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Motion Mate DSM302 for Series 90

1. GFK 1464C Appendix DSM Parameter Download Using the COMM_REQ Instruction B 13 B 14 In order to facilitate loading single precision registers 16 bits with double integer parameter values 32 bits you could use the Multiply DINT instruction to initialize the PLC registers that will CONST IN Q R0205 00205 LEN 00001 SEND 0001 MOVE_ WORD CMDTYP CONST IN Q R0202 E501 LEN 00001 SEND TOO01 MOVE_ INT DATAST BYTECNT CONST IN Q R0203 00068 LEN 00001 PAR_NO CONST IN Q R0206 00001 LEN 00001 MEMTYP CONST IN Q R0204 00008 LEN 00001 NO_VALS CONST IN Q R0207 00016 LEN 00001 KKK KK KKK KKK KK KK KK KK KK KKK KK KKK KK KKK KK KKK KKK KKK ckckckckckckckck ck ck ck ck k k k KK k k k k k k k k ADD LOGIC HERE TO MOVE THE PROPER DATA INTO THE REGISTERS 208 R239 SO THEY CAN BE SENT TO THE DSM302 PARAMETERS FOR EXAMPLE THE VALUE IN R208 R209 WILL BE SENT TO PARAMETER 1 NOTE THAT THE PARAMETERS ARE DOUBLE VALUE IN R210 R211 WILL BE SENT TO FINALLY THE VALUE IN R238 R239 WILL BE SENT TO PARAMETER 16 Coke ke E Fe ek koe ke e He He ke kc ek kc ke ck k INTEGER SIZE LIKEWISE THE PARAMETER 2 AND SO ON UNTIL
2. 06 Status Only lr Status Only tatus Only Program Acceleration too small defaulted to 32 cts sec sec tatus Only Scaled Velocity greater than 1 million cts sec 1 million cts sec is used ta 2 5 5 5 Axis Axis Axis Axis Axis se los 11 2 Configuration Errors tatus Only tatus Only ta i 10 Status Only Axis i i i i Axis overflow value tus Only Axis i i Axis tus Only 2 Axis Axis Axis Axis Axis Stop Normal Program Position too large Axis Axis Axis Axis Axis tus Only Program Velocity is zero defaulted to 1 count sec used Stop Normal Unconditional Jump Destination not found Stop Normal Jump Mask error Stop Normal Stop Normal Parameter Position too large atus Only Dwell time greater than 60 seconds 5 seconds used t Position Increment Errors t atus Only Position Increment Overrange error increment ignored Axis Find Home Errors Find Home while Drive Not Enabled error is is is is S S S S 2 15 si Find Home while Program Selected error Axi Axi Axi S 5 Find Home while Force Digital Servo Velocity error 5 5 Find Home while Jog error tus Only 1 Find Home while Move at Velocity error or 2 Find Home while another Find Home Cycle is still active User executed the Find Home command 1 while executing a Move at Velocity 22h AQ command or 2 while another F
3. Position Strobe 1 5 Position Strobe 1 5v N A N A N A 5 5 5 5 5 5 5 5 5 5 1 1 1 1 11 1 1 1 Position Strobe 2 5 5 5 09 10 11 Aux 3 Reserved 28 Follower Enabled Servoll 1 15 60 InputIN9 DQ4v Aw4 30 Reserved 1 62 DO4 Aw4 104 31 Reserved 1 96 Input 105 Dey Aux 104 Reserved 5 2 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C 1 01 Module Error Present This status bit is set when the DSM302 detects any error Errors related to Servo Axis 1 will be identified in the Servo Axis 1 Error Code AI word Errors related to Servo Axis 2 will be identified in the Servo Axis 2 Error Code AI word In follower mode errors related to the Aux Axis 3 position input will be identified in the Aux Axis 3 Error Code AI word Module errors not related to a specific axis will be identified in the Module Status Code AI word See section 2 AI Status Words for more details The Clear Error Q bit is the only command that will clear the Module Error Present 1 status bit and the associated Module Status Code and Servo Axis n Error Code AI word s If the condition causing the error is still present the Module Error Present 1 status bit will not be cleared 1 02 PLC Control Active Normally the PLC Control Active status bit i
4. H 6 Problems Resolved by Firmware Release 1 10 sene H 6 Encod r 3 Home Position ise ind ree Sars ive Roten e H 6 Module Sometimes Halted Responding to COMMREQ Commands H 6 xii Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Figure 1 1 Contents Hardware and Software Used to Configure Program and Operate a DSM302 Servo System 1 3 Figure 1 2 Simplified Standard Mode Position Loop with Velocity 1 9 Figure 1 3 Simplified Follower Mode Position Loop with Master Axis 2 4 44242221 1 10 Figure 2 1 Typical 2 Axis Motion Mate DSM302 Digital Motion Control System 2 2 Figure 2 2 Face Plate Connections on the Motion Mate DSM302 Motion Control System 2 5 Figure 2 3 SVU Amplifier Channel Switches esses eere trennen ens 2 7 Figure 2 4 Connecting the 04 Series Digital Servo Amplifier to the Motion Mate DSM302 2 8 Figure 2 5 Connecting the Motor to the amp Series Servo Amplifier Terminal Strip sss 2 9 Figure 2 6 Connecting the Series Motor Encoder sese 2 10 Figure 2 7 Connecting the Servo Amplifier to the Line Filter and Power Source sss 2 11 Figure 2 8 Connecting Emergency Stop to the Serie
5. C 4 Absolute Encoder Mode with Continuous Mode sss C 4 Restrictions when Absolute Encoder Mode is used with Continuous Mode C 5 Incremental Quadrature Encoder sss eene eere C 5 Appendix D Start Up and Tuning GE Fanuc Digital and Analog Servo Systems D 1 x Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Appendix E Appendix F Appendix G Appendix H GFK 1464C Contents Validating Home Switch Over Travel Inputs and Motor direction D 1 Digital Servo System Startup Troubleshooting D 3 Tuning a GE Fanuc Digital Servo Drive ener D 4 Tuning Requirements eee ea D 4 Tuning the Velocity Loop oc eit eR RR RATE e eee de Reo eR UE D 5 Method it lie ER ae D 5 Methodat2 aunt nonet ano ND D 5 Equation osos inen Det nm enm ama D 5 Sample Velocity Loop Tuning Session esses D 6 Tuning the Position Loop enne nennen D 12 Terminology iie noe esM IB emu D 12 High Bandwidth D 12 Analog Mode System Startup Procedures essere D 14 Startup 55 055 System Troubleshooting Hints Analog D 16 Using t
6. 2 26 Table 2 9 Additional Configuration Screen Information 2 esses 2 30 Table 3 1 DSM302 COMM Port Pin Assignments essere enne nennen 3 3 Table 3 2 Axis I O Connector Assignments esses eene 3 3 Table 3 3 Maximum Number of DSM Modules per System ccccesccesscesseceseceeeceeeeeeeeeseeeseeeeseeeeeeeseeeaes 3 6 Table 3 4 Digital Axis Terminal Board Pin Assignments esses enne 3 11 Table 3 5 Axis Terminal Board Assembly Components essere enne 3 13 Table 3 6 Auxiliary Terminal Board nennen 3 16 Table 3 Cables for the D SM O Z PURI THREE DAR NR CR ood ease soa E PRATER 3 18 Table 3 8 Separation of signal lines sess ener nennen enne nennen 3 21 Table 3 9 Signal Names Associated with OUT2 sese 3 25 Table 3 10 Connector Axis Assignment and Function eese nennen enne 3 25 Table 3 11 Circuit and Pin Assignments for Digital Servo Axis 1 and Digital Servo Axis 2 3 26 Table 3 12 Circuit and Pin Assignments for Analog Servo Axis 1 and Analog Servo Axis 2 3 27 Table 3 13 Circuit and Pin Assignments for Aux Axis 3 Connector 3 28 Table 3 14 Circuit and Pin Assignments for Aux Axis 4 Connector 0 3 29 Table 4 1 Module Configuration Data sess e
