Saia PCD2.H31x, PCD2.H310, PCD2.H311 User Manual

SAIAPCD

Process Control Devices

PCD2.H31x
Motion control modules
for servo drives

English edition 26/762 E2

SAIA-Burgess Electronics Ltd.

Bahnhofstrasse 18
CH-3280 Murten (Switzerland)
http;//www.saia-burgess.com

BA: Electronic Controllers Telephone 026 / 672 72 72

Telefax 026 / 672 74 99

___________________________________________________________________________________________________________________________

SAIA-Burgess Companies

Switzerland SAIA-Burgess Electronics AG

Freiburgstrasse 33
CH-3280 Murten
 026 672 77 77, Fax [phone]

France SAIA-Burgess Electronics Sàrl.

10, Bld. Louise Michel
F-92230 Gennevilliers
 01 46 88 07 70, Fax [phone]

Germany SAIA-Burgess Electronics GmbH

Daimlerstrasse 1k
D-63303 Dreieich
 06103 89 060, Fax [phone]

Nederlands SAIA-Burgess Electronics B.V.

Hanzeweg 12c
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 0662 88 49 10, Fax [phone]

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Avenue Roi Albert 1er, 50
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Via Cadamosto 3
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Liget utca 1.
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Representatives

Great Britain Canham Controls Ltd.

25 Fenlake Business Centre, Fengate
Peterborough PE1 5BQ UK
 01733 89 44 89, Fax [phone]

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Praceta Cesário Verde, No 10 s/cv, Massamá
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Denmark Malthe Winje Automation AS

Håndværkerbyen 57 B
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 70 20 52 01, Fax [phone]

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Poligono Industrial El Cabril, 9
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 91 884 47 93, Fax [phone]

Norway Malthe Winje Automasjon AS

Haukelivn 48
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Czech
Republic

ICS Industrie Control Service, s.r.o.
Modranská 43
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Sweden Malthe Winje Automation AB

Truckvägen 14A
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Poland SABUR Ltd.

ul. Druzynowa 3A
PL-02-590 Warszawa
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Suomi/
Finland

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Australia

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After sales service

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Buffalo Grove, IL 60089, USA
 847 215 96 00, Fax [phone]

___________________________________________________________________________________________________________________________
Issue : 22.11.2000

Subjet to change without notice

 SAIA- Bur gess Electronics Ltd.

SAIA® Process Con trol Devi ces

Moti on cont r ol modul es
for servo dr i ves

PCD2.H31x

SAIA-Burgess Electronics Ltd. 1999. All rights reserved.
Edition 26/762 E2 - 11.99

Subject to technical changes

 SAIA- Bur gess Electronics Ltd.

Updates

Manual : PCD2.H31x - Motion control modules for servo drives - Edition E2

Date Chapter Page Description

12.05.2000 Appendix A A-36 divers corrections

PCD2.H31x Contents

26/762 E2 (2H3-00-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 1

Contents

Page

1. Introduction

1.1 General 1-1

1.2 Function and application 1-2

1.3 Main characteristics 1-3

1.4 Typical areas of use 1-4

1.5 Programming 1-5

1.6 Operating modes 1-6

1.7 Commissioning 1-7

2. Technical data

2.1 Hardware technical data 2-1

2.2 Electrical specifications 2-3

2.3 Function-specific data 2-4

3. Presentation

4. Terminals and meaning of LEDs

5. Function description

5.1 Operating modes 5-1

5.2 Generator for the velocity profile 5-2

5.3 PID controller 5-4

5.4 Position decoder and input circuit 5-5

5.5 D/A converter 5-8

5.6 Complementary information: homing (FB Home) 5-9

6. Quick start

6.1 Getting started with IL programming 6-2

6.1.1 Entry-level example in IL with wait loop 6-3

6.1.2 Entry-level example in GRAFTEC 6-6

6.1.3 Simple commissioning program 6-11

6.2 Getting started with FUPLA programming 6-13

Contents PCD2.H31x

Page 2  SAIA- Bur gess Electronics Ltd. (2H3-00-E.DOC) 26/762 E2

Page

7. Programming

7.1 Programming in IL with FBs 7-2

7.1.1 The IL package (installation of FB) 7-2

7.1.2 Individual FBs 7-5

7.2 Programming in FUPLA with FBoxes 7-9

7.3 Programming in GRAFTEC with FBoxes 7-10

8. Error handling and diagnosis

8.1 Definition error checked by assembler 8-1

8.2 Error handling in RUN 8-2

8.2.1 Incorrect parameters 8-2

8.2.2 Error during homing 8-3

9. Installation and commissioning

9.1 Introduction 9-1

9.2 Installation and wiring 9-2

9.3 Commissioning drive without motion control module 9-3

9.4 Drive with motion control module 9-4

9.4.1 Switching on the supply voltage 9-4

9.4.2 Preparing the user program 9-5

9.4.3 Determining machine data 9-6

9.4.4 Direction, path measurement (encoder) 9-8

9.4.5 PID controller 9-10

9.4.6 Effect of individual factors
on controller behaviour 9-14

9.4.7 Simple commissioning program 9-15

10. Commissioning tool

11. Security aspects

12. Application examples

12.1 Example: 1 axis with homing 12-1

12.2 Example: 1 axis with two velocities 12-9

PCD2.H31x Contents

26/762 E2 (2H3-00-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 3

Page

Appendix A: Summary of all function blocks (FB)

Init: Initialization FB A-1
Home: Home position FB A-3
Exec: Execution FB A-5

StartMot Start motion A-7
StopUrg Stop motion in urgency A-8
Stop Stop motion A-9
MotOff Motor regulation off A-10
RdActPos Read Actual Position A-11
RdActVel Read Actual Velocity A-12
RdIntSum Read Integration Sum A-13
RdIndexRg Read Index Register A-14
RdStatRg Read Status Register A-15
RdTargPos Read Target Position A-16
RdTargVel Read Target Velocity A-17
GoForw Go Forwards A-18
GoBackw Go Backwards A-19
SgStpFor Single Step Forwards A-20
SgStpBak Single Step Backwards A-21
LdDestAbs Load Destination Absolute A-22
LdDestRel Load Destination Relative A-23
LdVelAbs Load Velocity Absolute A-24
LdVelRel Load Velocity Relative A-25
LdAccAbs Load Acceleration Absolute A-26
LdAccRel Load Acceleration Relative A-27
LdPropG Load Proportional Gain A-28
LdIntG Load Integrative Gain A-29
LdDerG Load Derivative Gain A-30
LdSampInt Load derivative Sampling interval A-31
LdIntLim Load Interactive Limit A-32
ActRegFact Activate Regulation Factors A-33
LdBrkPtAbs Load Breakpoint Absolute A-34
LdBrkPtRel Load Breakpoint Relative A-35
ResStatRg Reset Status Register A-36
SetIdxPos Set Index Position A-37
SetZero Set Home position A-38
MotConf Motion Configuration A-39
SetPosTol Set Position Tolerance A-40

Appendix B: Summary of all function boxes (FBox)

Contents PCD2.H31x

Page 4  SAIA- Bur gess Electronics Ltd. (2H3-00-E.DOC) 26/762 E2

Notes

PCD2.H31x Contents

26/762 E2 (2H3-00-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 5

Important note:

Many detailed manuals have been created to ensure perfect operation of
the SAIA PCD. These are for use by technically qualified staff, who
may also have successfully completed our workshops.

The diverse performance features of the SAIA



PCD best become appa­rent only by following closely all the information and guidelines con­tained in these manuals regarding assembly, wiring, programming and
commissioning.

Doing this will enable you to join the large group of enthusiastic SAIA



PCD users.

Summary

Hardware
PCD4

Hardware
PCD6

PCD 4 .H1 ..

PCD4.H 2 ..

PCD4 .H3..

Reference
Guide
(PG3)

PCD8.P1..

PCD 7.D1 ..
PCA2 .D1..
PCD 7.D2 ..

Installation
Components
for RS 485­Networks

FUPL A/
KOP L A
function
families

PCD1/2 series PCD4 series PCD6 series

General
Manuals

*)

*)

*)

*) Adapter module 4'717'4828'0
allows H modu les to be used
with th e PCD6.

User's
Guide

- PG4

- Modem

- S-Bu s

- PROFIBUS

- Remote I/O

PCD4 .H 4 ..

Hardware
PCD1
PCD2
Serie xx7

PCD2.M220

PCD2.H110
PCD2.H150
PCD2.H210

PCD2.H31x

Contents PCD2.H31x

Page 6  SAIA- Bur gess Electronics Ltd. (2H3-00-E.DOC) 26/762 E2

Reliability and safety of electronic controllers

SAIA-Burgess Electronics Ltd. is a company which devotes the greatest
care to the design, development and manufacture of its products:

• state-of-the-art technology

• compliance with standards

• ISO 9001 certification

• international approvals: e.g. Germanischer Lloyd, UL,

Det Norske Veritas, CE mark ...

• choice of high-quality componentry

• quality control checks at various stages of production

• in-circuit tests

• run-in (burn-in at 85°C for 48h)

Despite every care, the excellent quality which results from this does
have its limits. It is therefore necessary, for example, to reckon with the
natural failure of components. For this reason SAIA-Burgess Electronics
Ltd. provides a guarantee according to the "General terms and conditions
of supply".

The plant engineer must in turn also contribute his share to the reliable
operation of an installation. He is therefore responsible for ensuring that
controller use conforms to the technical data and that no excessive stres­ses are placed on it, e.g. with regard to temperature ranges, overvoltages
and noise fields or mechanical stresses.

In addition, the plant engineer is also responsible for ensuring that a
faulty product in no case leads to personal injury or even death, nor to
the damage or destruction of property. The relevant safety regulations
should always be observed. Dangerous faults must be recognized by ad­ditional measures and any consequences prevented. For example, outputs
which are important for safety should lead back to inputs and be monito­red from software. Consistent use should be made of the diagnostic ele­ments of the PCD, such as the watchdog, exception organization blocks
(XOB) and test or diagnostic instructions.

If all these points are taken into consideration, the SAIA



PCD will pro­vide you with a modern, safe programmable controller to control, regu­late and monitor your installation with reliability for many years.

PCD2.H31x Introduction

26/762 E2 (2H3-01-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 1-1

1. In troduction

1.1 General

The PCD2.H3.. motion control module is an intelligent I/O module from
the PCD2 series. This module is used for positioning an independent axis
with a variable speed control drive (servomotor). The servomotor can be
any adjustable DC or AC motor having a power stage and incremental
shaft encoder for the registration of position and speed.

PCD1/2-BUS

PROCESSOR PCD1/2

BUS

INTERFACE

M

+

–

POWER

AMPLIFIER

INCREM.

INPUTS

DIGITAL
INPUTS

ANALOG

DIGITAL

POSITION
DECODER

PID

REGULATOR

24 V or 5 V

±

10 V

24 V

SET-

POINT

PCD2.H3..

Block diagram of a servo drive for 1 axis

v1

v2

v

s1s

2

s

Destination position

Position control operation with constant acceleration, delay and slow ad­vance to approach destination position

Y

X

Coordinated, quasi-synchronous operation of 2 axes

Introduction PCD2.H31x

Page 1-2  SAIA-Burgess El ectronics Ltd. (2H3-01-E.DOC) 26/762 E2

1.2 Function and application

The ..H3.. module is used to position a single axis with variable speed
control DC or AC servomotors. This requires the drive unit to have a
power stage and incremental shaft encoder for capturing position or
speed. In a PCD1 system up to 4 motion control modules (4 axes) and in
a PCD2 up to 8 ..H3.. modules (8 axes) can be plugged anywhere on the
I/O bus and operated together with all base units.

The motion control module contains a single-chip processor that inde­pendently directs and PID controls every movement according to pa­rameters supplied by the user program (velocity, acceleration and desti­nation position). This enables each axis to be controlled independently. It
is possible to program the linkage of several axes (point-to-point) in co­ordinated, quasi-synchronous mode. Linear motion is thereby achieved
with cartesian axes.

PCD2.H31x motion control modules should be plugged into the
PCD2.M1xx base unit and not the PCD2.C1xx expansion unit. This is to
take account of the relatively high current consumption.

PCD2.H31x Introduction

26/762 E2 (2H3-01-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 1-3

1.3 Main characteristics

• Ideal for compact or economical machines

• PID controlled regulation of servomotor position and speed

• Velocity, destination position and PID parameters can be modified,

even during motion

• Analogue ±10V output with 12 bits inc. sign bit for triggering the

motor power stage

• Digital input for reference switch with the .. H310

• Encoder signal inputs of 24 VDC (source operation) or

5 V/RS 422 (antivalent line driver)

• Other axis-specific inputs and outputs (such as the limit switches, the

reference switch for the PCD2.H311 module, ENABLE for the driver)
must be monitored or controlled with a standard I/O module (e.g.
PCD2.B100, PCD2.E110/E111 or PCD2.A410).

