IMC-S/23x is a compact, rugged, microprocessor-based twoor four-axis servo motion controller. By including the logic and field power supplies, the IMC-S/23x provides a completely programmable, 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 time 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, etc. are provided by direct connection of Allen-Bradley Flexä I/O modules. Up to eight Flex I/O modules–providing a total of 128 discrete I/O points–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 stored in non-volatile memory (write-protected battery-backed RAM).

A prompted, English-language machine setup procedure, complete hookup diagnostics, and improved Automatic Servo Setup routines for self-tuning the servo parameters make setting up the IMC-S/23x quick and easy.

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2-2 Introduction

	A dedicated serial port–which can be field-configured for RS-232,
	RS-422, or Allen-Bradley DH-485 communications–is provided 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 located on the front panel. If DH-485 is not
	used, a multi-unit addressing scheme (Multidrop) allows up to eight
	IMC-S/23x motion controllers 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.
Features	∙ 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; will not drift with time temperature or humidity.
	∙ Multitasking operating system allows simultaneous 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 coordinated motion profiles on one or more axes.
	Profiles may be position versus time or slave axis position versus
	master axis position.
	∙ Sophisticated phase shift and advance/retard capabilities for
	electronic gears and cams allows complex motions to be easily
	programmed.
	∙ Auto-registration and auto-correction make high-speed registration
	applications easy.
	∙ Exclusive Imaginary Axis provides additional command-only axis
	for precise generation of master motion in master-slave applications
	or correction moves in registration and synchronization
	applications.
	∙ Concurrent, independent, or synchronous motion on all axes.
	Interpolated motion on up to three axes.

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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 function allows seamless transition between all types of motion.

∙Most motion parameters (including master axis for electronic gears and cams) can be changed on-the-fly with no delays.

∙Powerful floating-point math capabilities including transcendental functions (sin, cos, log, etc.).

∙Sophisticated Nested Digital Servo Control Loop with automatic servo setup for quick and easy servo tuning.

∙Isolation of all external connections from the microprocessor logic for reliable performance.

∙4 MHz maximum feedback count rate allows high speed operation without sacrificing resolution.

∙Encoder loss detection protects operators and machinery from damage in the event of encoder feedback failure.

∙Isolated 16-bit DACs 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 position error tolerances for servo fault protection.

∙Programmable directional software travel limits for enhanced overtravel protection.

∙Velocity 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.

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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 twoor four-axis motion controller
		with optional Remote I/O Adapter and AxisLink. The complete model
		number is specified as shown below:

Pre-Engineered Cable

Assemblies

IMC-S/ 2 3

-

Platform

2 = Stand Alone

Packaging

3 = Compact Package

Number of Axes

2 =Two Axes

4 = Four Axes

Remote I/O Option

R = Remote I/O Adapter

AxisLink Option

L = AxisLink Multi-Axis Synchronization Link

Pre-engineered cable assemblies are used for connecting the Flex I/O, servo amplifiers, feedback devices, axis-specific (dedicated) I/O, and the CPU watchdog. The table below shows the available cable assemblies.

ATTENTION: Do not attempt to make any electrical 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!

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Introduction 2-5

	IMC S/23x Pre-Engineered Cable Assemblies
Catalog Number	Used to Connect. . .	Length		Number
		(ft)	(m)	Required
4100-CCF1 or	Flex I/O	1	0.3	1 per S Class
4100-CCF3		3	1
4100-CCS15F	Servo and Feedback	15	4.5	1 per Axis
4100-CCAQB	1391B-ES or 1391-DES	-	-	1 per Axis
4100-CCA15F	Dedicated Discrete I/O	15	4.5	1 per Axis
4100-CCW15F	CPU Watchdog	15	4.5	1 per S Class
4100-RCS3T	REC Interface	3	1	1 per Axis

Mechanical Specifications	Front Panel Layout
	(IMC-S/23x-RL model shown.)

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Mounting and Clearance Dimensions

General Specifications

Motion Control
Microprocessor	Intel 80960SB @ 16 MHz.
Number of	2 (Axis 0 and Axis 1)	IMC-S/232...	models.
Controlled Axes	4 (Axis 0, 1, 2, and 3)	IMC-S/234...	models.
Application	Write-lockable battery-backed RAM (Random-Access Memory) with 10
Storage	year (minimum) battery life for application program (32K) and setup
	parameter values.
Data Storage	Write-lockable battery-backed RAM (Random-Access Memory) with 10
	year (minimum) battery life for cam table and default user variable values.
Number of User
Variables	2,000 user-definable; values stored as 64-bit floating-point numbers.
Number of Electronic
Cam Points	26,000 total.

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Environmental Specifications

Storage	-40°C to 70°C (-40°F to 158°F).
Temperature
Operating	0°C to 50°C (32°F to 122°F).
Temperature
Maximum
Humidity	95% non-condensing.