7. Velocity Jax At 24 X Distance VDA a r Let s take a look at the figure below Beginning at zero velocity the axis will accelerate in a positive direction ta run slew at velocity for some time t then decelerate back to zero velocity ty That s a complete move or move segment Looking at the figure below we can easily separate the different portions of the move A common rule of thumb is to divide the trapezoidal move into three time portions one third for acceleration one third at slew velocity and the remaining third to decelerate The slew X section of an equally divided trapezoidal velocity profile represents of the distance moved and the acceleration and deceleration portions each represent of the total distance The rule of thirds minimizes the RMS torque current in the motor and is the most economical use of energy 7 28 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Trapezoidal Move es Limits max motor speed Higher accel torque than triangle move Symmetrical profile 1 3 1 3 1 3 time maximizes power transfer to load Most common for long moves Velocity A acceleration time D deceleration X distance velocity peak t time acceleration t time at slew velocity t time deceleration T acceleration Torque Equations 0 51 1 0 51 T
8. AK IK KK KK I I KR OK k k k KR KK k k k k k k THE BLKMV BLOCK MOVE LOADS THE COMM REQ HEADER DATA NOTE THAT RO196 RO201 ARE IMPLIED ADDRESSES IN THE BLKMV INSTRUCTION kkkkkxkkxkxkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxk SEND LOAD T0001 t SEND STOOL eme STATUS CONST IN1 Q R0195 00099 CONST IN2 00004 CONST IN3 00000 CONST IN4 00008 CONST 5 00194 CONST IN6 00000 CONST IN7 00000 4 kkkkkxkxkxkxkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxk PUT THE COMMAND TYPE E501 hex IN THE FIRST DATA WORD R202 PUT THE BYTE COUNT OF THE DATA IN THE NEXT WORD R203 PUT THE MEMORY TYPE OF THE DATA 8 R IN THE NEXT WORD R204 PUT THE STARTING LOCATION OF THE DATA BLOCK IN THE NEXT WORD R205 PUT THE STARTING PARAMETER NUMBER 1 IN THE LOWER BYTE OF R206 AND THE NUMBER OF PARAMETERS TO BE SENT 16 IN THE LOWER BYTE OF R207 NOTE THE FIRST MOVE INSTRUCTION SHOULD BE A WORD TYPE TO FACILITATE ENTERING THE HEX VALUE E501 THE REST OF THE MOVE INSTRUCTIONS SHOULD BE INTEGER TYPES TO FACILITATE ENTERING DECIMAL VALUES kc kc kc kc kc kc kc kc kc
9. Jog Velocity Absolute Encoder Mode Load Parameter Immediate 5 28 Hi Lo Limits C 2 Move 5 22 Limitations on Total Travel C 2 Move At Velocity 5 19 Motion Mate DSM302 Power Up C 4 Null Restrictions when used with Continuous Mode Position Tnerement 5 19 Position Increment With Position Update 5 20 with Continuous Mode C 4 Position Loop Time Constant 5 23 Absolute Encoder Mode Considerations C 3 Rate Override Find Home Cycle C 3 Select Return Data Position Initialization C 3 Set Configuration Complete 5 28 Set Position Command Set Psion 320 Absolute Positioning 17 4 Velocity Feed pus UT AC Line Filter 2 11 2 17 Velocity Loop Gain ACCEL Command Program Zero 4 28 ol Status Bit Acceleration Axis Enabled Drive Enabled Drive OK Input 4 5 6 5 In Zone 5 5 Time Maximum 7 21 Module z Present 5 3 Types of Moving pner 5 i ctual Position AI Status Word 5 8 EL Na ar ived 5 3 Actual Velocity AI Status Word 5 9 Linear Ramp a 75 1 Follower Axis 8 10 S Curve PLC Control Active 5 3 Position Error Limit Analog Input Position Valid 5 4 Master 8 4 Program Active 5 5 Maximum Velocity Torque Limit Automatic Data Transfers I Status Bits Input Status Data 5 1 Follower Enabled 5 6 Output Command Data 5 1 Follower Velocity Limit Aux Axis 4 Pin Assignments 3 2 Position Strobe 1 Auxiliary Terminal Board 3
10. 0 QURE RT NEN 7 20 Example 14 S CURVE Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While 1 7 20 Other Programmed Motion Considerations cccsccesccessceseceseceeeeceeeseeeeeeseeeeseeesseeeaes 7 21 Maximum Acceleration Time eese rennen 7 2 Example 15 Maximum Acceleration Time sss 7 21 Feedhold with the 5 302 887 7 22 Example 16 ERE ERE 7 23 beedrate Override s i deer te ett eb E E 7 23 Example 17 Feedrate 7 24 Multiaxis 7 24 Example 18 Multiaxis Programming essere 7 24 Parameters PO P255 in the D8M302 sse ener 7 26 Calculating Acceleration Velocity and Position Values sese 7 28 Kinematic Equations to sb res ve Ya esed beri o Neben 7 2 Master SOUICES nb a n era n ee ep bere 8 1 Aux Axis 3 ENC 3 Master Input 8 2 Example 1 Following Aux Axis 3 Encoder Master Input esses 8 2 Internal Master Velocity Ge
11. 05 IN9 B 07 OT CTLO6 16 16 HOME CTLO7 INCOM_B STROBE1 CTLO8 35 35 OUT1P_B SSR OUT 18 18 OUT1M_B SSR OUT 36 36 OUT3P_B 14 14 5 OUT3M B DIFFERENTIAL 32 32 OUTPUT 105 STROBE1 oV B SINGLE ENDED 27 27 DRIVER 106_B STROBE2 10 10 i 5v OV B OV SINGLE ENDED 28 28 L DRIVER 8 SHIELD_B 1 AIN1P_B AIN1 7 ANALOG AIN1M B AIN1 INPUT E AIN2P AIN2 ANALOG AIN2M_B AIN2 Li o INPUT NOTES Denotes a negated signal See Chapter 6 for home switch information Figure 3 20 Analog Servo Axis 2 Connections 3 32 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Terminals IC693ACC336 Aux Terminal Board Aux TB Terminal Q5 RORF1 s oV C OV AES AE SINGLE ENDED au DRIVER 106 C STROBE2 5V oV C OV AND SINGLE ENDED NE DRIVER 1 INA 5V oV C OV AED SINGLE ENDED 7 DRIVER SHIELD C IN9 C 24V INPUT IN10 C 24V INPUT INPUT ALBH No C Ciia IN11 C HOME ENCODER 3 nie HOME SWITCH INCOM STROBE1 CTL146 24 VDC OUT1P C SSR OUT 5 24 125 MA OUT1M C SSR OUT OAD VDC OUT3P_C SN lourme 2X 7X OUT3M C DIFFERENTIAL OUTPUT SHIELD C C AINT 2 lt 11 gt Era AIN1M C AIN1 o _ INPUT AIN2P C AIN2 Ea AIN2M C AIN2 _ INPUT SHIELD C