Introduction PCD2.H31x

Page 1-4  SAIA-Burgess El ectronics Ltd. (2H3-01-E.DOC) 26/762 E2

1.4 Typical areas of use

• Handling robots

• Automatic placement and assembly machines

• Automatic palletizers

• Packing machines

• Sheet metal working machines

• Automatic drilling machines

• etc.

PCD2.H31x Introduction

26/762 E2 (2H3-01-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 1-5

1.5 Programming

The availability of practical function blocks (FBs and FBoxes) means that
only the desired parameters need to be entered for the various motion
and travel functions. The present detailed manual contains descriptions of
each function block, complemented with practical application examples.
Programming is via the standard PG4 programming tool from version
V2.0.70, either in IL (Instruction List) or graphically (FUPLA).

Initialization instruction

INIT FB. When it is called, 11 parameters are given with it.

See section 7.1.2 and appendix A, pages A1/2

Execution instruction

EXEC FB, always including 3 parameters. Over 30 different in-

structions can be executed.

See section 7.1.2 and appendix A, pages A5/40

Home instruction

HOME FB for automatically seeking the reference switch. This

FB has 7 parameters.

See section 7.1.2 and appendix A, pages A3/4

Diagnostics and error handling

Recognition of incorrect FB parameters (diagnostic register)
Timeout monitoring for FB 'Home'.

See chapter 8.

Introduction PCD2.H31x

Page 1-6  SAIA-Burgess El ectronics Ltd. (2H3-01-E.DOC) 26/762 E2

1.6 Operating modes

When solving motion control tasks with a servo drive, two different oper­ating modes are fundamentally available:

• position control mode

• speed control mode

In position control mode various parameters are entered (PID factors, ac­celeration, velocity, etc.) after which a preset destination position is ap­proached in a controlled manner

In speed control mode the desired velocity is attained with a preset rate
of acceleration. Travel continues at this velocity in a controlled manner
until there is a stop instruction. The desired velocity can be changed even
during motion.

v1

v2

v

s1s

2

s

Destination position

Position control mode with constant acceleration and delay, plus reduced
speed on approach to destination position

PCD2.H31x Introduction

26/762 E2 (2H3-01-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 1-7

1.7 Commissioning

Convenient commissioning software is available in the form of a FUPLA
program. This tool offers a simple method whereby all tests and adjust­ments required during commissioning can be carried out or checked on­line.

This commissioning tool is available on diskette, order reference:
PCD8.H31.

See chapter 10 for more details.

Introduction PCD2.H31x

Page 1-8  SAIA-Burgess El ectronics Ltd. (2H3-01-E.DOC) 26/762 E2

Notes

PCD2.H31x Technical data

26/762 E2 (2H3-02-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 2-1

2. Technical data

2.1 Hardware technical data

Digital inputs of the PCD2.H310 module

Number of inputs: 1 encoder A, B, IN

1 reference input
Input voltage: typically 24 V
"Low" range: 0 ... +4 V
"High" range: +15 ... +30 V
Source operation only (pos. logic)
Input current at 24 VDC: 6 mA (typical)
Circuit type electronically connected
Reaction time 30 µs

Digital inputs of the PCD2.H311 module

Number of inputs: 1 encoder A, /A, B, /B, IN, /IN

(no reference input)
Input voltage: typically 5 V
Signal level: Antivalent inputs according to RS 422
Hysteresis: max. 200 mV
Line termination resistance: 150 Ω

Analogue output for the PCD2.H310/311 modules

Analogue controller output 12 bit resolution (with sign bit)
Short-circuit protection yes
Electrical isolation no
Output voltage *) ± 10 V, accuracy of adjustment ± 5 mV
Logic positive (positive switching)
Minimum load impedance 3 kΩ

5 V supply of 5 V encoder for the PCD2.H311 module

5 V output 5 V supply of encoder
Short-circuit protection yes
Electrical isolation no
Output voltage 5 V
Max. load current 300 mA
Short-circuit current 400 mA
(This current additionally loads the 5 V bus of the PCD1/2)

*) Balancing output voltage is carried out in the factory. You are there-

fore strongly advised not to adjust the tuning potentiometer.

Technical data PCD2.H31x

Page 2-2  SAIA-Burgess El ectronics Ltd. (2H3-02-E.DOC) 26/762 E2

Operating conditions

Ambient temperature Operation: 0 ...+50°C without forced ven-

tilation

Storage: -20 ... +85°C
Noise immunity CE mark, compliant with EN 50081-1 and

EN 50082-2

LED displays and possibilities for querying from software

Total 5

LED "A" Status of encoder input "A"
LED "B" Status of encoder input "B"
LED "IN" Status of index input
LED "Ref" Status of reference switch (H310)
LED "Pw 5V" Encoder 5 V supply (H311)
LED "Power" ± 15 V supply

Querying from software

Input Power (addr. 08) Enables software monitoring of supplies
Input Ref (addr. 11) Enables the logic status of the reference

switch to be queried (H310)
Input Pw5V (addr. 11) Enables software monitoring of the 5 V

supply (H311)
Input Version (addr. 12) Enables module type to be queried H310

or H311 (H = H310, L = H311)

General

Processor LM 628
Programming Based on PCD user program (PG4) and

supported by a library of FBs and FBoxes.

Ordering details

PCD2.H310 1 axis for encoder 24 VDC
PCD2.H311 1 axis for encoder 5 V/RS 422
PCD9.H31E Software library with function blocks (FBs)

for programming in IL.
PCD8.H31 Commissioning tool in FUPLA

PCD2.H31x Technical data

26/762 E2 (2H3-02-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 2-3

2.2 Electri cal specifications

Internal power consumption (without encoder)

+5 V typically 125 mA, max. 150 mA
Uext typically 10 mA, max. 15 mA

External supply
Terminals +/-: 24 V (19 ... 32 V) smoothed,

max. permissible ripple: 10%

Digital inputs

4 or 6 respectively (see section 2.1)

Analogue output

1 (see section 2.1)

Important :

The maximum current that can be supplied to the 5V is 1600 mA for a
PCD2 or 750 mA for a PCD1.

Users of PCD2.H310 and/or PCD2.H311 modules are urged to check the
overall current consumption of all modules in a PCD2/1 and in any C100
or C150 expansion units, and to ensure that this maximum is not ex­ceeded. (The current provided to supply the 5V encoder also comes from
this source and must equally be taken into consideration).

When working with an expansion unit, care should be taken to place the
PCD2.H31x modules in the base unit and only to plug “normal” I/O
modules into the expansion unit, otherwise the potential drop on the con­necting cable might take on excessively high values.

Technical data PCD2.H31x

Page 2-4  SAIA-Burgess El ectronics Ltd. (2H3-02-E.DOC) 26/762 E2

2.3 Function-specific data

Number of systems 1

Motion parameters

(31-bit registers are used for destination position, velocity and accelera­tion, numerical range ± 2

30

)

Position Resolution selectable (depending on machine

factor)

Velocity Resolution selectable (depending on machine

factor)

Acceleration Resolution selectable (depending on machine

factor)

PID controller Sample time 341 µs, programmable proportional,

integral and differential factors. Sample time for
differential part can be programmed separately

Counting frequency up to 50 kHz

PCD2.H31x Presentation

26/762 E2 (2H3-03-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 3-1

3. Presentation

Assembled module with terminals PCD2.H310 (24V encoder)

9876543210

BINOut

Ref IN B APower

Ref nc Anc nc

Bus connector
Addressing circuit
Connector for address program­ming (not for user)
Processor
Potentiometer for balancing output
voltage (not for user)

DAC (D/A converter)

Supply

LEDs

Terminals

−−−− and + are the external supply terminals: V

ext

Ref is the digital input for the reference switch
Out is the analogue controller output
A, B, IN are the 3 encoder signals
nc terminals are not used (not connected)

Assembled module with terminals PCD2.H311 (5V encoder)

9876543210

BINOut

Pw 5V IN B APower

5V

/IN A/B /A

LEDs

Terminals

− and + are the external supply terminals: V

ext

5V is the output for the encoder’s 5V supply (300 mA max.)
Out is the analogue controller output
A, B, IN are the encoder’s 3 non-inverted signals
/A, /B, /IN are the encoder’s 3 inverted signals

Presentation PCD2.H31x

Page 3-2  SAIA-Burgess El ectronics Ltd. (2H3-03-E.DOC) 26/762 E2

Simple block diagram

Other axis-specific inputs and outputs (such as limit switches, the
PCD2.H311 module’s reference switch, the driver’s ENABLE) must be
monitored or controlled with a standard I/O module (e.g. PCD2.B100,
PCD2.E110/E111 or PCD2.A410).

A

/A

B

/B

/IN

IN

A
B

IN

5V encoder24V encoder

LS ref

(H310)

PID

regulator

Trajector

generator

Out (+/- 10V)
to amplifier

Bus interface

PCD1/2 bus

Position counter

PCD2.H31x Terminals

26/762 E2 (2H3-04-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 4-1

4. Terminals and meaning of LEDs

Terminals and LEDs of the PCD2.H310 (24V encoder)

The picture shows the labelling of the printed circuit board. The I/O con­nector block has standard 0 .. 9 numbering (right to left)

Inputs:

Number 4
Terminal 0 = "A": Encoder signal "A"

Terminal 1 = nc: not used *)
Terminal 2 = "B": Encoder signal "B"
Terminal 3 = nc: not used *)
Terminal 4 = "IN": Encoder signal "IN"
Terminal 5 = nc: not used *)

Terminal 7 = "Ref": Digital input for reference switch

Ausgang:

Terminal 6 = "Out": Analogue controller output

Speisung:

Terminal 8 = + + 24 VDC, smoothed
Terminal 9 = - GND

*) Do not wire – not for use as a restart point

Ref Out nc IN nc B nc A

ABINRefPower

9876543210

Terminals PCD2.H31x

Page 4-2  SAIA-Burgess El ectronics Ltd. (2H3-04-E.DOC) 26/762 E2

Terminals and LEDs of PCD2.H311 (5V encoder)

The picture shows the labelling of the printed circuit board. The I/O con­nector block has standard 0 .. 9 numbering (right to left)

Inputs:

Number 6
Terminal 0 = "A": Encoder signal "A"

Terminal 1 = "/A": Encoder signal "/A"
Terminal 2 = "B": Encoder signal "B"
Terminal 3 = "/B": Encoder signal "/B"
Terminal 4 = "IN": Encoder signal "IN"
Terminal 5 = "/IN": Encoder signal "/IN"

Outputs:

Terminal 6 = "Out": Analogue controller output

Terminal 7 = "5V": 5V supply for encoder

(max. 300 mA)

Supply:

Terminal 8 = + + 24 VDC, smoothed
Terminal 9 = - GND

5V Out /IN IN /B B /A A

ABINPw 5 VPower

9876543210

PCD2.H31x Terminals

26/762 E2 (2H3-04-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 4-3

Meaning of LEDs

LED Ref shows the logic state of the reference switch.
This LED is "on" when a reference is requested or when the switch has
not been wired. (Applies to PCD2.H310 only).

LED Pw5V represents the supply of a connected encoder.
This LED is "on" when the 5V are OK (no short-circuit). (Applies to
PCD2.H311 only).

LED Power shows the presence of ±15V .
This LED is "on" when both 15V supplies are OK.

LEDs A, B represent the encoder inputs.
These LEDs are "on" when the logic state is "H".

LED IN represents the encoder’s index input.
This LED is "on" in the active state (negative logic with H310).

Caution: This module includes components that are

sensitive to electrostatic discharges.

Terminals PCD2.H31x

Page 4-4  SAIA-Burgess El ectronics Ltd. (2H3-04-E.DOC) 26/762 E2

Notes

PCD2.H31x Function description

26/762 E2 (2H3-05-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 5-1

5. Function description

5.1 Operating modes

Two fundamentally different operating modes are available :

• position control operation

• speed control operation

Position control operation (Initiation with instruction: 'StartMot')
Motion control instructions follow the pattern below:

1. Position and parameter entry for velocity profile

2. Start motion control

3. Await signal for "Destination position reached".
In position control mode various parameters are entered (PID factors, ac-

celeration, velocity, etc.) after which a preset destination position is ap­proached in a controlled manner. During the motion, velocity, PID fac­tors and destination position can be changed.

Speed control operation

(Initiation with instructions 'GoForw' or 'GoBackw')
Pattern of instructions :

1. Parameter entry for the velocity profile

2. Start motion

3. Stop motion by entering a stop instruction
In speed control mode the desired velocity is attained with a defined rate

of acceleration. Travel continues at this velocity in a controlled manner
until there is a stop instruction. The desired velocity can be changed even
during motion.