Electrical Specifications

AC Power Input	90	- 132 or 175 - 264 Volts AC,
	47	- 63 Hz,
	3 Amperes maximum.
AC Fuse	3A Dual Element Time Delay (Slow Blow) 1/4 x 11/4
I/O Power Input	18	- 36V DC,
	3A maximum (24V nominal).
I/O Fuse	3A Dual Element Time Delay (Slow Blow) 1/4 x 11/4

Encoder Input Specifications

Number of	2 (Axis 0 and Axis 1)	IMC-S/232...models.
Encoder Inputs	4 (Axis 0, 1, 2, and 3)	IMC-S/234...models.
Type of	Incremental AB quadrature; optically isolated, differential with marker
Encoder Input	channel.
Encoder
Interface IC	AM26LS32 or equivalent.
Compatible	Differential, TTL-Level (5V DC) line driver outputs, with or without
Encoder Types	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...
Decode Modes	4X Quadrature, Step/Direction, Count Up/Count Down.
Maximum Encoder	4,000,000 counts per second (4 MHz). This is equivalent to a channel
Frequency	frequency of 1 MHz in 4X quadrature decode mode.
Input	7 kΩ minimum (each input).
Impedance
Encoder	5 or 12 Volts DC at 1 Ampere (total) available from IMC-S/23x. Voltage
Power	selection by internal switch.

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Servo Output Specifications

Number of	2	(Axis 0 and Axis 1)	IMC-S/232...models.
Servo Drive Outputs	4	(Axis 0, 1, 2, and 3)	IMC-S/234...models.

Type of Output Isolated analog voltage or current; individually field-configurable via internal switch for each axis.

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 current output.

Output Offset ±80 μV maximum. Compensated to 0 volts via software setup procedure.

Dedicated Discrete I/O

Specifications

Number of
Dedicated Discrete	10 (5 each for Axis 0 and 1)	IMC-S/232...models.
Inputs	20 (5 each for Axis 0, 1, 2, and 3)	IMC-S/234...models
Dedicated	Home Limit Switch,
Discrete Input	Positive Overtravel Limit Switch,
Functions	Negative Overtravel Limit Switch,
	Drive (Amplifier) Fault,
	Position Registration.
Input Type	Optically isolated.
Operating	24 Volts DC nominal; 28V DC maximum.
Voltage	24 Volts DC nominal; 28V DC maximum or 5 Volts DC nominal;
	10V DC maximum for position registration inputs.
Input ON	12 μΑ per input (nominal);
Current	2.5 μΑ for position registration inputs.
Input	2 kΩ (resistive) per input;
Impedance	8.8 kΩ (resistive) for 24V position registration inputs.
Input Response	5 μs maximum;
Time	1 μs maximum for position registration inputs.
Number of
Dedicated	4 (2 each for Axis 0 and 1)IMC-S/232...models.
Discrete Outputs	8 (2 each for Axis 0, 1, 2, and 3)IMC-S/234...models.
Dedicated Discrete	Drive (Amplifier) Enable.
Output Function	Absolute Position Strobe.
Output Type	Normally-open relay contacts (Drive Enable);
	Optically isolated, floating, solid-state relay (Position Strobe).
Operating	0.010 - 40 Volts DC; 24V DC nominal for drive enable outputs,
Voltage	5.10± 0.10 Volts DC for position strobe outputs.
Output	1 Ampere per output maximum for drive enable outputs;
Current	10 μΑ per output maximum for position strobe outputs.

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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
	configurable via internal switch.
Information Code	ASCII (American Standard Code for Information Interchange).
Baud Rate	User-selectable up to 128k Baud (RS-422).
	User-selectable up to 115.2k Baud (RS-232C).
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 transmitted;
	Receive parity ignored (may be Mark, Space, Even, or Odd).
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	User-selectable 220Ω resistor via internal switch.
Termination

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	User-selectable 220Ω resistor via internal switch.
Termination
Node Address	User-selectable between 0 and 31 inclusive.
Node Type	Token-passing master.
Accessible Data	1	Binary file (B3) for up to 16,384 bits
Files	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).

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2-10 Introduction

Flex I/O Compatibility

Specifications

Maximum Number of
Flex I/O Modules	8.
Compatible	1794-IB16	16 24V		DC Discrete Inputs
Modules	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
S Class Interface	Direct-no 1794-ASB or other adapter required.