12. I O Type Circuit Type Encoder Marker Encoder Marker Input Impedance or Input Maximum Input Voltage Logic 0 Threshold Logic 1 Threshold Input Filtering Quadrature Encoder Frequency Strobe Response Notes Chapter 3 Installing and Wiring the DSM302 Differential Single Ended 5v Inputs Source Input 9 4K ohm pulldown to Ov 9 4K ohms common mode to 0v 18 8K ohms differential t 15 v common mode 20 v differential 0 8 v max single ended 0 4 v max differential 2 0 v min single ended 1 5 v min differential 0 5 microseconds typical 250 khz channel 1 mhz count rate max with differential inputs 150 khz channel 600 khz count rate max with single ended inputs Quadrature Tolerance 90 degrees 45 degrees Minimum Pulse Width 3 microseconds Position Capture Delay 10 to 260 microseconds Use Input for single ended mode and leave input floating Use faceplate Ov pins for common mode reference or single ended signal return Inputs can be driven by 5v TTL or CMOS logic 4700 4700 4700 ov 0 75V 3 37 Single Ended 5v Sink Input Circuit Servo Axis 1 2 Aux Axis 3 Aux Axis 4 Signal Name Faceplate Auxiliary Servo Identifier Circuit Function Circuit Function Circuit Function Axis 1 listed Pin Terminal Terminal Board Board I O Type Single Ended 5v Sink Input Circuit Type Sink Input 4 7K ohm pull up to internal 5v Input
13. 10 0v Refer to Chapter 8 Follower Motion for an explanation of Follower Program Command Position and Follower Winder Zone Position At least three PLC sweeps or 20 milliseconds whichever represents more time must elapse before the new Selected Return Data is available in the PLC 4 22 Follower Ramp Distance Make Up Time When the Follower Ramp feature has been selected FOLLOWR MODE is configured for ACC RAMP and the follower is enabled the following axis is ramped up to the Master velocity at the current Jog Acceleration rate when the Master Velocity is non zero at the time the Follower is enabled The master counts that accumulate during acceleration of the follower axis are stored In this mode the follower axis will accelerate to a velocity that exceeds the Master Velocity in order to make up the position error that accumulated while the Follower axis was accelerating to the Master Velocity This make up distance correction has a trapezoidal velocity profile determined by the Follower Ramp Distance Make Up Time and jog acceleration at the beginning of the correction This mode is used when the Follower axis must be position and velocity synchronized to the Master position at the instant the Follower mode was enabled If the Follower Ramp Distance Make Up Time is too short then the velocity profile is a triangular profile If during the distance correction velocity exceeds 80 of the velocity limit then the automatically calc
14. K12 Series 2 19 Considerations Incremental Encoder Mode 3 Considerations Absolute Encoder Mode C 3 Find Home Cycle Position Initialization C3 Set Position Command Continuous Mode Restrictions Continuous Move 7 Continuous Move OVE 7 6 5 Control Sequence 9 Coordinated Non coordinated moves 6 7 CTLO9 CTL12 Output Controls Q Discrete Command CX4 Connector 2 11 D D A Command Force Data Field Program Zero 1426 Diagnostics Beta amplifier G3 Digital servo benefits Digital Servo Motors list paa DisDly Servo Drive Disable Dela Drive Enabled I Status Bit 5 5 Drive OK Input 4 I Status Bit 5 6 DSM302 Error Codes A 1 DSM302 Hardware Description 3 1 DSM302 Module Installation 3 5 DSM302 Module per System DSM302 max number G 9 Dwell 7 2 Dwell d DWELL Command Program Zero 4 28 Dynamic braking compared to regenerative G 5 Index Index EN4 LED 3 211 Enable Drive MCON Q Discrete Command Enable Follower Discrete Command 5 Enabling Follower with External Input Encoder Axis 2 Master 8 4 Encoder and Internal Master Synchronizing 8 9 Home Position Home Switch Enable Maste Encoder 3 Position High Count Limit 4 24 Low Count Limit Encoder Incremental Quadrature C 5 End of Program 7 2 Enhanced Position Loop Resolution 4 21 Error Code Format Error Reporting E STOP Series Connecti
15. 3 Thea and Series Digital Servo amplifier encoder feedback cable always requires an A99L 0035 0001 Cable Shield Grounding Clamp and one of the 11 available slots on a 44B295864 001 Grounding Bar at the amplifier end of the cable This clamp arrangement serves as a 3 20 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C mechanical strain relief and as cable shield ground The outer insulation of the Digital servo amplifier cable must be removed to expose the cable shield in the contact area of the clamp Cable Grounding Clamp Figure 3 12 Detail of Cable Grounding Clamp A99L 0035 0001 Figure 3 13 44B295864 001 Grounding Bar Side View Dimensions GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 21 9 84 gt 8 51 1 38 Figure 3 14 44B295864 001 Grounding Bar Dimensions Rear View Showing Mounting Holes 4 For installations which must meet IEC electrical noise immunity standards a Cable Shield Grounding Clamp A99L 0035 0001 and one of the 11 available slots on the Grounding Bar 44B295864 001 must also be used at the Digital Servo Axis Terminal Block end of the servo amplifier cable IC800CBL001 002 If the Digital servo amplifier cable is connected directly to the DSM302 faceplate no Digital Servo Axis Terminal Block used the Grounding Clamp and Bar are not required at the faceplate end of the cable For additional information refer to nstallation Requir
16. At the conclusion of every request the PLC CPU reports the status of the request to the Status Word which is a location in PLC memory that is designated by the Status Word Pointer in the Command Block GFK 1464C Appendix DSM Parameter Download Using the COMM REQ Instruction B 5 Section 2 The COMM_REQ Ladder Instruction The Communications Request begins when the COMM REQ Ladder Instruction is activated The COMM REJQ ladder instruction has four inputs and one output Enable Input Command Block Pointer 9999999 7 Fault Output Rack Slot Location 9929999 Port Number 9999999 5 Figure B 3 DSM COMM_REQ Ladder Instruction Each of the inputs and outputs is discussed in detail below It is important to understand that the Command Block Pointer points to another location in memory where you must enter additional information about the Communications Request Enable Input Must be Logic 1 to enable the COMM REQ Instruction It is recommended that the enabling logic be a contact from a transition one shot coil IN The memory location of the first word of the Command Block It can be any valid address within a word oriented area of memory R AI or AQ SYSID A hexadecimal value that gives the rack and slot location of the DSM module that the COMM REQ is targeting The high byte first two digits of the hex number contains the rack number and the low byte contains the slot number The table below shows some examp