Function units

As the block diagram shows (page 3-2) the motion control module essen­tially consists of the following function units:

• Generator for velocity profile

• PID controller

• Position decoder and input circuit

• Bus interface (CPLD) to PCD bus

• D/A converter for the analogue controller output

Function description PCD2.H31x

Page 5-2  SAIA-Burgess El ectronics Ltd. (2H3-05-E.DOC) 26/762 E2

5.2 Generator for the velocity profile

The profile generator calculates theoretical speed according to the accel­eration and velocity presets and as a function of time in position or speed
control mode. In position control operation, the difference between de­sired and actual positions is fed to the PID controller during motion. Very
accurate positioning of the motion is thereby achieved.

Standard velocity profile

Velocity profile with desired velocity and destination position changed
during motion.

Velocity and destination position can be changed at any point along the mo­tion and the controller will accelerate or brake accordingly at the defined rate
of acceleration. Acceleration and braking ramps are symmetrical.

In speed control mode, the controller accelerates to the user-defined desired
speed and runs on at a constant velocity until there is a stop command.

Operating principle of speed control:
The destination position is continuously augmented (according to the re-

quired velocity). The difference between destination and actual position
(captured with the encoder) is again conveyed to the PID controller. The
latter immediately compensates for speed fluctuations (caused by what­ever disturbance) by making the controller output greater or smaller.

Preset velocity

Constant

acceleration

and delay

Destination position

v

t

v

t

+

v = velocity
t = time

PCD2.H31x Function description

26/762 E2 (2H3-05-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 5-3

If the motor fails to reach the desired speed (e.g. due to a blocked rotor)
the difference between the destination and actual positions is very large.
This generates a position error message, which can trigger an interrupt or
automatic motor stop. The maximum allowable position error is a pro­grammable value.

Function description PCD2.H31x

Page 5-4  SAIA-Burgess El ectronics Ltd. (2H3-05-E.DOC) 26/762 E2

5.3 PID controller

The PID controller can be used to help the motor to approach the desti­nation position accurately and keep it in that position, as the controller
remains active until a stop command occurs.
The controller utilizes the following algorithm:

where: U(n) → Controller output for the motor

e(n) → Position error at the n'th sampling
n → Sampling for the integral portion
n' → Sampling for the differential portion
kp → Proportional factor
ki → Integral factor
kd → Differential factor

User programmable parameters:

• Control factors kp, ki, kd

• Differential sampling time

• Integration limit (IL) for the integral portion

Control factors kp, ki and kd can be changed during motion.
The sampling time for the proportional and for the integral factor is

341 µs. This means, that the value of the controller output is refreshed
any 341 µs.

The sampling time of the differential portion can be adjusted in steps
of 341 µs (max. 256*341 µs). For operation at slow speeds, a greater
sampling time should be selected.

Integration limit IL : limitation applies to the amount of the expression

PCD2.H31x Function description

26/762 E2 (2H3-05-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 5-5

5.4 Position decoder and input circuit

Position and velocity capture

The precise position and/or speed of the motor is captured with an incre­mental shaft encoder. The following encoder signals can be connected:

PCD2.H310: A, B, IN (terminals)

24V signals in source mode

PCD2.H311: A, /A; B, /B; IN, /IN (terminals

5V RS422 inputs (antivalent line driver)

Inputs A, B, /IN :

Status diagram of signals A, B, /IN at position decoder :

Inputs A, B:

Whenever signals A or B change status (0 → 1 and 1 → 0) the internal
position register is incremented or decremented by 1. In this way the
quadruple resolution of encoder division is achieved. Correspondingly,
the entry for destination position must also be multiplied by four when
working with encoder impulses.

For the position decoder, signals must demonstrate the exact sequence
illustrated in the figure above.

A

B

IN

12341234

1 Encoder-

division

Status

Ind e x = A & B & IN

Impulses to
position reg ister

12341234

Direction

neg. pos.

Status

A
B

IIII

III

OO OO

OO

OO

I

Function description PCD2.H31x

Page 5-6  SAIA-Burgess El ectronics Ltd. (2H3-05-E.DOC) 26/762 E2

Input IN:

With modules for 24V encoders (type H310) input IN can be used as an
index impulse input (zero signal from the encoder) or reference point input.

- Use as index impulse input:
Whenever all 3 encoder signals have a status of zero and the "SetIdx-

Pos" (Set Index Position) function block has been called, the absolute
motion position is written to the index position register .

- Use as reference point input:
A reference switch can be connected, e.g. to define the zero position.

Modules for the connection of 5V encoder signals

The PCD2.H311 module is used. Shielded cable must be used for connec­tion to the 5V encoder:

- max. cable length: 20m

- min. line cross section: 0.25 mm

2

e.g. cable types PCD2.K271 or PCD2.K273

Reference switch

Only the PCD2.H310 has the 'Ref' input (24 VDC, source mode). The sig­nal for this switch is carried directly to the PCD2 bus. This means that the
input should be monitored from the user program to trigger any necessary
action.

With the PCD2.H311, any reference switch should be wired to a "normal"
digital I/O module.

The 'reference switch' is used in combination with the 'limit switches' for
the 'Home' FB. In both modules (H310 and H311) these limit switches
should be carried to a digital I/O module.

PCD2.H31x Function description

26/762 E2 (2H3-05-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 5-7

Input wiring diagrams and connections

PCD2.H310

PCD2.H311

+5V

+5V

A

B

IN

A

B

IN

+5V

A

B

A

IN

/A

B

/B

IN

/IN

Function description PCD2.H31x

Page 5-8  SAIA-Burgess El ectronics Ltd. (2H3-05-E.DOC) 26/762 E2

5.5 D/A converter

Both PCD2.H310 and H311 modules have an analogue output for the
motor’s controller output.

A 12 bit D/A converter has been used.

Analogue output connection:

PCD2.H31x Function description

26/762 E2 (2H3-05-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 5-9

5.6 Complementary information: homing (FB Home)

With the 'Home' FB, independent homing can take place. Seven parame­ters are required for definition of the home travel. The use of the 'Home'
FB is described in section 12.1.

The axis to be referenced must have been initialized (FB Init). (The fol­lowing description refers to the figure on the next page). For successful
use of the 'Home' FB, the axis and reference switch must be located be­tween 'LS1' and 'LS2'.

1.

The search for the reference switch is undertaken at the velocities de-

fined in parameter 5 (Vmax). The search direction is defined in parame­ter 2. If the reference switch is not found and the axis meets a limit
switch, the search direction is inverted.

2.

The digital input to which the reference switch is wired is defined in pa-

rameter 7. For a PCD2.H310 module this address is the module base ad­dress plus 11. For a PCD2.H311 module any address can be chosen
("normal" digital input module).

3.

When the reference switch has been found free travel commences. The

direction of free travel is defined in parameter 3; the velocity for free
travel is Vmin (parameter 4).

4.

When the reference switch has been released, the axis travels as far as

the next encoder index signal and stops. This position is now defined as
the zero position.

5.

The module is configured with the original settings (from FB Init) and FB

Home is exited.

Function description PCD2.H31x

Page 5-10  SAIA-Burgess Electronics Ltd. (2H3-05-E.DOC) 26/762 E2

Instructions:

• Several modules can be referenced on one PCD at the same time.

• The 'fEndHome_x' flag must be =L for the start of the homing proce-

dure.

• Flags 'fLS1_x' and 'fLS2_x' are representations of the limit switches.

The logic states of both flags are the result of querying both digital in­puts to which these LSs are connected.

• Break contacts should be used for the switches.

• During the homing procedure, limit switches are switched off inter-

nally and are only used for reversing the direction of travel.

• If no reference switch is found, the error flag

'fHomeErr_x' (x = module no.) is set and the 'Home' FB is exited.

• When the 'Home' FB has finished (successfully or broken off by an

error) the 'fEndHome_x' flag is set automatically.

• Since the 'Home' FB is only exited when homing has been success-

fully completed or an error has been detected, the FB can be broken
off with a timeout (parameter 6). Its value corresponds to the time in
seconds after which the 'Home' FB will be abandoned. In this case, as
well as the error flag 'fHomeErr_x', the diagnostic register 'rDiag' is
loaded with code 6 (for parameter 6) in the third byte (for FB Home).
Parameter checking takes place as described in chapter 8.

A

1.

3.

Reference switch released

"LS 1"

"LS 2"

LS emerg. off

LS emerg. off

Reference switch

Axis

Stop pos. after free travel
from the reference switch

Reference switch addressed

2.

Reference position

PCD2.H31x Quick start

26/762 E2 (2H3-06-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 6-1

6. Quick start

Minimal arrangement for position control using a PCD2.H310 or
PCD2.H311, not including reference switch and limit switches.

The individual elements are:

• PCD1 or PCD2, equipped at least with 1 PCD2.H310/311

with F510/530 display
1 PCD2.E110

• Motion model with DC motor, spindle and incremental shaft encoder

• DC Motor with gears: approx. 500 rev/min at 10 VDC

Spindle gradient: 1 mm/revolution
Incremental shaft encoder: 1000 signals per revolution

• 4-quadrant servo amplifier

e.g. with Op-Amp LM 12 (National Semiconductor)
for details see: http://www.national.com/pf/LM/LM12.html

• PG4 from version V2.0.70 and FBs PCD9.H31E

Carriage

Shaft
encode

DC

Motor

9876543210

5V Out /IN IN /B B /A A

H311

E110

24V

0V

0V

Servo

amplifier

Start

PCD2

+/-10V

0163248

648096112

Quick start PCD2.H31x

Page 6-2  SAIA-Burgess El ectronics Ltd. (2H3-06-E.DOC) 26/762 E2

6.1 Entry with programming in IL

The basic program shown below is proposed as the simplest way of com­missioning a regulated position controller:

A properly written user program should not contain any
wait loops. Despite this, our first example has been de­signed with wait loops to demonstrate the main instruc­tions for driving a PCD2.H31x. In practice a GRAFTEC or
(in future) a FUPLA structure should always be chosen for
this type of program. (See second example and chapter

10).

Task: After switching on the PCD’s 'Start' input, the carriage is to

travel first in one direction and then, after a pause, back
again to the starting position. It is assumed that, at the start,
the carriage will be located roughly in the middle of the axis.

The purpose of this example is to demonstrate the principle
and possible user program structures. Above all note the be­ginning of the program with its assembler directives
'$include ' and '$group'.

The meaning and definition of individual parameters require
some knowledge of control technique and are explained in
chapter 9: 'Installation and commissioning'.

This first example (with wait loops) is entitled
'Intro-1.src'. The same example shown subsequently in
GRAFTEC is called 'Intro-2.sfc'

The FBs (IL for PG4 from version V2.0.70) are on the PCD9.H31E diskette.
To install the FBs on the PC, follow the instructions in chapter 7 below and
the README.TXT file. This file can also be found on the diskette.

The number of modules (1) and the address of the PCD2.H311 module (ad­dress 80) must be entered in the file D2H310_B.MBA:

NbrModules EQU 1 ; No. of H31x modules used (0...16)

BA_1 EQU 80 ; Base address of module 1

This file (D2H310_B.MBA) must be located in the project directory for the
example, i.e. the file should be copied manually from the diskette into the
current project directory.

PCD2.H31x Quick start

26/762 E2 (2H3-06-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 6-3

6.1.1 Entry-level example in IL with wait loop: INTRO-1.SRC

$include D2H310_B.equ
$group H310

xob 16

LD R 1000

4.0 ; Mechanical factor

LD R 1001

8000 ; Initial absolute speed

LD R 1002

10000 ; Initial absolute acceleration

CFB Init ; Initialization FB

K 1 ; Module number

250 ; Proportional factor (regulator)
0 ; Integrative factor (regulator)
0 ; Derivative factor (regulator)
4000 ; Integrative limit value
5 ; Derivative term sampling interval
500 ; Position tolerance

0 ; Behaviour in case of position error
R 1000 ; Mechanical factor register
R 1001 ; Initial velocity register
R 1002 ; Initial acceleration register

exob

; ---------------------------------------------------------------

cob 0

0

start: sth i 0

CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position
R 90 ; Actual Position register

DSP R 90 ; Display register

jr l start ; If Start is not done, wait

LD R 100 ; Target Position

20000 ; Absolute value

CFB Exec ; Executable FB

K 1 ; Module number

LdDestAbs ; Command: Load Absolute Destination
R 100 ; Absolute Destination register

CFB Exec ; Executable FB

K 1 ; Module number

StartMot ; Command: Start motion

rNotUsed ; Dummy register

Quick start PCD2.H31x

Page 6-4  SAIA-Burgess El ectronics Ltd. (2H3-06-E.DOC) 26/762 E2

pos1: CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position
R 90 ; Actual Position register

DSP R 90 ; Display register

CFB Exec ; Executable FB

K 1 ; Module number

RdStatRg ; Command: Read Status Register
R 0 ; Value of Status Register

STH fOnDest_1 ; Position reached?
jr l pos1 ; if no - wait (loop)

ld t 0 ; load timer for pause

50 ; 5 sec

pause1: sth t 0 ; pause elapsed?

jr h pause1 ; if no - wait (loop)

LD R 100 ; Target Position

0 ; Absolute value

CFB Exec ; Executable FB

K 1 ; Module number

LdDestAbs ; Command: Load Absolute Destination
R 100 ; Absolute Destination register

CFB Exec ; Executable FB

K 1 ; Module number

StartMot ; Command: Start motion

rNotUsed ; Dummy register

pos2: CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position
R 90 ; Actual Position register

DSP R 90 ; Display register

CFB Exec ; Executable FB

K 1 ; Module number

RdStatRg ; Command: Read Status Register
R 0 ; Value of Status Register

STH fOnDest_1 ; Position reached?
jr l pos2 ; if no - wait (loop)

ld t 0 ; load timer for pause

50 ; 5 sec

pause2: sth t 0 ; pause elapsed?

jr h pause2 ; if no - wait (loop)

ecob

$endgroup

PCD2.H31x Quick start

26/762 E2 (2H3-06-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 6-5

Description of programs:

The directive '$include' is used to integrate file 'D2H310_B.equ'. (This
file in turn integrates the 'D2H310_B.mba' file with information about the
number of H31x modules and their base addresses. This happens auto­matically. The user has nothing to do with it.)