Servo Performance

Specifications

Servo Loop
Sample and Update
Rate	250 Hz to 2 kHz for each of 2 or 4 axes.
Maximum Feedback
Frequency	4 MHz (4,000,000 feedback counts per second).
Absolute	± 1,000,000,000 feedback counts for Linear AxisAxis:Linearlinear axes;
Position Range	R for rotary axes.
Absolute Position	15 position unit digits or
Resolution	32 feedback count bits, whichever is less.
Speed Range	0.00001 feedback counts per servo update to 4,000,000 feedback counts
	per second.
Speed Resolution	15 position unit digits or
	15 feedback count bits, whichever is less.
Acceleration/	0.00001 feedback counts per servo update2 to 4,000,000,000 feedback
Deceleration Range	counts per second2.
Acceleration/Deceleration	15 position unit digits or
Resolution	15 feedback count bits, whichever is less.
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
Range	0 to 100%.
Servo Output Limit	305 μ (voltage output); 4.58μΑ (current output).
Resolution

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Servo Gain Units

			IMC-S/23x Servo Gain Units
	Gain		Description		Units
	P		Proportional Gain		Counts per Millisecond
					Count of Error
	I		Integral Gain		Counts per Millisecond2
					Count of Error
	V		Velocity Gain		Millivolts
					Count per Millisecond
	F		Feedforward Gain		Counts per Millisecond
					Count per Millisecond
			Deadband Compensation		Volts
			Offset Compensation		Volts
Remote I/O Adapter
	IMC-S/23x-R and IMC-S/23x-RL models only.
Specifications

Baud Rate 57.6K, 115.2K or 230.4K (User-selectable).

Rack Address User-selectable between 0 and 31 decimal.

Rack Width User-selectable in quarter-rack increments (1/4, 1/2, 3/4, Full).

I/O Group Address User selectable as shown below:

IMC-S/23x Remote I/O Adapter Addressing

Type of Transfer					I/O Group
Block	0	2	4	6	0	2	4	0	2	0
Discrete	1	3	5	7	1	3	5	1	3	1
Discrete					2	4	6	2	4	2
Discrete					3	5	7	3	5	3
Discrete								4	6	4
Discrete								5	7	5
Discrete										6
Discrete										7
Starting I/O Group	0	2	4	6	0	2	4	0	2	0
Rack Width			1/4			1/2			3/4	Full

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Number of	12 dedicated inputs,
Discrete I/O Bits	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			4		4
	1/2			36		36
	3/4			68		68
		Full		100		100
Maximum Block
Transfer Length	64 words (128 bytes).
Block Transfer	User Variable values,
Data Types	Axis Data Parameter value,
	Axis Data Bit state,
	Master Cam Position Point values,
	Master Cam Time Point values,
	Slave Cam Position Point values,
	Axis or System Variable value.
Block Transfer	32-bit (double-word) 2s complement integer,
Data Formats	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.

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AxisLink Specifications		IMC-S/23x-L and IMC-S/23x-RL models only.
Baud Rate	Standard and extended		1 megabit per second.
	node configurations
	Extended length		500 kilobit per second.
	configuration
Cable Type	Standard and extended		Allen-Bradley 1770-CD RIO cable (Belden 9463 or
	node configurations		equivalent).
	Extended length		Belden 9182, Carol C8014 or equivalent.
	configuration
Cable Length	Standard and extended		25 meters (82 feet) maximum total. Minimum of 1
	node configurations		meter (3 feet) between controllers.
	Extended length		125 meters (410 feet) maximum total. Minimum of 1
	configuration		meter (3 feet) between controllers.
Number of	Standard and extended		8 maximum for a total of 32 possible axes.
Motion Controllers	length configurations
	Extended node		16 maximum for a total of 64 possible axes.
	configuration
Addressing	Standard and extended		User-selectable address via rotary selector switch on
	length configurations		front panel.
	Extended node		User-selectable address via GML.
	configuration

Number of Virtual	Standard configuration
Master Axes

Extended length and extended node configurations

4 maximum total; 1 per motion controller maximum.

Any axis on any motion controller can be a virtual master axis to any other motion controller. Each motion controller can define a total of two separate axes on any other motion controllers as virtual master axes, but only one can be active at any time. A total of four different axes can be active as virtual master axes at any time.

2 maximum total; 1 per motion controller maximum.

Any axis on any motion controller can be a virtual master axis to any other motion controller. Each motion controller can define a total of two separate axes on any other motion controllers as virtual master axes, but only one can be active at any time. A total of two different axes can be active as virtual master axes at any time.

Type of Virtual	All configurations	2: Command and Actual. Each virtual master axis may
Master Axes		be defined to report its command or actual position.
Slave Axes	Standard and extended	31 maximum total per virtual master axis (3 local + 4
	length configurations	x 7 other motion controllers = 31).
	Extended node	63 maximum total per virtual master axis (3 local + 4
	configuration	x 15 other motion controllers = 63).

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Number of	All configurations	112 inputs maximum total and 16 user-definable
Discrete I/O		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), not from all 15 other controllers
		available in a 16 node maximum extended node
		configuration.
Discrete I/O	All configurations	≤1 millisecond.
Response

Publication 999-122 - January 1997