17. Iouis PLC Analog In AIN2P A AIN2P B 8 8 PLC Analog In AIN2M AIN2M B 26 10 Analog Out Servo Vel Cmd B l6 Analog Servo Vel Com B 24 4 SHIELD Cable Shield Cable Shield SHIELD A SHIELD B IS 1 19 0 1 10 11 12 16 4 17 5 18 6 13 1 2 15 3 5 6 24 S GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 25 3 26 Aux Axis 3 Follower Master Axis Circuit and Pin Assignments This table identifies all circuits and pin assignments for Aux Axis 3 Connector C The shaded areas indicate signals that are unused and not available for user connections Table 3 13 Circuit and Pin Assignments for Aux Axis 3 Connector C Circuit Circuit Type Aux Axis 3 Circuit Faceplate Aux Term Identifier Function Pin Board Terminal Encoder Chan A INIP C 1 1 Encoder Chan INIM_C 19 19 Single ended Encoder ChanB IN2P C 2 2 differential 5v A inputs Encoder Chan B IN2M_C 20 20 3 3 21 21 Encoder Marker IN3P_C Encoder Marker IN3M C PSV 5v from PLC 5v Encoder Power 5 C m Strobe 1 Input 105 C 106 eg A Strobe 2 Input 106 5v inputs outputs 107 IOS 108 isolated inputs Home Switch 35 18 36 13 31 IN4 Single ended 5vin PLC 5v Input INA 24v opticall PLC 24v Input INI0 INCOM 24v Input Common 24v Input Common
18. 1 Continued DSM302 Error Codes Error Number Response Description Error Type Hexadecimal Special Purpose Errors EO Stop Fast Custom Loop Type Mismatch E2 DSP Interrupt failure Set Internal Master Velocity command out of range command ignored S Follower Ramp Errors Status Only Master velocity greater than 0 8 velocity limit no distance compensation S Error in calculation during ramp up tus Only Programmed makeup time is not long enough for trapezoidal correction of the makeup distance Velocity limit violation during ramp ta St ta Stai Status Only Time limit violation during acceleration sector of the distance correction Stai ta ta ta El Q Follower Errors Follower Position Error Limit Encountered Follower Velocity Limit Condition Encountered Follower Ratio B value 0 Follower Ratio B value 0 tus Only Follower Ratio or B A gt 32 Winder Mode Errors Status Only A B Change Not Allowed in Winder Mode With Follower Enabled Set Winder Position Immediate Command Out of Zone Zone Length Out of Range or Zone Length Change Exceeded 25 Status Only Zone Length Change Not Accepted Previous Change Still in Effect Status Only Combination of follower B A ratio and winder zone length exceeds limit default winder zone length of 10000 used Internal Errors Stop Fast System software error Stop Fast Unrecognized encoder not supported hj w rj N
19. be sent to the DSM302 There are several possible advantages to this approach This is an easy way to convert single word registers to double integer form thus simplifying your number handling in the ladder program It gives flexibility 1f you need to scale the values Since User Unit scaling usually implies a decimal point i e 1000 1 000 inch you could for example use the DINT Multiply instruction and a constant of 1000 This would let you specify an inch as 1 instead of 1000 on your Operator Input device Many low cost Operator Interface devices cannot write a double integer value Multiplying the single register value from the Operator Interface in a double integer instruction produces a double integer result In the example below the single word value from an Operator Input device will be scaled by a factor of 1000 then placed into the double integer word R208 R209 for Parameter 1 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C 1810001 BCD4_ BLK _ CLR INT LEN 1 1500017 IN Q R0150 RO151 IN 00021 00021 1510001 MUL DINT RO150 1 Q R0208 0000000021 0000021000 CONST I2 0000001000 In the example above the BCD
20. Appendix 1464 Using the APM Motion Programmer Status Screen with the DSM302 The APM Motion Programmer may be used both to program and to monitor the operation of a DSM302 module While there are NO restrictions regarding programming there are several issues to be aware of when using the Status screen to monitor the DSM302 The Status screen was designed for use with the Motion Mate APM300 modules IC693APU301 and IC693APU302 The Status screen display will operate with the DSM302 although some screen items have different meanings Standard Mode Status Screen The figure below indicates the Standard mode Status screen items that have a different interpretation for the DSM302 PROGRM 1 SETUP FOLDER UTILTY PRINT 1 7 10 gt Axis LC INPUTS Axis Enabl reserved 0 Block Number Strobe 1 Pos Valid reserved 0 Cmd Position Positi Drive Enab reserved 0 Actual Pos 0 0 osition Prog reserved 0 Posn Error 0 0 Moving ol 0 0 In Zone reserved 0 Cmd Velocity 0 0 PLC Ctrl 1 Actual Veloc 0 0 PLC OUTPU Abort Movs 0 0 o Feedhold 0 0 o Enab Drive 0 0 o Find Home 0 0 0 4 Pos Strobe 1 Jog Plus 0 0 Jog Minus 0 0 o Reset Strb o 0 o i ID 00001 DISABLED MONITOR APM REY s LOGIC EQUAL C LM90 DSMTEST APM CTRL PLC Reset Strobe 1 amp 2 Non zero Status Code Aux Axis 3 Displayed in Following Analog Input 1 Priority Order 1 Module Status 2
21. GFK 1464C The figure below illustrates the Analog Servo terminal boards and cables associated with the DSM302 1C693AC C336 Auxiliary Terminal Board USER I O IC693ACC336 Auxiliary Terminal Board USER I O Oooooooooooooooooooo 1C693ACC336 Auxiliary Terminal Board TO MOTION PROGRAMMER ANALOG SERVO ENCODER AND Comm Cable 1 p USER 1 IC693CBL316 Cables supplied by 1C693ACC336 m Auxiliary Terminal Board DSM to Terminal ANALOG SERVO Board Cables f ENCODER AND IC693CBL324 1M USER I O IC 693CBL325 3M Figure 3 11 DSM302 Terminal Boards and Connectors for Analog Servos see GFK 1581 for SL Servos Chapter 3 Installing and Wiring the DSM302 3 19 Cable Grounding Properly routing signal cables amplifier power cables and motor power cables along with installation of proper Class 3 grounding will insure reliable operation Typically Class 3 grounding specifies a ground conductor of a minimum wire diameter larger than the power input wire diameter connected via a maximum 100 ohm resistance to an earth ground Consult local electrical codes and install in conformance to local regulations The specifications for completing the and Series Digital Servo amplifier installation and wiring including amplifier grounding are completely described in the manual GFH 001 Servo Product Specification Guide