The directive '$group H310' declares the program code up to '$endgroup'
as belonging to PCD2.H31x.

In XOB 16 (coldstart block) module initialization takes place. Before FB
INIT the 3 registers for machine factor, velocity and acceleration should
be loaded. The choice of individual values is explained in chapter 9: 'In­stallation and commissioning'.

FB INIT is then called. Choosing the 11 parameters is also described in
chapter 9.

The actual motion program occurs in COB 0.
Start is awaited with PCD input 0. To enable current position to be cap-

tured even during this phase and appear on the display, the instruction
'RdActPos' is incorporated in the wait loop. This means that, if the start
condition is not met, the position will be read continuously.

The absolute destination position is loaded into PCD register R 100. This
value is transferred to the module with 'LdDestAbs'. The 'StartMot' com­mand starts the motion. (20 mm traverse)

In a program loop the position is continuously read with 'RdActPos' and
output to the display via PCD register R 90. Motion takes place accord­ing to the parameters selected in FB INIT, i.e. the motion is travelled in
the best way, controlled by the module itself, uninfluenced by the user
program, up to the destination point. To allow the program sequence to
continue correctly, it is necessary to determine when motion has con­cluded. This is done by querying the 'fOnDest_x' flag (fOnDest_1 for
module no. 1 in our case). However, before this flag can be queried, it
must be activated with the 'RdStatRg' instruction.

The program loop that reads or displays current position and activates or
queries the position flag is in a constant cycle until the destination posi­tion has been reached.

When the destination position has been reached a pause of, e.g. 5 sec­onds is loaded and waited through. The new destination position (zero) is
then loaded and motion travels back to the starting point.

In order to know the real, current position even during pauses (stabiliza­tion of final position), it would also be necessary to incorporate the com­mands 'RdActPos' and 'DSP R 90' into wait loops for these pauses.

Quick start PCD2.H31x

Page 6-6  SAIA-Burgess El ectronics Ltd. (2H3-06-E.DOC) 26/762 E2

6.1.2 Entry-level example in GRAFTEC: INTRO-2.SFC

Same example as under section 6.1.1, but in a proper GRAFTEC struc­ture without any program jumps or wait loops. Individual steps and tran­sitions have been edited in IL.

PCD2.H31x Quick start

26/762 E2 (2H3-06-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 6-7

Program code for "intro-2.sfc"

(To obtain this representation, file "intro-2.sfc should be renamed as
“intro-2.src").

SB 0

;-------------------------------

IST 10 ;Initialization

O50

$include D2H310_B.equ
$group H310

LD R 1000

4.00 ; Mechanical factor

LD R 1001

8000 ; Initial absolute speed

LD R 1002

10000 ; Initial absolute acceleration

CFB Init ; Initialization FB

K 1 ; Module number

250 ; Proportional factor (regulator)
0 ; Integrative factor (regulator)
0 ; Derivative factor (regulator)
4000 ; Integrative limit value
5 ; Derivative term sampling interval
500 ; Position tolerance

0 ; Behaviour in case of position error
R 1000 ; Mechanical factor register
R 1001 ; Initial velocity register
R 1002 ; Initial acceleration register

EST ;10

;-------------------------------

ST 11

I50
I 55 ;Pause 2 elapsed ?
O 51 ;Start OK ?

EST ;11

;-------------------------------

ST 12 ;Move forwards

I 51 ;Start OK ?
O 52 ;Move forwards ended ?

LD R 100 ; Target Position

20000 ; Absolute value

CFB Exec ; Executable FB

K 1 ; Module number

LdDestAbs ; Command: Load Absolute Destination
R 100 ; Absolute Destination register

CFB Exec ; Executable FB

K 1 ; Module number

StartMot ; Command: Start motion

rNotUsed ; Dummy register

EST ;12

Quick start PCD2.H31x

Page 6-8  SAIA-Burgess El ectronics Ltd. (2H3-06-E.DOC) 26/762 E2

;-------------------------------

ST 13 ;Pause 1

I 52 ;Move forwards ended ?
O 53 ;Pause 1 elapsed ?

ld t 0

50

EST ;13

;-------------------------------

ST 14 ;Move backwards

I 53 ;Pause 1 elapsed ?
O 54 ;Move backwards ended ?

LD R 100 ; Target Position

0 ; Absolute value

CFB Exec ; Executable FB

K 1 ; Module number

LdDestAbs ; Command: Load Absolute Destination
R 100 ; Absolute Destination register

CFB Exec ; Executable FB

K 1 ; Module number

StartMot ; Command: Start motion

rNotUsed ; Dummy register

EST ;14

;-------------------------------

ST 15 ;Pause 2

I 54 ;Move backwards ended ?
O 55 ;Pause 2 elapsed ?

ld t 0

50

EST ;15

;-------------------------------

TR 50

I 10 ;Initialization
O11

ETR ;50

;-------------------------------

TR 51 ;Start OK ?

I11
O 12 ;Move forwards

CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position
R 90 ; Actual Position register

DSP R 90 ; Display register

sth i 0

ETR ;51

PCD2.H31x Quick start

26/762 E2 (2H3-06-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 6-9

;-------------------------------

TR 52 ;Move forwards ended ?

I 12 ;Move forwards
O 13 ;Pause 1

CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position
R 90 ; Actual Position register

DSP R 90 ; Display register

CFB Exec ; Executable FB

K 1 ; Module number

RdStatRg ; Command: Read Status Register
R 0 ; Value of Status Register

STH fOnDest_1 ; Position reached?
ETR ;52

;-------------------------------

TR 53 ;Pause 1 elapsed ?

I 13 ;Pause 1
O 14 ;Move backwards

stl t 0
ETR ;53

;-------------------------------

TR 54 ;Move backwards ended ?

I 14 ;Move backwards
O 15 ;Pause 2

CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position
R 90 ; Actual Position register

DSP R 90 ; Display register

CFB Exec ; Executable FB

K 1 ; Module number

RdStatRg ; Command: Read Status Register
R 0 ; Value of Status Register

STH fOnDest_1 ; Position reached?
ETR ;54

;-------------------------------

TR 55 ;Pause 2 elapsed ?

I 15 ;Pause 2
O11

stl t 0

$endgroup

ETR ;55

ESB ;0

Quick start PCD2.H31x

Page 6-10  SAIA-Burgess Electronics Ltd. (2H3-06-E.DOC) 26/762 E2

Explanatory notes to the program

Knowledge of the PG4 in general and GRAFTEC in particular is as­sumed.

During assembly, sequential block SB 0 is called automatically from a
COB.

The course of the GRAFTEC program can be viewed online.

Initialization of the H310 module takes place in IST 10. In the arrange­ment chosen, this IST is only processed when the SB is called for the first
time, like XOB 16. It makes sense if initialization of the H310 module
takes place in the IST of whichever SB deals with the module, so that the
whole program routine stays together. XOB 16 is preferred for carrying
out initializations that apply to the whole PCD.

In ST 12 and ST 14 the absolute destination position is loaded via PCD
register R 100 into the H310 module and motion is started.

In TR 52 and TR 54 the end of a motion is queried from software so that
the program can be released to continue its course. Motion itself is con­trolled directly by the module. Before querying the continuation condi­tion (sth fOnDest_1) the current position is read and output to the dis­play, and the 'fOnDest_1' flag is refreshed with 'RdStatRg'. In accordance
with GRAFTEC rules, for every unfulfilled TR (e.g. destination position
not yet reached) the program returns to the calling COB and continues
working. At the next program cycle the unfulfilled TR is processed again
in full. This ensures that the position is read and displayed automatically
each time and that the 'fOnDest_1' flag is refreshed.

To be correct, the position in an experimental set-up should also be read
and displayed during pauses, so that carriage status can be viewed even
during stabilization.

PCD2.H31x Quick start

26/762 E2 (2H3-06-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 6-11

6.1.3 Simple commissioning program *)

To try out the different parameters for achieving optimal motion, the fol­lowing program "test-par.sfc" is proposed. (It has been derived from the
previous example "intro-2.sfc").

Function:

I 0: Start of backwards and forwards motion (as "intro-2.sfc")
I 1: Adoption of new parameters, which were changed online in the

debugger. By activating I 1, motion can also be stopped
abruptly.

I 2: From the resting position, the carriage can be moved forward

with the chosen parameters for as long as I 2 remains switched
on.

I 3: From the resting position, the carriage can be moved backward

with the chosen parameters for as long as I 3 remains switched
on.

Parameters can be modified online in the debugger. To identify the ab­solute addresses of parameters, the IST should be displayed or even
printed
out with <Display> <Program> <Step> <10> <CR>.

*) A more convenient commissioning program (commissioning

tool) in FUPLA is presented in chapter 10.

Quick start PCD2.H31x

Page 6-12  SAIA-Burgess Electronics Ltd. (2H3-06-E.DOC) 26/762 E2

LD R 1000

4.0 ; Mechanical factor

LD R 1001

8000 ; Initial absolute speed

LD R 1002

10000 ; Initial absolute acceleration

CFB Init ; Initialization FB

K 1 ; Module number

250 ; Proportional factor (regulator)

0 ; Integrative factor (regulator)

0 ; Derivative factor (regulator)

4000 ; Integrative limit value

5 ; Derivative term sampling interval

500 ; Position tolerance

0 ; Behaviour in case of position error
R 1000 ; Mechanical factor register
R 1001 ; Initial velocity register
R 1002 ; Initial acceleration register

EST ;10

For example, if initial absolute acceleration is to be increased from
10 000 to 30 000, absolute program line 19 should be processed:

<Write> <Program> <19> <CR> <30000> <CR> <Esc>

When motion is resting: Switch PCD input I 1 on and off. This means that
the modified parameters are adopted. By switching on I 0 the new be­haviour can be tried out, etc.

PCD2.H31x Quick start

26/762 E2 (2H3-06-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 6-13

6.2 Entry with programming in FUPLA

In preparation

Quick start PCD2.H31x

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Notes

PCD2.H31x Programming

26/762 E2 (2H3-07-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 7-1

7. Programming

The PCD is programmed to use the PCD2.H.. counting and motion con­trol modules via the PCD user program with the standard PG4 program­ming tool from version V2.0.70. (For applications with the older PG3
programming tool, use FBs for the PCD4.H3.. module).

Programming takes place either in IL (Instruction List) with FBs (Func­tion Blocks) or in FUPLA with FBoxen (in preparation). FBs are avail­able on diskette under reference PCD9.H31E.

Since motion control tasks are always sequential processes, it is prefer­able if user programs are written in GRAFTEC, editing the individual
steps and transitions in IL with FBs or, in FUPLA, FBoxes. However,
user programs can also be written in straight BLOCTEC or FUPLA.

Programming PCD2.H31x

Page 7-2  SAIA-Burgess El ectronics Ltd. (2H3-07-E.DOC) 26/762 E2

7.1 Programming in IL wit h FBs

7.1.1 The IL package (Installation of FB)

This diskette has order reference PCD9.H31E. It contains the following
directories:

• APPSDIR : containing all helps

• FB : containing the .SRC and .EQU files of the H31x

• FBOX : containing FBoxes for the H31x

• PG3_FB : containing all FB files for the PG3

• PG4_FB : containing examples and the .MBA file

• Readme : containing general information

This package is provided for use with SAIA PG4 from version V2.0.70.
Consult the 'Readme' file for all other PG4 versions. (The package also
contains FBs for use with the earlier PG3, see 'Readme').

FBoxes for FUPLA are not yet available.

Installation of package for the PG4

The easiest method of installation is with the PG4 'Setup Extra Files' pro­gram:

Insert diskette PCD9.H31E into drive A:
<Start> <Programs> <SAIA PG4> <Setup Extra Files>. FBs and the
'Help' file are installed on the hard disk in directory 'PG4'.