22. lt 1 073 741 823 counts 2 Command the follower axis to the winding start point and then send the Set Winder Position AQ immediate command to synchronize the axis position to the winder zone and define the starting position within the zone The magnitude of this preset value indicates the axis position GFK 1464C Chapter 8 Follower Motion 8 13 orientation within the winder zone Zone position 0 corresponds to the extreme left most negative side of the zone and Zone position zone length 1 corresponds to the extreme right side of the zone The sign of the preset value determines the initial direction of movement More specifically when positive master commands are followed a positive position preset will cause the winder axis to first move in the positive direction and a negative position preset will cause the winder axis to start in the negative direction The reverse of this is true when the master command is negative 3 Set the Enable Follower Q bit and the optional Enable Trigger bit if configured to start the axis winder motion in response to master commands Operation Description Once the follower is enabled the winder axis will follow the master command to one end of the move zone and then reverse and proceed to the other end for as long as the master commands are in the same direction If the master command reverses direction the winder axis will follow in the reverse direction until the end of the zone is encountered
23. 208 Velocity Loop Step Response Velocity vs Time vi GN 1 1 1 1 1 mimm mm een eee eee 1 1 1 1 Gd cheeses aeu damus ae SSeS RR rR Or Soom 4 OF r 3 2 1 Alda AeA 4 0 3 04 05 02 Time Sec 0 1 208 Figure 0 10 Velocity Loop Step Response Velocity vs Time VLGN 208 Velocity Loop Step Response Torque Command vs Time VLGN PUBLULUOS enbuo 05 04 Time Sec 208 Figure D 11 Velocity Loop Step Response Torque Command vs Time VLGN The response shown in Figures D 10 and D 11 1s marginally stable and would be unacceptable in many applications The plots are shown for reference only D 11 Appendix D Tuning GE Fanuc Digital and Analog Servo Systems GFK 1464C Tuning the Position Loop The very first step in adjusting the tuning for the position loop is to insure that the velocity loop is stable and has response suitable to the application Refer to the previous section for methods of setting the velocity loop Preliminary Position Loop Settings for Tuning Session 1 Ifusing Standard Mode control loop settings set the User Unit and Counts configuration to values appropriate to the mechanical configuration for the axis See the discussion and examples in the configuration chapter for details Set th
24. 8 5 Regenerative braking compared to dynamic braking G 5 Reset Strobe 1 2 Flags Q Discrete Command Resonance defined D 12 Response Methods A 2 Response DSM302 input G 8 Restrictions Absolute Encoder Mode with Continuous Mode C 5 Rev Comp Reversal Compensation 4 18 Revision History H 1 See also Firmware history S Scaling example 4 12 Schematics Simplified 13 38 S Curve Acceleration 7 5 S Curve Acceleration Equations 7 3 S CURVE Jumps 7 18 7 19 7 20 Select Follower Internal Master Q Discrete Command 5 14 Select Return Data AQ Immediate Command 5 24 Serial Communications Connector 3 3 Serial Communications Port Configuration Data 4 7 Serial encoder described G 7 Serial Encoder Modes C 2 Servo Amplifier Ol Series Connecting 220 Power 2 10 17 2 19 9 Connecting 24 VDC Jumper 24 External Regeneration Resistor or Jumper Connecting Machine Emergency Stop Connecting the E STOP 2 10 10 Connecting to Line Filter Connecting the Motor Encoder Connecting to Machine Emergency Stop Index 7 Index Index 8 Connection to Motion Mate DSM302 Connection to Motor Encoder Connection to Motor Power Cabl Servo Axis 1 4 2 Pin 27 Servo Control 2 1 Servo Motors Digital 4 5 Set Configuration Complete AQ Immediate Command 5 28 Set Position AQ Immediate Command Set Position Command C 4 Setting the Configurati
25. C and D above for each additional amplifier Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C OOQOOOOOO DSM SERVO 1C693ACC335 Axis Terminal Board Servo Amplifier 1C693CBL324 325 Terminal Board Connection Cable Not used if connecting directly from DSM302 to Servo FANUC AC SERVO UNIT Ol SERIES get STATUS 1 800 1 001 00 2207 2800 BE 001 002 arf Cable K1 d NOT READY READY NALARM Note If Terminal Board not used connect K1 cable directly from Servo to DSM302 5 302 JS1B JA4 JF1 JS1B D D Front Face a CX4 JV1B Bottom View IC800CBL061 062 Motor Power Cable K4 IC800CBL021 Motor Encoder Cable K2 LLL Motor Figure 2 4 Connecting the Series Digital Servo Amplifier to the Motion Mate DSM302 2 Connect the Motor Power Cable to the Series Digital Servo Amplifier A The size of the motor ordered for your system determines the K4 motor power cable you will use if you ordered prefabricated cables with your system The motors in the following table are grouped to use one of the prefabricated cables available through GE Fanuc This is not a complete listing of all Series servomotor power cables however the ones most commonly specified are included A
26. Descriptions Manual GFZ 65192EN 01 Control Motor Amplifier amp Series SVM GFZ 65162E 02 a Series Servo Motor Manuals GFZ 65165E 01 GFZ 65150E 02 GFZ 65142E 02 Series Servo Product Specification Guide GFH 001 SL Series Servo User s Manual GFK 1581 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter 1 Chapter 2 GFK 1464C Contents Product meme M 1 1 Servo Types Supported eed itte ree edet hits e nes eus 1 1 Features of the Motion Mate 0 5 302 2222 22222 2 0 12 1 000 0000000 0 1 1 High Performance ente resiste reo e EET een cios 1 1 Easy 10 I Se ec testet ette etd eh ttis eee ee siete rises 1 2 Versatile re epe tu ire e aes 1 2 Section 1 Motion System Overview 1 2 1 1 1 esee eren sette 1 3 The Series 90 30 PLC and the 5 302 1 4 PLC Data Latency and DSM302 1 4 DSM302 Servo Loop Update Times essen 1 5 DSM302 Position 1 5 Configuration Software Packages sss eee trennen 1 5 90 30 1 5 Windows Programming Software sse 1 6 PC Control Programming Softwa
27. Insert one UMK BF mounting ear into the appropriate two holes in the side element Note that the mounting ear has a recessed hole for later inserting a user supplied mounting screw The recessed hole should face upwards to accommodate the mounting screw 5 Repeat steps 1 4 above for the other side of the terminal board GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 13 Auxiliary Terminal Board IC693ACC336 Description and Mounting Dimensions The IC693ACC336 Auxiliary Terminal Board is used to connect the DSM302 to Analog Servo Axes and auxiliary devices such as Incremental Quadrature Encoders Strobe detectors and external switches The board contains one 36 pin connector labeled DSM A cable IC693CBL324 1 meter or IC693CBL325 3 meters connects from the DSM connector PL2 to the DSM302 faceplate Thirty eight screw terminals are provided on the Auxiliary Terminal Board for connections to user devices These screw terminals have the same pin labels as the 36 pin DSM302 faceplate connector Refer to Chapter 3 for detailed connection information The maximum voltage that should be applied to I O terminals 16 18 and 34 36 is 30 VDC The maximum voltage for any other input terminal is 5 VDC Six 130V MOVs are installed between selected I O points and the shield frame ground for noise suppression The I O terminal points so connected are 16 17 18 34 35 and 36 The I O terminals support a wire gauge of 14 28 AWG Maximum