The following files are installed:

D2H310_B.SRC FB source code read-only file
D2H310_B.EQU FB definitions read-only file

These 2 files are copied from the diskette into PG4 directory ...\PG4\FB.

FB_LIB.HLP FB library data
D2H310_B.HLP FB help file

This file is located in directory A:\APPSDIR and is copied into the
PG4 directory ...\PG4.

The file D2H310_B.MBA (module base addresses) must be copied
manually from the diskette, directory PG4_FB, into the relevant proj­ect directory.

PCD2.H31x Programming

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File 'D2H310_B.MBA' is important for the user and is shown below:

File: D2H310_B.MBA (MBA = Module Base Address)

;
; This file can be modified by the user
;
; Base addresses defined by the user
; ----------------------------------­$group H310
NbrModules EQU 1 ; No. of H310 modules used (0...16)

;
; Module base addresses (only the used modules must be defined)

BA_1 EQU 32 ;Base address of module 1
BA_2 EQU 0 ;Base address of module 2
BA_3 EQU 0 ;Base address of module 3
BA_4 EQU 0 ;Base address of module 4
BA_5 EQU 0 ;Base address of module 5
BA_6 EQU 0 ;Base address of module 6
BA_7 EQU 0 ;Base address of module 7
BA_8 EQU 0 ;Base address of module 8
BA_9 EQU 0 ;Base address of module 9
BA_10 EQU 0 ;Base address of module 10
BA_11 EQU 0 ;Base address of module 11
BA_12 EQU 0 ;Base address of module 12
BA_13 EQU 0 ;Base address of module 13
BA_14 EQU 0 ;Base address of module 14
BA_15 EQU 0 ;Base address of module 15
BA_16 EQU 0 ;Base address of module 16
$endgroup

The number of PCD2.H31x modules should be specified. The hardware base
addresses of PCD2.H31x modules utilized should then be entered.

Since the '.mba' file does not appear in the Project Manager, a text editor
is required for any adjustments, e.g. SEDIT32.

Modules should be numbered consecutively, starting from 'BA_1'. For
example, if 3 x H310 modules are used in a project, use 'BA_1', 'BA_2'
and 'BA-3'. Module sockets can be assigned as desired, for example:

NbrModules EQU 3 ; No. of H310 modules used (0...16)
;
; Module base addresses (only the used modules must be defined)

BA_1 EQU 64 ;Base address of module 1
BA_2 EQU 208 ;Base address of module 2
BA_3 EQU 112 ;Base address of module 3
BA_4 EQU 0 ;Base address of module 4
BA_5 EQU 0 ;Base address of module 5

The base addresses of registers, flags and FBs are assigned automatically
and can be consulted in the resource list under 'View' - 'Resource List'.

Programming PCD2.H31x

Page 7-4  SAIA-Burgess El ectronics Ltd. (2H3-07-E.DOC) 26/762 E2

Arrangement of files and procedure when writing a user program. The proj­ect created is to be entitled "TEST-H3" and the actual user program should
have the name "move-01.sfc".

C:\PG4 \FB \D2H310_b.equ

\D2H310_b.src
\...
\FBOX \...
\GALEP3 \...
\PROJECTS \FUP_E (Demo example PG4)

\GRAF_E (Demo example PG4)

\TEST-H3 \D2H310_b.mba

\move-01.sfc
\...
\D2H310_b.hlp

The user program for the H310 section has the following presentation:

$include D2H310_b.equ
$group H310

XOB 16

PCD-Code

ecob
$endgroup

If the program is written in GRAFTEC, the assembler directives "$include" and
"$group" will usually be located in the first step (ST), normally the initial step
(IST). "$endgroup" comes at the end of the last transition (TR).

If everything has been correctly installed, the user program edited and all
parameters defined, it is possible with 'Project' - 'Build' to process the
program and load it into the PCD.

PCD2.H31x Programming

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7.1.2 Individual FBs

The whole package basically consists of 2 (3) FBs with parameters:

• INIT Initialization FB with 11 parameters

• EXEC Execution FB with 3 parameters

• HOME Home position FB with 7 parameters

Calling FB "INIT" always has the following presentation:
(values entered serve as examples only)

CFB init ; Intitialization of a PCD2.H31x module

k 1 ; Par. 1: Module number (k1-k16)

250 ; Par. 2: Proportional factor
150 ; Par. 3: Integral factor
10 ; Par. 4: Differential factor
4000 ; Par. 5: Integration limit
5 ; Par. 6: Sample time of D factor
500 ; Par. 7: Position tolerance

0 ; Par. 8: Behaviour under position error
r 1000 ; Par. 9: Mechanical factor *)
r 1001 ; Par. 10: Velocity *)
r 1002 ; Par. 11: Acceleration *)

*) Registers for parameters 9, 10 and 11 should be loaded with the

correct values before processing FB INIT.

Calling FB 'EXEC' has the following presentation for some typical exam­ples:

CFB exec

k 1 ; Par. 1: Module number (k1–k16)

LdDestRel ; Par. 2: Function (instruction)
r 777 ; Par. 3: Value (from source register)

CFB exec

k 1 ; Par. 1: Module number (k1-k16)

start ; Par. 2: Function (instruction)

rNotUsed ; Par. 3: not used

CFB exec

k 1 ; Par. 1: Module number (k1-k16)

RdActPos ; Par. 2: Function (instruction)
r 1000 ; Par. 3: Value (in dest. register)

Three parameters must always be specified, even if only 2 are required for a
function. For the third parameter, specify 'rNotUsed', or any register.

A list with all instructions follows on the next page.

Programming PCD2.H31x

Page 7-6  SAIA-Burgess El ectronics Ltd. (2H3-07-E.DOC) 26/762 E2

Instructions (functions) for FB 'Exec' (Parameter 2):

No. Symbol Instruction Page

----------------------------------------------------------------------------------------------------­01 Start M ot Start M ot ion A-7
02 StopUrg Stop motion in Urgency A-8
03 Stop Stop motion A-9
04 MotOff Motor regulation Off A-10

05 RdActPos Read Actual Position A-11
06 RdActVel Read Actual Velocity A-12
07 RdIntSum Read Integrat ion Sum A-13
08 RdIndexRg Read Index Register A-14
09 RdStatRg Read Status Register A-15
10 RdTargPos Read Target Posit ion A-16
11 RdTargVel Read Target Velocity A-17

12 GoForw G o For w ar ds A-18
13 GoBackw G o Backwar ds A-19
14 SgStpFor Single Step Forwards A-20
15 SgStpBak Single Step Backwards A-21

16 LdDestAbs Load Destination Absolute A-22
17 LdDestRel Load Destination Relative A-23
18 LdVelAbs Load Velocity Absolute A-24
19 LdVelRel Load Velocity Relative A-25
20 LdAccAbs Load Acceleration Absolute A-26
21 LdAccRel Load Acceleration Relative A-27
22 LdPropG Load Proportional Gain A-28
23 LdIntG Load Integrat ive Gain A-29
24 LdDerG Load Derivative Gain A-30
25 LdSampInt Load derivative Sampling Interval A-31
26 LdIntLim Load Integrative Limit A-32

27 ActRegFact Act ivate Regulation Factors A-33
28 LdBrkPtAbs Load Breakpoint Absolute A-34
29 LdBrkPtRel Load Breakpoint Relative A-35

30 ResStatRg Reset Stat us Register A-36
31 SetIdxPos Set Index Position A-37
32 SetZero Set Zer o posit ion A-38
33 MotConf M ot ion Configuration A-39
34 SetPosTol Set Position Tolerance A-40

The figure in the first column (0 - 34) is the absolute value of parameter
no. 2 in FB 'Exec'. This figure can be used to interpret the function of FB
'Exec' when viewing the user program in the debugger.

PCD2.H31x Programming

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Calling FB "HOME" always has the following presentation:
(values entered serve as examples only)

CFB home ; Intitialization of reference position

k 1 ; Par. 1: Module number (k1-k16)

1 ; Par. 2: Search direction

0 ; Par. 3: Free travel direction
r 990 ; Par. 4: Minimum velocity
r 991 ; Par. 5: Maximum velocity

1000 ; Par. 6: Timeout
i 7 ; Par. 7: Reference input

Elements that can be queried by the user:

Element Description

fHomeErr_x When error with 'Home', element = H.

(Timeout, home position not found)
fLS1_x H on arrival at limit switch 1
fLS2_x H on arrival at limit switch 2
fEndHome_x Always = H, except during home procedure
fBrkPt_x H, when breakpoint reached
fOnDest_x H, when destination position reached

fPosErr_x H, in case of major position error

fPar_Err Parameter error (outside range)
fTimeout Read/write (with hardware problem)

Ref_1 Representation of reference input

'_x' corresponds to the module number

Effective element addresses should be taken from the resource list: from
Project Manager 'View' - 'Resource List'. A complete, detailed list ap­pears.

Programming PCD2.H31x

Page 7-8  SAIA-Burgess El ectronics Ltd. (2H3-07-E.DOC) 26/762 E2

A clear list with absolute addresses, which ought to be adequate for de­bugging, is supplied by the project .map file:

SAIA PCD LINKER SP 2.0.83 FILE: test-2h3.pcd
LINKED: 06/30/99 10:57 PAGE 3

FOR SAIA'S INTERNAL USE ONLY

SYMBOL TYPE VALUE DEFINED REFERENCED

H310.Exec FB 1 D2H310_B 2-speed
H310.fBrkPt_1 F 7517 D2H310_B
H310.fEndHome_1 F 7516 D2H310_B
H310.fHomeErr_1 F 7513 D2H310_B
H310.Flag_base F 7502..7528 D2H310_B 2-speed
H310.fLS1_1 F 7514 D2H310_B
H310.fLS2_1 F 7515 D2H310_B
H310.fOnDest_1 F 7518 D2H310_B
H310.fPar_Err F 7502 D2H310_B
H310.fPosErr_1 F 7528 D2H310_B
H310.fTimeout F 7512 D2H310_B
H310.Home FB 2 D2H310_B
H310.Init FB 0 D2H310_B 2-speed
H310.rDiag R 3500 D2H310_B
H310.Reg_base R 3500..3524 D2H310_B 2-speed
H310.rIniVel_1 R 3524 D2H310_B
H310.rMecFac_1 R 3522 D2H310_B
H310.rSampInt_1 R 3523 D2H310_B

Linkage complete. 0 errors, 0 warnings.

Assignment of addresses on the bus

Each module occupies 16 addresses as inputs (readable) and 16 addresses
as outputs (writeable).

Bit no. DATA In (read) DATA Out (write)

0 Bus dat a (LSB) Bus data ( L SB)
1 Bus data B us da ta
2 Bus data B us da ta
3 Bus data B us da ta
4 Bus data B us da ta
5 Bus data B us da ta
6 Bus data B us da ta
7 Bus dat a (MSB) Bus data ( M SB)
8 Supply *) Wr ite ( W R LM628)

9 - Read (RD LM628)
10 - Port select ( PS LM628)
11 Ref. Switch **)/ Pw5V ***) ­12 Version ****) -

13 - 15 - -

*) Monitoring ±15V (H: Supply OK; L: Supply not OK).
**) Ref Switch. For H310 only. (H: RS active; L: RS not active).
***) Monitoring 5V. H311 only. (H. 5V OK; L: 5V not OK).
****) Module version (H: H310; L: H311).

PCD2.H31x Programming

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7.2 Programming in FUPLA with FBox es

in preparation

Programming PCD2.H31x

Page 7-10  SAIA-Burgess Electronics Ltd. (2H3-07-E.DOC) 26/762 E2

7.3 Programming in G RAFTEC with F Box es

in preparation

PCD2.H31x Error handling and diagnosis

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8. Error handling and diagnosis

8.1 Definition error checked by assembler

The following definition errors in file D2H310_b.MBA are checked du­ring assembly:

• If the number of modules (NbrModules) is < 1, no code is assembled

and the following warning is written in the 'Make' window:

"Remark: No H310 used (NbrModules = 0 in D2H310_B.MBA)"

• If the number of modules (NbrModules) is > 16, no code is assembled

and the following error message is written in the 'Make' window:

"Error : more than 16 Modules H310 defined (NbrModules = 0...16)"

• If an incorrect instruction code is used for FB 'Exec' (e.g. RdIdenti in-

stead of RdIdent), the assembler reports an error:

"Symbol not defined 'H310.RdIdenti'"

(where the expression 'H310' is generated by $group h310)

• If the definition $group H310 is missing, the assembler reports:

"Symbol not defined"

for every instruction and every register/flag used in the program.

Error handling and diagnosis PCD2.H31x

Page 8-2  SAIA-Burgess El ectronics Ltd. (2H3-08-E.DOC) 26/762 E2

8.2 Er ror handling in Run

8.2.1 Incorrect parameter

In FB 'Exec' the instruction code only is checked. Parameters 1 (module
no.) and 3 (source/destination register) are not checked, to avoid making
the execution time longer.