28. Machine Moveable Alignment Mark Frame Stationary Alignment Mark 27 Negative Overtravel Position Home Position 45742 cvs Figure 6 2 Move Minus Home Position Example Find Home Routine for Move or Move When the find home command an OFF to ON transition of the Find Home Q bit is initiated the following sequence of events occurs 1 The axis is accelerated at the Jog Acceleration rate and moved at the configured Final Home Velocity positive direction for MOVE negative direction for MOVE until a marker pulse is sensed This marker pulse establishes the home reference position 2 The axis is stopped at the configured Jog Acceleration rate and with the configured Jog Acceleration Mode 3 The axis is moved at the configured Jog Velocity and with the configured Jog Acceleration rate and Jog Acceleration Mode the number of user units specified by the Home Offset value from the home reference position 4 The axis is stopped at the configured Jog Acceleration rate and with the configured Jog Acceleration Mode Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C 5 5 DSM302 sets the Commanded Position and Actual Position AI status words to the configured Home Position value the DSM302 sets the Position Valid 1 bit to indicate the home cycle is complete Jogging with the DSM302 The Jog Velocity Jog Acceleration and Jog Acceleration Mode are configu
29. Note that the mounting ear has a recessed hole for later inserting a user supplied mounting screw The recessed hole should face upwards to accommodate the mounting screw 4 Repeat steps 1 3 above for the other side of the terminal board Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Cables Five cables are available for use with the DSM302 Table 3 7 Cables for the DSM302 Cable Description Application IC693CBL316 Station Manager Cable DSM302 Comm to Motion Programmer PC IC693CBL324 Terminal Board Connection Cable 1 meter DSM3002 to Servo Axis Terminal Board or Aux Terminal Board IC693CBL325 Terminal Board Connection Cable 3 meters DSM302 to Servo Axis Terminal Board or Aux Terminal Board IC800CBLO001 Digital Servo Command Cable 1 meter Digital Servo Axis Terminal Board or DSM to Digital Servo Amp IC800CBL002 Digital Servo Command Cable 3 meters Digital Servo Axis Terminal Board or DSM to Digital Servo Amp Custom Terminal Board and Servo cables are available in longer lengths by contacting your GE Fanuc distributor The maximum recommended cable length for the DSM connector to the and Series servo amplifier is 50 meters The cables use special shielding and construction to ensure reliable servo operation GE Fanuc recommends that users do not attempt any field modifications of the cables or connectors Note If a Digital Servo Axis does not use any of
30. The following sequence of commands illustrates this effect assume ACCELs are chosen to allow motions to complete normally Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Command Data Comments VELOC 10000 Set velocity of first move 10000 CMOVE 15000 ABS LINEAR Reach velocity of second move 20000 at position 15000 VELOC 20000 Set velocity of second move 20000 CMOVE 0 INC LINEAR Flag to signal the DSM302 to wait for next move before changing to the next velocity CMOVE 30000 ABS LINEAR Stay at velocity 20000 until position 30000 then change to velocity 5000 VELOC 5000 Set velocity of third move 5000 PMOVE 40000 ABS LINEAR Final stop position 40000 v a45739 20000 10000 5000 15000 30000 40000 t Figure 7 3 Example 1 Before Inserting CMOVE 0 345740 20000 10000 5000 15000 30000 40000 t Figure 7 4 Example 2 After Inserting CMOVE 0 Chapter 7 Programmed Motion 7 7 Programmed Moves 7 8 By combining CMOVEs and PMOVES absolute and incremental moves and linear and s curve motion virtually any motion profile can be generated The following examples show some simple motion profiles as well as some common motion programming errors Example 1 Combining PMOVEs and CMOVEs This example shows how simple PMOVEs and CMOVES combine to form motion profiles ACCEL 1000 VELOC 2000 5000 ABS LINEAR VELOC 1200 PMOVE 10000 ABS SC
31. When routing signal lines amplifier input power line and motor power line the signal lines must be separated from the power lines The following table indicates how to separate the cables Table 3 8 Separation of signal lines Amplifier input power Separate a minimum 10cm from group B signals by bundling separately or use Master Control Contactor electromagnetic shielding MCC drive coil The MCC grounded steel plate Use switches amplifier input power noise protector for MCC Motor Power DSM to Axis Terminal cable Separate a minimum 10cm from group A signals by bundling separately or use electromagnetic shielding DSM to Aux Terminalcable grounded steel plate Use all required individual cable shield grounds and grounding bar connections Axis terminal cable to amplifier Encoder feedback cable DSM to a or Series Digital Servo Amplifier Signal Cable Grounding The signal cables used with the DSM302 contain shields which must be properly grounded to ensure reliable operation The illustration below shows cable grounding recommendations for typical installations The following points should be considered 1 The DSM302 faceplate ground wire must be connected to a reliable panel ground 2 The Digital Servo Axis Terminal Block and Auxiliary Terminal Block each provide two screw terminals labeled S A short ground wire must be connected from one of the S terminals to a reliable panel ground