In FBs 'Init' and 'Home' the values of all parameters are checked to ensu­re they are within the premitted range. If a parameter lies outside a range
it is brought to the minimum value, the error flag 'fPar_Err' is set and the
diagnostic register 'rDiag' is loaded with the relevant error code.

The 'fPar_Err' flag is not reset within FBs. This should take place in XOB
16 or the 'Init' step.

The error code is made up as follows:

rDiag bit 31 . . . . . . . 24 23 . . . . . . . 16 15 . . . . . . . 8 7 . . . . . . . 0

\ Reserve / \ FB no. / \ Par. no. / \ Mod. no./

(Init = FB 1)
(Exec = FB 2)
(Home = FB 3)

Example: If the sample time (parameter 6) in FB 'Init' of module 2

is incorrectly defined (>255), 'rDiag' is loaded with the
hex value 00 01 06 02.

At each incorrect parameter, the diagnostic register is overwritten and
always contains the last error. It should therefore be evaluated as soon as
the 'fPar_Err' flag signals a range error. The absolute addresses of 'rDiag'
and 'fPar_Err' can be seen in the 'project.MAP' file (see section 7.1.2, pa­ge 7-8). This can be userful during commissioning with the debugger to
locate an error:

- Run until flag 'fPar_Err' = H

- Display register 'rDiag' hex

- Delete flag 'fPar_Err'

PCD2.H31x Error handling and diagnosis

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8.2.2 Error during homing

If it has not been possible to find the reference position (e.g. due to a
faulty reference switch), the 'fHomeErr_x' error flag is set, motion is
stopped, the absolute position is zeroed and FB 'Home' is broken off.

Reference switch absent or incorrectly wired:

If FB 'Home' has been broken off because the specified timeout has elap­sed, the diagnostic register 'rDiag' is additionally loaded with code 6 as
the parameter number (the timeout is parameter 6).

The 'fHomeErr_x' flag is defined for each module (_x is the module no.)
and is reset at the start of FB 'Home'. This flag should be queried each ti­me FB 'Home' is called, to ensure that the axis is correctly referenced:.

Example:

CFB Home ; Homing axis 3

k 3 ; Module number

0 ; search direction
r 1010 ; min. speed
r 1011 ; max. speed

50 ; timeout
i 64 ; input reference switch

STH fHomeErr_3 ; Query home error flag

; of axis 3

CFB h Errorhandl ; Call (user specific)

; FBs, in case fHomeErr_3 = H

CFB Exec ; Motion 1

LS1 LS2

1

2

3

- Error flag "fhomeErr_x"

- Absolute position at 0

Error handling and diagnosis PCD2.H31x

Page 8-4  SAIA-Burgess El ectronics Ltd. (2H3-08-E.DOC) 26/762 E2

Notes

PCD2.H31x Installation and commissioning

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9. Installation and commissioning

9.1 Introduction

The following description shows the procedure for commissioning a ser­vodrive with the PCD2.H3.. motion control module. To guarantee fault­free operation of the H3 module, during commissioning the steps de­scribed below should be executed in the same sequence.

Selection criteria for a servo-drive with the PCD2.H3.. module

A motion control unit always comprises the following parts:

• A motion controller for setting the motion control parameters (position,

velocity and acceleration) and for position control. This task is per­formed by the PCD1/2 with the H3 module.

• A servo-amplifier for triggering the servomotor.

• A servomotor for converting electrical into mechanical energy.

• A position transmitter, in the form of an incremental shaft encoder.

• A mechanical drive unit.

Selection of servo-amplifier and servomotor:
Regardless of whether a DC or AC servodrive is used, special attention

should be paid to the following points.

• Amplifier and motor must match each other (power, voltage and cur-

rent).

• For precise position and speed control, a four-quadrant power output

stage is required with integral speed governor.

• The greatest possible governing range for amplifier and motor speed,

so that the necessary torque can be applied even at low speeds.

• The H3 module supplies an analogue ±10V signal as the speed set-

point.

• For position capture, the H3 module needs an incremental shaft en-

coder that supplies at least two square-wave signals in phase quadra­ture.

Block diagram of a motion control drive with the H3 module

1 2 3 4 5 6

M

POWER

AMPLIFIER

PCD2.H31x

POSITION
COUNTER

PID
REGULATOR

10V

DISPLAY
(fak.)

Installation and commissioning PCD2.H31x

Page 9-2  SAIA-Burgess El ectronics Ltd. (2H3-09-E.DOC) 26/762 E2

9.2. Installation and wiri ng

When installing the PCD2 system particular attention should be paid to
the points listed below. Before powering up the system, a visual check of
the installation and wiring should be made as follows:

• Has the overall PCD1/2 system suffered any damage during trans-

portation or assembly?

• Is the H3 module plugged into the space provided on the PCD1/2

bus and is the wiring complete on the relevant bus module?

• Wiring and connection of user supply:

The H3 module must have a smoothed, +24 V DC supply voltage
(19..32 V, max. ripple 10%) at the "+" and "-" terminals.

• System earth

For fault-free operation, a perfect earth to divert external noise volt­age is indispensable. The PCD1/2 system should be connected to the
"GND" terminal (24 VDC -) with the largest possible cross-section
on the earth rail of the control box. It should further be ensured that
all earth lines have been laid without loops.

• Laying the cables

Regulations prescribe the laying of high-voltage cables and control
cables in separate cable channels.

• Motor controller output (±±±± 10V analogue)

Check connections as described in manual, chapter 5.5. The cable
must be shielded.

• Enable for the driver is triggered through a "normal" digital output of

the PCD1/2.

• Encoder connections

For special attention with the 5V encoder:

• Cable must be shielded and lines must be in twisted pairs.

• Max. cable length 20m, min. conductor cross-section 0.25mm2. In

addition, check that encoder is correctly mounted (no slippage in
coupling), check type and technical data (impulses per revolution).

• Ref (for PCD2.H310) wire directly

• LS1 / LS2, for PCD2.H311 also Ref, wire to "normal" digital inputs of

PCD1/2.

PCD2.H31x Installation and commissioning

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9.3 Commissioning drive without mot ion control module

The drive alone (power stage and motor) is commissioned first, without
the motion controller. The following measures are necessary:

• Release connection of the H3 module’s controller output "Out" (+

10V) to the power stage at terminals 6 and "-" (minus) of the H3
module.

• The PCD1/2 and H3 module have been switched off. If this is not

possible, execute point 9.4.1 first (switching on the supply voltages).

• The drive’s emergency stop limit switches should be set to prevent

any damage arising from uncontrolled axis motion.

Commissioning of the power stage and motor can now take place ac­cording to the supplier’s instructions.

Installation and commissioning PCD2.H31x

Page 9-4  SAIA-Burgess El ectronics Ltd. (2H3-09-E.DOC) 26/762 E2

9.4 Drive with motion control module

9.4.1 Switching on the supply voltages

This step can also take place before commissioning the power stage and
motor, however, it is necessary to ensure that the axis cannot make any
uncontrolled movements (power stage off-voltage, controller release in­terrupted).

When the supply voltage of the PCD1 or PCD2 and H310 or H311 mod­ule is powered up for the first time (programming unit disconnected) the
control LEDs should be noted

on the PCD1:

Meaning LED Behaviour

24 VDC yellow 'Supply voltage present': must be on
Run yellow 'CPU in Run': not on, as no program has been

loaded

Error yellow should not be on

on the PCD2:

Meaning LED Behaviour

24 VDC yellow 'Supply voltage present': must be on
Battery red 'Battery' (fail): should not be on
Watch Dog yellow Watch Dog inactive: not on (as no program has

been loaded).

Run yellow 'CPU in Run': not on, as no program has been

loaded
Halt red 'CPU in Halt' is on, as no program is present
Error yellow should not be on

on the motion control module PCD2.H310:

Meaning LED Behaviour

Power yellow

shows the presence of ± 15V: must be on
Ref (H310) yellow Reference switch

on the motion control module PCD2.H311:

Meaning LED Behaviour

Power yellow

shows the presence of ± 15V: must be on
Pw 5V yellow 5V supply for encoder: must be on

PCD2.H31x Installation and commissioning

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9.4.2 Preparing a basic user program

For commissioning a drive with the H3 module, a basic user program
should be loaded into the PCD1/2 so that all checks and adjustments can
be made. The "simple commissioning program" in section 6.1.3 can be
used for initial trials. A comprehensive tool (Commissioning Tool), in­cluding limit and reference switches, is described in chapter 10.

Preparation of the user program comprises the following steps:

• Installation of the PCD9.H31E programming package, according to

section 7.1.1.

• Opening a new project.

• Copying in the D2H310_B.MBA file.

• Adjusting the D2H310_B.MBA file with the number of H31x

modules and their base addresses.

• Definition of the machine data.

• Adjusting (parameters in FB INIT and path to travel back and forth)

and loading the commissioning program

Evaluation of 'fPar_Err' flag

Evaluation of this flag is particularly recommended for commissioning.
This flag is only present once for all axes in a project.

After the flag has responded it is possible to view the cause of the error in
the PCD register 'rDiag'. See section 8.2.1.

The user is responsible for resetting the 'fPar_Err' flag.

Installation and commissioning PCD2.H31x

Page 9-6  SAIA-Burgess El ectronics Ltd. (2H3-09-E.DOC) 26/762 E2

9.4.3 Determining machine data

Before commissioning for the first time, various parameters for FB 'Init'
should be determined, some of which are already fixed by the machine,
whereas other are recommended as test values.

Position tolerance → see FB 'Init', par. 7, manual page A-1/2

Recommended value 1 encoder revolution

When an encoder has 500 imp./revolution, this parameter has the value
2000 = 4 * 500 imp./revolution (evaluation of encoder impulse edges).

PID factors → see FB 'Init' manual page A-1/2
Recommended start values:

Proportional factor (Parameter 2): 10
Integral factor (Parameter 3): 0
Differential factor (Parameter 4): 0
Integration limit (Parameter 5): 30000
Sample time D portion (Parameter 6): 15 (= 5.61 msec.)

Machine factor FB 'Init', PCD register for parameter 9 (floating-

point format)

This factor results from the resolution of the encoder used, the spindle
gradient and any gears.

Important: The unit of measurement chosen here (m, cm, mm, 1/10mm,

1/100mm, µm) must also be used for the velocity (par. 10),
acceleration (par. 11) and all values relating to path, break­point, velocity and acceleration throughout the user program
for this axis.

4 x In

Assume: k = ------- [impulses/unit of measurement]

s

where In: impulses/revolution (encoder resolution)

s: path/revolution (spindle gradient and gears)

PCD2.H31x Installation and commissioning

26/762 E2 (2H3-09-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 9-7

Example: In = 1000 impulses per revolution

s = 2 mm (spindle gradient) (no gears)

4 x 1000

k = ----------- = 2000 impulses/for 1 mm

2

= 2 impulses for 1 µm

If the chosen unit of measurement is 1 mm, a value of 2000.0 (floating­point format) should be written in the PCD register for parameter 9. If
the chosen unit of measurement is 1 µm, a value of 2.0 (floating-point
format) should be entered.

Velocity FB 'Init', PCD register for parameter 10
When commissioning for the first time, it is advisable to work with a low

velocity. The value should be entered as an integer in the PCD register
provided, using the same unit of measurement as the machine factor.

Recommendation: 0.05 m/s → 50 mm/s or 50000 µm/s

Ensure that the chosen drive can actually achieve the velocity of its pa­rameter, otherwise the controller continuously detects a deviation from
the target velocity and adds up these deviations. This will then lead to an
incorrect braking ramp or to an abrupt halt of the motion.

Acceleration FB 'Init', PCD register for parameter 11
When commissioning for the first time, it is advisable to work with a low

acceleration. The value should be entered as an integer in the PCD reg­ister provided, using the same unit of measurement as the machine factor.

Recommendation: 0.01 m/s

2

→ 10 mm/s2 or 10000 µm/s

2

Before starting any motion, check encoder function by manually moving
the axis (amplifier powered off). See also section 9.4.5.

Installation and commissioning PCD2.H31x

Page 9-8  SAIA-Burgess El ectronics Ltd. (2H3-09-E.DOC) 26/762 E2

9.4.4 Direction, path measurement (encoder)

To check direction of rotation and path measurement, the following pre­conditions must be met:

• The connection between the H3 module’s controller output (+ 10V)

and the power stage has been released at terminals 6 and GND for the
H3 module’s axis.

• The PCD1/2 has been switched on (commissioning program loaded)

and is in "Run".

• The programming unit is connected and the commissioning software

has been started. All the necessary adjustments have been made in
the "Configure" menu. These settings must agree with definitions in
the D2H310_B.MBA file.

For the following tests, a display of actual position is viewed.