32. attached to one of the motor s connection points Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 Motor power cables purchased from GE Fanuc will include a 1 meter single conductor wire with a CX11 3 connector on one end and a ring terminal on the other This cable provides grounding connections for the frame of the motor and should always be connected Custom cable builders should always include this cable See the previous connection diagram for proper connection to the amplifier Repeat this procedure as needed for the other axis in the system For more information please refer to the Servo Product Specification Guide GFH 001 GFK 1464C 3 Connect the Motor Encoder Cable K2 to the Series Digital Servo Amplifier The size of the motor ordered for your system determines the K4 motor power cable you will use if you ordered prefabricated cables with your system Please refer to the table below to determine the correct encoder cable catalog number A Remove the protective plastic cap from the connector on the motor and locate the encoder cable K2 see table 2 5 This cable has two distinct connectors B Plug the end of the cable with the D shell style connector into the connection labeled JF1 on the servo amplifier see Figure 2 9 C The other end of the cable is configured so that it can only be attached to one connection on the motor encoder red end cap Repeat this procedure for all
33. the source of the value sent by the COMM_REQ to DSM Parameter 1 with the value returned in AI0021 AI0022 If the values are equal the output coil VERIFY will turn on GFK 1464C Appendix DSM Parameter Download Using the COMM Instruction B 17 Appendix C Position Feedback Devices There are four GE Fanuc a and Series Digital serial encoder models that will function with the DSM302 8K 8 192 cts rev No longer available on new motors 32K 32 768 cts rev Standard on B Series motors 64K 65 536 cts rev Standard on amp Series motors 1000K 1 048 576 cts rev Optional on o Series motors Table C 1 Digital Serial Encoder Resolutions Note The older A or C Series million count serial encoder will not operate with the DSM302 An error will be reported if this encoder is connected For position control purposes by default the DSM302 treats all encoders as 8192 counts rev The additional resolution of 32K 64K and 1000K encoders will still be used in the digital servo velocity controller to provide smooth operation at low speeds To use the increased position feed back resolution available in release 1 3 or later firmware refer to the Tuning Parameter section of the Configuration Chapter Digital Serial Encoder First Time Use or Use After Loss of Encoder Battery Power GFK 1464C The encoder temporarily provides incremental data during the first use or after res
34. top Machine Slide Machine Frame Home Switch Cam Home Switch Zo La Negative Overtravel Position i Home Position 45741 cvs Figure 6 1 Home Switch Example Move and Move Modes GFK 1464C If Find Home Mode is configured as MOVE or the first encoder marker pulse encountered when moving in the appropriate direction positive for MOVE negative for MOVE after the find home command is given is used to establish the exact location In this mode the operator usually jogs the axis to a position close within one revolution of the encoder to the home Chapter 6 Non Programmed Motion 6 3 6 4 position first then initiates the find home command To assist the operator in jogging to the correct position a set of alignment marks indicating a close proximity to the home position is sometimes placed on the machine and machine axis The next picture shows an example of the Home Position parameter set to Move minus In this example the operator jogs the axis until the moveable mark on the machine slide lines up with the stationary mark on the alignment plate mounted to the machine frame Note that the marks align on the positive side of home position since the Home Position parameter is set to Move Then the operator initiates the find home routine which causes the axis to move in the negative direction until the marker pulse occurs 4 Direction Positive Stop p Machine Slide
35. when the axis is on the positive side of home Typically the Home switch is mounted at or near one end of the axis travel It is important to verify the operation of 10 the home switch prior to attempting a home cycle It may be necessary to reverse the motor direction Motor or Motor2 Dir POS NEG in the module configuration Use the configuration software to set the desired user scaling factors and other configurable parameters The following items MUST be changed from the default configuration settings Configuration Item Setting Feedback Type Digital Servo Cmd Digital Motor Type Select from Table in Chapter 4 Position Loop Time Constant 60 ms Velocity Loop Gain Load Inertia Motor Inertia 16 User Units Counts See Chapter 3 Standard Mode Only Position Error Limit 30000 x User Units Counts Velocity at 10v 139820 x User Units Counts Set the configuration parameters in the order shown above Changing Feedback Type or Control Loop type will cause all other DSM configuration changes to be erased and set back to the default values If a Follower Control Loop is used be sure to set the AYAQ Length to 50 9 so that the additional Aux Axis 3 AI data will be reported to the PLC Store the configuration to the PLC Clear the program from the PLC turn off all DSM302 Q bits and place the PLC in RUN mode Monitor the CTL bits for Home Switch Overtravel and Overtravel and confirm that each bit responds to the co
36. 01 provided with the module This wire has a stab on connector on one end for connection to a V4 inch terminal on the bottom of the DSM302 module and a terminal on the other end for connection to a grounded enclosure 845515 BOTTOM VIEW POE SELF TAPPING SCREW STAB ON OF DSM MODULE N666P14006B6 CONNECTOR 44A735970 001R01 MOUNT ON GROUNDED ENCLOSURE Figure 3 2 Connecting the Shield Ground Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 2 GFK 1464C Installing the DSM302 Module The Motion Mate DSM302 can operate in any Series 90 30 CPU expansion or remote baseplate Series 90 30 release 6 50 or later The configuration files created by Logicmaster 90 30 Configuration software must match the physical configuration of the modules To install the DSM302 on the baseplate follow these steps 1 Use the Logicmaster 90 30 Configuration software or the Hand Held Programmer to stop the PLC This will prevent the local application program if any from initiating any command that may affect the module operation on subsequent power up 2 Power down the Series 90 30 PLC system 3 Align the module with the desired base slot and connector Tilt the module upward so that the top rear hook of the module engages the slot on the top edge of the baseplate 4 Swing the module down until the connectors mate and the lock lever on the bottom of the module snaps into plac