Checking the direction:

1. Rotate drive shaft in a positive direction

→ actual position must increment

2. Rotate drive shaft in a negative direction

→ actual position must decrement

If this is possible, the drive shaft can be turned by hand. Otherwise it
must be moved by applying a set value (using a voltage source of + 0.5 ..
10V) to the power stage.

Definition of positive and negative directions:

• Positive direction corresponds to the direction moved when a positive

setpoint voltage is applied (0...+10V) at the power stage.

• Negative direction corresponds to the direction moved when a negative

setpoint voltage is applied (0...-10V) at the power stage.

• If behaviour is the reverse, both phase signals A and B of the encoder

should be exchanged.

PCD2.H31x Installation and commissioning

26/762 E2 (2H3-09-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 9-9

Checking path measurement:

Turn drive shaft through one revolution and observe display of actual po­sition.

A path value corresponding to the machine factor k (parameter 9 in
FB 'Init') must be displayed as the actual position. If the display is incor­rect, recheck the calculation and entry of machine factor 'k'.

Checking the index signal IN:

This check is only necessary if the index signal (also called zero impulse)
is evaluated by the encoder to define the zero position.

Procedure:
(All the following actions are carried out manually by commands from
the commissioning program.)

1. Observe display of index position register → any value is dis-

played.

2. Execute the instruction 'SetIdxPos'.

→ When the next index impulse is captured, the actual position is
written in the index position register.

3. Turn the axis until the actual position is written in the index posi­tion register.
The position must be written to the register once within an en­coder revolution.

4. Execute the instruction "SetIdxPos" again and check whether,
during a revolution, the current position is written once only to the
register.

If the check produced another result, this may be due to the following:

• Faulty encoder

• Encoder signals A, B and IN are not in the order required at the H3

module’s position decoder input.

If the order of encoder signals is not known, it must be established with
the help of an oscilloscope.

Installation and commissioning PCD2.H31x

Page 9-10  SAIA-Burgess Electronics Ltd. (2H3-09-E.DOC) 26/762 E2

9.4.5 PID controller

To check and tune the PID controller, the following preconditions must
be met:

• With the controller powered off, the control circuit is closed by re-

connecting the setpoint cable of the power stage to terminals 6 and
GND of the H3 module.

• Power up the controller:

CAUTION: Activate emergency stop if the axis should proceed out of
control.

• The programming unit is connected and commissioning software has

been started.

Checks:

1. Load destination position 0 and execute start instruction.
→ The H3 module regulator is switched on and the axis is held in
its position by the regulator.

2. Load a destination position that is located within the allowed trav­elling range and start motion.
→ The axis runs towards the fixed destination position.

Incorrect behaviour:

• The axis runs at maximum velocity.

Possible cause

• Position control circuit (H3 module) or speed control

circuit (power stage) incorrectly poled.
This means that, when the setpoint voltage is posi­tive (= positive destination position) motion in the
axis is in a negative direction.

• The H3 module’s analogue output is faulty and sup-

plies a constant, maximum voltage of approx. +12V
or –12V to the controller output.

Remedy

• Check direction, execute section 9.4.4 once again

and make the necessary changes to poling.

• Change the H3 module.

PCD2.H31x Installation and commissioning

26/762 E2 (2H3-09-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 9-11

• The axis runs at a constantly slow velocity (drift).

Possible cause

• The setpoint is not reaching the power stage, regula-

tion is not active in the H3 module.

Remedy

• Check wiring.

• Check whether, after the 'StartMot' instruction, the

profile generator in the H3 module outputs a target
velocity (instruction 'RdTargVel'), which means that
the regulator in the H3 module is working correctly.

• The axis starts running briefly, and stops again.

Possible cause

• Position error monitoring has responded and stopped

the drive. (The motor cannot follow the motion de­fined)

Remedy

• Correct possible mechanical problems.

• Adjust velocity and acceleration.

• Increase max. value for position error.

• The axis runs jerkily to an incorrect destination position.

Possible cause

• Loose mechanical connection of encoder and motor

(coupling).

Remedy

• Correct possible mechanical problems.

When approaching the destination position a persistent position error is
noticeable. This is accounted for by the permanent control deviation in a
straight P controller (I and D factors are 0).

In a subsequent step, therefore, control factors must be determined which
achieve the desired quality of regulation (accuracy and hardness).

The set-up rules indicated below have arisen from experience in practical
applications and tests.

Installation and commissioning PCD2.H31x

Page 9-12  SAIA-Burgess Electronics Ltd. (2H3-09-E.DOC) 26/762 E2

Setting the proportional factor (kp):

1. Set a small proportional factor (experience recommends 10).
Integral and differential factors must be 0 (→ straight P control­ler).

2. Travel slowly with the axis (approach destination position or use
the 'GoForw'/'GoBackw' functions)

3. Increase the kp factor gradually until the control circuit starts to
pulse. Then reduce that value by approx. 30% and load it as the
kp factor. This sets the proportional factor and should not be
changed further for the time being.

Setting the integral factor (ki):

The ki factor is gradually increased until the desired settling time is
achieved for the position error. This sets the integral factor and should
not be changed further for the time being.

If excessive overshoot is noticed when approaching the destination posi­tion, this may be due to the following:

• The chosen rate of acceleration or braking is too high. The motor

cannot follow the setpoint. → Reduce acceleration.

• The same behaviour can also result when the chosen velocity is too

high.

• The chosen ki factor is too high.

• Practice has shown that, if the integral factor is increased and the dif-

ferential factor is left at zero, the tendency of the controller to pulse
rises. → The differential factor should be increased simultaneously
with the integral factor to reduce overshoot.

Observing the integration sum (instruction 'RdIntSum') is a good way of
tracking such behaviour. During motion, if the integration sum adds up to
a high value, overshoot can be expected.

Action: - Reduce the above parameters.

- Limit the integration sum (instruction 'LdIntLim').

PCD2.H31x Installation and commissioning

26/762 E2 (2H3-09-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 9-13

Setting the differential factor (kd):

The kd factor is gradually increased until the desired overshoot width or
settling time is achieved for the position error. This also sets the differen­tial factor.

Set-up rule for sample time (instruction 'LdSampInt') in the D portion:
For operation at low velocities, opt for a rather large sample time.
Experience shows that sample time values generally lie between 2 ms and
9 ms. This corresponds to values 5 and 25 in the instruction 'LdSampInt'.

Optimization of settings:

If regulation does not proceed satisfactorily after values have been set as
above, a further attempt must be made to vary individual parameters, so
that a satisfactory result is achieved.

Installation and commissioning PCD2.H31x

Page 9-14  SAIA-Burgess Electronics Ltd. (2H3-09-E.DOC) 26/762 E2

9.4.6 Effect of individual factors on controller behaviour

Increasing the kp factor heightens the tendency to overshoot but equally
reduces the permanent control deviation and increases controller hard­ness.

Raising the ki factor heightens the tendency to overshoot, but simultane-
ously ensures faster settling of the position error.

A correctly adjusted kd factor stabilizes the system and ensures less
overshoot and a shorter settling time. If the kd factor is too high, it pro­duces pulsing in the system.

PCD2.H31x Installation and commissioning

26/762 E2 (2H3-09-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 9-15

9.4.7 Simple commissioning program

A convenient, graphical commissioning tool in FUPLA is described in
chapter 10.

The following is an extremely simple user program for forward and back­ward motion with actual position display, using a single axis. The parameters
suggested above have been applied:

(Explanatory notes on this user program can be referred to in section

6.1.1: "Entry-level example in IL with wait loops").

$include D2H310_B.equ
$group H310

xob 16

LD R 1000

2.0 ; Mechanical factor

LD R 1001

50000 ; Initial absolute speed

LD R 1002

10000 ; Initial absolute acceleration

CFB Init ; Initialization FB

K 1 ; Module number

10 ; Proportional factor (regulator)
0 ; Integrative factor (regulator)
0 ; Derivative factor (regulator)
30000 ; Integrative limit value
15 ; Derivative term sampling interval
2000 ; Position tolerance

1 ; Behaviour in case of position error
R 1000 ; Mechanical factor register
R 1001 ; Initial velocity register
R 1002 ; Initial acceleration register

exob
; --------------------------------------------------------­;

cob 0

0

start: sth i 0 ; 'Start' OK?

CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position

R 90 ; Result register

DSP R 90 ; Display register

jr l start ; if 'Start' not OK, wait

LD R 100 ; Target Position

10000 ; Absolute value

CFB Exec ; Executable FB

K 1 ; Module number

LdDestAbs ; Command: Load Absolute Destination

R 100 ; Absolute Destination register

Installation and commissioning PCD2.H31x

Page 9-16  SAIA-Burgess Electronics Ltd. (2H3-09-E.DOC) 26/762 E2

pos1: CFB Exec ; Executable FB

K 1 ; Module number

StartMot ; Command: Start motion
rNotUsed ; Dummy register

CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position

R 90 ; Actual Position register

DSP R 90 ; Display register

CFB Exec ; Executable FB

K 1 ; Module number

RdStatRg ; Command: Read Status Register

R 0 ; Value of Status Register

STH fOnDest_1 ; Position reached?

jr l pos1 ; if no, wait

ld t 0

50

pause1: sth t 0

jr h pause1

LD R 100 ; Target Position

0 ; Absolute value

CFB Exec ; Executable FB

K 1 ; Module number

LdDestAbs ; Command: Load Absolute Destination

R 100 ; Absolute Destination register

CFB Exec ; Executable FB

K 1 ; Module number

StartMot ; Command: Start motion
rNotUsed ; Dummy register

pos2: CFB Exec ; Executable FB

K 1 ; Module number

RdActPos ; Command: Read Actual Position

R 90 ; Result register

DSP R 90 ; Display register

CFB Exec ; Executable FB

K 1 ; Module number

RdStatRg ; Command: Read Status Register

R 0 ; Value of Status Register

STH fOnDest_1 ; Position reached?

jr l pos2 ; if no, wait

ld t 0

50

pause2: sth t 0

jr h pause2

ecob

$endgroup

PCD2.H31x Commissioning tool

26/762 E2 (2H3-10-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 10-1

10. Commissioning Tool

The PCD8.H31 diskette includes a programming tool for use during
commissioning entitled 'comtool-fup'. This tool offers a moderate level of
user comfort and is based on the PG4’s FUPLA program from version
V2.0.70.

The program consists of an organization FBox, an FBox for the initializa­tion of a PCD2.H31x, an FBox with a simple path program enabling the
online modification of all PID parameters (for the purpose of optimizing
control behaviour) and all path parameters, plus a final FBox that allows
the creation and online modification of a path program with any 4 se­quences. The optimum PID parameters determined in this way are trans­ferred to the final user program (FB 'Init' and possibly an additional FB
'Exec' to adjust individual PID parameters).

This is how the tool appears on the screen. The adjust window for the FBox
with the simple path program is open.

PID parameters are set individually, transferred separately and then acti­vated together with 'Update'.

Commissioning tool PCD2.H31x

Page 10-2  SAIA-Burgess Electronics Ltd. (2H3-10-E.DOC) 26/762 E2

The following keys are used to activate a single path (Start Step), back­and-forth path (Start Cycle) or continuous back-and-forth path (Start for­ever). The 'Waiting time' parameter can be used to define a pause after
each sequence in the path program. It is also possible to travel forwards
or backwards as desired (Go forward or Go backward) and to stop travel
smoothly (Stop smooth) or abruptly (Stop abrupt). With 'Set Zero' any
position can be declared as the new zero position. It is also possible to
switch off the motor control (Motor off) or find the next index position.

PCD2.H31x Commissioning tool

26/762 E2 (2H3-10-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 10-3

The adjust window of the previously described FBox for simple back­and-forth travel by the carriage is shown below in full size.

As before, PID parameters are set individually, transferred separately and
then activated together with 'Update'.

Parameters in the lower section, i.e. those for the path program, are trans­ferred immediately after confirmation.

Commissioning tool PCD2.H31x

Page 10-4  SAIA-Burgess Electronics Ltd. (2H3-10-E.DOC) 26/762 E2

Adjust window of the initialization FBox.

Parameters are only transferred after a download. The parameters of this
adjust window, therefore, should be set before compiling and before
downloading to the PCD.

PCD2.H31x Commissioning tool

26/762 E2 (2H3-10-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 10-5

The last of the 4 FBoxes can be used to create a path program with any 4
desired sequences. In each sequence all parameters can be set individu­ally and modified online.

Operation is the same as for the simple 'back-and-forth' program. With
the 'Start Step' button, individual sequences are set off one after the
other. 'Start Cycle' is used to start a single complete sequence and 'Start
for ever' keeps the cycle of sequences moving until 'Stop ...' or 'Motor
Off' interrupts it. The 'Waiting time' parameter can be used to define a
pause after each sequence. It is also possible to move back or forth as de­sired (Go forward or Go backward) and to bring the path to a halt
smoothly (Stop smooth) or abruptly (Stop abrupt). 'Set Zero' enables any
position to be declared as the new zero position. It is also possible to
switch the motor control off (Motor off) or to seek the next index posi­tion (Backwards or Forwards). Positions, velocity and acceleration can
be set with 'Absolute' or 'Relative' parameters.

Commissioning tool PCD2.H31x

Page 10-6  SAIA-Burgess Electronics Ltd. (2H3-10-E.DOC) 26/762 E2

The adjust window for the FBox with a 4-sequence cycle appears as fol­lows: (The values entered serve only as an example, but work well with
the V-PCX 24 demonstration model).

PCD2.H31x Commissioning tool

26/762 E2 (2H3-10-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 10-7

(Adjust window, continued)

For the best possible commissioning, a storage oscilloscope to display the
±10V control voltage should also be available, as this is the only way of
viewing controller behaviour under the various loads and optimizing its
settings. Unfortunately, the present commissioning tool does not include
this display.

Commissioning tool PCD2.H31x

Page 10-8  SAIA-Burgess Electronics Ltd. (2H3-10-E.DOC) 26/762 E2

Description of the commissioning tool’s individual FBoxes

The commissioning tool appears as follows:

The delay time on the lower margin is not present in the original tool. It is
advisable not to release the motor control until the CPU’s self diagnostic
is completed. This prevents the carriage from making any uncontrolled
jump when the controller is switched on.

FBox 'H31-Library'

Organization FBox. Must be located at the beginning of a tool page. This
FBox has no inputs or outputs and no adjust window either.

FBox 'H31-Module'

Initialization of PCD2.H31x module.
The module base address should be written in the 'Add' window, e.g. O 80.

FBox outputs:
'PEr' binary Position error
'PAc' integer Actual position

Adjust window: see page 10-4

PCD2.H31x Commissioning tool

26/762 E2 (2H3-10-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 10-9

FBox 'H31-Tuning'

Simple back-and-forth path program to seek and optimize the best possi­ble parameters.

FBox outputs:
'OnD' binary On destination
'PEr' binary Position error
'PAc' integer Actual position (in units of length)
'PIm' integer Actual position (in impulses) *)
'Vel' integer Actual velocity
'IdX' integer Index register
'Sta' integer Status register

Adjust window: see page 10-3

FBox 'H31-Tuning-Exp.'

FBox with path program comprising any 4 sequences, whose parameters
can be set individually.

FBox outputs:
'OnD' binary On destination
'PEr' binary Position error
'PAc' integer Actual position (in units of length)
'PIm' integer Actual position (in impulses) *)
'Vel' integer Actual velocity
'IdX' integer Index register
'Sta' integer Status register

adjust window: see page 10-6/7

*) The 'PIm' output shows the result of multiplying the 'PAc' output

value by the 'Mechanical Factor'.

Commissioning tool PCD2.H31x

Page 10-10  SAIA- Burgess Electronics Ltd. (2H3-10-E.DOC) 26/762 E2

Notes

PCD2.H31x Security aspects

26/762 E2 (2H3-11-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 11-1

11. Security aspects

If a drive unit is triggered with a PCD2.H31x module, particular attention
should be paid to the following points:

Drive power-up phase

When the main supply for the PCD has been switched on, it takes max. 2
seconds before all input/output modules are initialized, the CPU is in
RUN and the user program can therefore be processed.

During this power-up phase (max. 2 seconds), the analogue controller
output of the H3 module have any value between -10V and +l0V. For this
reason it is absolutely necessary that the power section of the drive
should either be switched on or released by the user program through a
digital output. This guarantees that the drive does not proceed out of
control during this power-up phase.

Monitoring the position error

(See flag 'fPosErr_x')

Exceeding the permitted position error signals serious problems and
should therefore always be monitored.

The following causes can result in exceeding the position error:

1. Connection fault in the H3 installation.
Examples: - loose connection

- directional mismatch in rotation of motor and
incremental shaft encoder.

2. Badly adjusted PID parameters

3. The size of drive (amplifier and/or motor) is not strong enough.

4. Wrong choice of motion parameters. The servo-amplifier or motor
cannot follow the acceleration or velocity ordered by the H3 module.

5. Blocked rotor in servomotor due to mechanical problems.

6. Hardware error in H3 module (e.g. faulty analogue controller output).

7. Hardware error in servo-amplifier.

If points 1 to 4 account for the position error being exceeded, this is usually
discovered during commissioning and can be remedied immediately.

Security aspects PCD2.H31x

Page 11-2  SAIA-Burgess Electronics Ltd. (2H3-11-E.DOC) 26/762 E2

If points 5 to 7 account for the position error being exceeded, this can
also occur after commissioning. To avoid damaging the machine, the fol­lowing measures are necessary:

Permanently monitor the 'fPosErr_x' flag (which signals that the position
error has been exceeded) from the user program and, in case of error,
disconnect the drive via a digital output.

There are different ways of disconnecting the drive. With some drives it
is enough to withdraw the controller release at the power section. With
others again it is necessary to reduce drive speed as quickly as possible
by braking (shorting out the setpoint input at the power section) and to
disconnect the main supply with a time delay (of a few milliseconds).
However this disconnection can or must take place depends on the ma­chine concerned and must be decided on a case by case basis.

Limit Switches

These can be used in different ways:

• in connection with the 'Home' function to find the zero position

when the installation is powered up

• as an alarm message in the user program to signal that the posi-

tion has been exceed (if appropriately located and programmed)

Security limit switches

The security limit switches (emergency-off limit switches) should always
disconnect the drive directly. (Cut main supply to drive.)

Watchdog

Always activate the PCD’s watchdog and use the watchdog contact to
disconnect the drive directly.

X0Bs for PCD hardware errors

Program XOBs 0 to 5 and, if necessary, disconnect the drive directly via
a digital output.

PCD2.H31x Application examples

26/762 E2 (2H3-12-E.DOC)  SAIA-Burgess Electronic s Ltd. Page 12-1

12. Application ex amples

12.1 Example: 1 axis with homing

This example concerns the simple backward and forward motion of a car­riage as already described in chapter 6: "Quick start". The present exam­ple additionally includes the reference switch and both limit switches at
either end of the range of travel for automatic homing.

The hardware is based on workshop model V-PCX 24 and consists of the
slide with DC motor, reference switch, limit switches and final limit
switches, the servo-amplifier with emergency switch, the supply and a
PCD2 with 6-digit display.

When fully assembled and wired up, the model has the following presen­tation:

H311

E110

Start

PCD2

0163248

648096112

B100

9876543210

A7 A6 E /A5 E/A4 E/A3 E/A2 E1 E0

9876543210

5V Out /IN IN / B B / A A

Carriage

Shaft encoder

DC

motor

0VServo amplifier

Enable +/-10V

EOFF2EOFF1

LS2

LS1 Ref

Supply 24 VDC

230 VAC

Emergency

stop

Application examples PCD2.H31x

Page 12-2  SAIA-Burgess Electronics Ltd. (2H3-12-E.DOC) 26/762 E2

Data for carriage:

Encoder: 500 impulses/revolution
Spindle: gradient 2 mm
Maximum velocity: 100 mm/s
Max. permissible acceleration: 50 mm/s

2

After homing, directly following system power-up, the following motion
sequence should be executed:

Homing

Before presenting the overall user program, homing should be looked at
more closely.

The arrangement of switches on the model is roughly in line with the
above drawing. During normal program execution the carriage is in the
position illustrated.

Pos. = 0 Pos. = 150 mm

Pos. = 0

t = 5 sec

100 mm/s

+V

+V

- V

t

400 mm/s2

LS1 Ref LS2

Carriage

forwards (+ V)

backwards (- V)

PCD2.H31x Application examples

26/762 E2 (2H3-12-E.DOC)  SAIA-Burg ess Electronics Ltd. Page 12-3

An assumption is made that, in normal cases, the carriage is located be­tween the positions 'Ref' and 'LS2'. For homing, the carriage should travel
in the direction of the reference switch, i.e. searching in a 'backwards' di­rection. On reaching the reference switch it should travel freely in a for­wards direction until it arrives at the next index signal of the incremental
shaft encoder. This means that the reference position has been reached
and the travel program can start.

For this purpose, the following parameters should be set for FB 'Home':

LD R 1010 ; PCD register with velocity for free

500 ; travel of the reference switch (slow)

LD R 1011 ; PCD register with velocity for seeking

5000 ; the reference switch (fast)

CFB Home ; Call FB 'Home'

K 1 ; Par 1: Module number

0 ; Par 2: Search backwards

1 ; Par 3: Free travel forwards
R 1010 ; Par 4: Velocity for free travel
R 1011 ; Par 5: Velocity for search

30 ; Par 6. Timeout 30s
I 64 ; Par 7: Reference input address

Behaviour under various starting positions:

a) Starting position 'normal' (carriage between 'Ref' position and

'LS2'): Behaviour as described above. If the reference point is
not found within a defined timeout, homing is halted. If the ref­erence switch is activated on power-up (carriage located on ref­erence switch), free travel only takes place and travel to the next
index signal.

b) Starting position with carriage between 'LS1' and 'Ref': The car-

riage first travels backwards to 'LS1', then forwards to reference
switch 'Ref'. The reference switch is travelled over at the veloc­ity of free travel. After this free travel, it again travels on until it
reaches the next index signal of the incremental shaft encoder.
This means that the home position has been reached and the
travel program can start.

c) Starting position located to the right of 'LS2': Homing proceeds

as with a). 'LS2' is travelled over and does not affect homing.

d) Starting position located to the left of 'LS1'. The carriage travels

backwards as defined until the final limit switch. The home po­sition cannot be found. If the final limit switch is not reached
within the defined timeout, homing is halted.

Application examples PCD2.H31x

Page 12-4  SAIA-Burgess Electroni cs Ltd . (2H3-12-E.DOC) 26/762 E2

User program in GRAFTEC (int-home.sfc)

Initialization occurs in IST. Homing is then executed (ST 1). ST 1 will run
through continuously until homing is complete. The end of homing is sig­nalled by the 'fEndHome_x' flag. Before calling the 'Home' FB, limit
switches 'LS1' and 'LS2', which are wired to digital PCD inputs, must be
read into flags 'fLS1_x' and 'fLS2_x'.

After completion of homing the program goes to TR 53, where the start
condition of the actual travel program is awaited.

Consult section 6.1.2 for a description of the travel program.

PCD2.H31x Application examples

26/762 E2 (2H3-12-E.DOC)  SAIA-Burg ess Electronics Ltd. Page 12-5

Program code for "int-home.sfc"

(To obtain this representation, rename the file "int-home.sfc" as
"int-home.src").

SB 0

;-------------------------------

IST 10 ;Initialization

O50

$include D2H310_B.equ
$group H310

LD R 1000

1.00 ; Mechanical factor

LD R 1001

100000 ; Initial absolute speed

LD R 1002

400000 ; Initial absolute acceleration

CFB Init ; Initialization FB

K 1 ; Module number

250 ; Proportional factor (regulator)
0 ; Integrative factor (regulator)
60 ; Derivative factor (regulator)
4000 ; Integrative limit value
5 ; Derivative term sampling interval
500 ; Position tolerance
0 ; Behaviour in case of position error
R 1000 ; Mechanical factor register
R 1001 ; Initial velocity register
R 1002 ; Initial acceleration register

ld t 0 ; Delay for Enable

20 ; 2 sec

EST ;10

Application examples PCD2.H31x

Page 12-6  SAIA-Burgess Electroni cs Ltd . (2H3-12-E.DOC) 26/762 E2

;-------------------------------

ST 11 ;Home

I50
I 52 ;Home running ?
O 51 ;Home ended ?
O 52 ;Home running ?

set o 71 ; Enable
res fEndHome_1

stl i 65
out fLS1_1

stl i 66
out fLS2_1

ld r 1010

1000

ld r 1011

10000

cfb home

k 1 ; Module number

0 ; search direction

1 ; free run direction
r 1010 ; min. speed
r 1011 ; max. speed

50 ; timeout
i 64 ; input reference switch

EST ;11

;-------------------------------

ST 12

I 51 ;Home ended ?

I 57 ;Pause 2 elapsed ?

O 53 ;Start OK ?

EST ;12

;-------------------------------

ST 13 ;Move forwards

I 53 ;Start OK ?

O 54 ;Move forwards ended ?

LD R 100 ; Target Position

60000 ; Absolute value

CFB Exec ; Executable FB

K 1 ; Module number

LdDestAbs ; Command: Load Absolute Destination
R 100 ; Absolute Destination register

CFB Exec ; Executable FB

K 1 ; Module number

StartMot ; Command: Start motion

rNotUsed ; Dummy register

EST ;13

;-------------------------------

ST 14 ;Pause 1

I 54 ;Move forwards ended ?

O 55 ;Pause 1 elapsed ?

ld t 0

50

EST ;14