37. 131 seconds per acceleration or deceleration the DSM will calculate a value within its limit In this case the DSM calculates that to reach a velocity of 24 000 in 131 seconds an acceleration of 183 would be required The Example 1 solid line velocity profile shows the higher 183 acceleration rate used by the DSM The dashed line profile in that drawing indicates the desired programmed acceleration rate and velocity profile that could not be attained 2453122 ACCEL 100 V Actual Desired VELOC 24000 Profile Profile PMOVE 8000000 INC LINEAR Figure 7 18 Maximum Acceleration Time Example 1 One solution which requires some extra calculations for obtaining a low acceleration for a long period of time breaks a move up into separate continuous moves using CMOVE commands with each move s acceleration time being less than 131 seconds In the problem introduced in Example 1 the programmed move would require 240 seconds each for acceleration and deceleration We can easily see that if we divide this time in half by using two moves whose acceleration or deceleration times are each 120 seconds we would be within the DSM s limit of 131 seconds This scheme is used in the following example Example 2 below shows how the result desired in Example could be obtained by replacing Example 17 single move with four moves Four moves are required since both the acceleration and deceleration portions of the profile must each be divided into two
38. 2 Section 2 9o AI Status Wrds cccccccccssccccccccsssssssscccccsccccesesscccsccscsscesessssees 9 7 Section 3 Q Discrete Commands 8 11 Section 4 AQ Immediate Commands 2 5 15 Noii Programnied 2 225 ortae esteso toe erba aset ota ent so se posteo tio seesessesestesessc Dc DSM302 Home Cycle tete tret roe Ee rene e etie eie ipe roe rep leek eed 6 1 Home Switeh Mode erret eet ier e eite es e ie NAT e eerte 6 1 Find Home Routine for Home essere 6 2 Home Switch 6 2 Mover and Move Modes sse eene enne enne entrent nennen nns 6 3 Find Home Routine for Move or 6 4 Jogging with the 0 5 302 6 5 Move at Velocity Command eseesssssssssseeeee eene eene nennen nnns 6 5 Force Digital Servo Velocity Command DIGITAL Servos eee 6 6 Force Analog Output Command ANALOG Servos 6 6 Contents vii Contents Chapter 7 viii Position Increment 6 7 Other GonsiderattOns i s ret tto eivai eto 6 7 Programmed MOOD ius etta t Pe yn o aerea be eoe ipn oceve teen ben Prerequisites for Programmed 299 7 3 Conditions That Stop a Motion Program sss eene 7 4 Parameters for Programmed
39. 255 Position or Parameter Move 27h Move Command Type Pos 8 388 608 8 388 607 User Units 0 255 Velocity 28h Jog Velocity Vel 1 8 388 607 User Units sec Acceleration 29h Jog Acceleration Acc 1 134 217 727 User Units sec sec XX XX Time Constant 2Ah Position Loop Time Constant Time Constant 0 5 10000 VFF Velocity Feedforward VFF 0 100 Time Constant Time Constant 0 10 10 000 ms Ratio B Ratio A Follower A B Ratio Ratio A 32 768 32 767 Ratio 1 432 767 XX XX XX VLGN Velocity Loop ym Digital mode only VLGN 0 XX XX XX Torque Limit Digital mode only Limit Range 0 100 Velocity Internal Master Velocity Vel 1 000 000 1 000 000 counts sec GFK 1464C Chapter 5 Motion Mate DSM302 to PLC Interface 5 17 Table 5 7 Continued Immediate Commands Using the 6 Byte Format Immediate Command Definition Position Set Aux Axis 3 Position 19 Pos 8 388 608 8 388 607 counts XX XX Digital Servo Force Digital Servo Velocity 4 20 Velocity Cmd Servo Velocity Cmd 4 095 4 095 RPM Make Up Time Follower Ramp Distance Make Up Time 4 22 Active Range 0 10 32000 ms 4 Position Set Follower Winder Position Pos 0 8 388 606 counts Position Set Follower Winder Zone Length Enc ee 100 8 388 607 counts Maus Parameter Data Par h Load
40. 3 Someamplifiers have field replaceable fan units If a replacement fan unit is not available replace the amplifier 4 8 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C HC HCL etc High Current Alarm Motor current is excessive For Series amplifiers the suffix L M N etc indicates which axis is in alarm 1 Motor power wiring V and W may be shorted to ground or connected with improper phase connections Check the wiring and connections Check the servomotor for shorts to motor frame Replace the motor if shorted 2 Improper motor type code may be configured or excessive values for tuning parameters Confirm that the proper motor is configured and lower gain values 3 The amplifier maintenance manual will describe the procedure for monitoring motor current signals IR and IS If the waveforms are abnormal replace the amplifier If excessive noise is observed check grounds and especially the cable shield grounds for the command cable K1 to the amplifier 4 The motor may be operating in violation of duty cycle restrictions Calculate the amount of cooling time needed based on the duty cycle curves published for the particular motor 5 The motor may be over loaded Check for excessive friction or binding in the machine For all the above problems allow ten minutes cooling of the amplifier with minimum or no motor loading then cycle amplifier power to reset LV Low Voltage Contr
41. 3 12 Converting From DIN Rail Mounting to Panel Mounting sess 3 13 Auxiliary Terminal Board 69 36 3 15 Description and Mounting 10 eee nennen 3 15 Converting From DIN Rail Mounting to Panel Mounting 3 16 o te ede t ba Here P eet 3 18 I Q Cable Grou nding t emere ed 3 21 I O Circuit Identifiers and Signal Names seen 3 25 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter 4 Chapter 5 Chapter 6 GFK 1464C Contents Circuit Function and Pin Assignments sees 3 25 Digital Servo Axis 1 2 Circuit and Pin Assignments eee 3 26 Analog Servo Axis 1 2 Circuit and Pin Assignments eene 3 27 Aux Axis 3 Follower Master Axis Circuit and Pin Assignments 3 28 Aux Axis 4 Circuit and Pin Assignments 3 29 Connection Diagrams esses enne eene nnne 3 30 Specifications eere e red ede UNE eed egens 3 38 Differential Single Ended Sv Inputs sse 3 39 Single Ended 5v Sink Input essere 3 40 Optically Isolated 24v Source Sink Inputs sese 3 41 Single Ended 5v Inputs Outputs essen eene 3 42 5y Differential Outputs ene eire ei e eds 3 43 24v DC O
42. 31 N C Faceplate 5v Output Faceplate Sv Faceplate 5v OUT3P_A 14 14 5 Output Output Faceplate 5v Output Faceplate Sv Faceplate 5v OUT3M A 32 32 13 Output Output I O Type 5v Differential Outputs Circuit Type Differential Totem Pole Source Sink Output Source Sink Current 20 ma max Output Voltage 1 5 v min across 120 ohm differential load Notes Servo Axis 1 and Aux Axis 3 use CMOS Drivers with 47 ohm series resistors Servo Axis 2 and Aux Axis 4 use RS 422 Line Drivers CMOS Driver 5V OUTxP RS422 Line Driver OUTxM CMOS Driver CMOS Driver OUTxP OUTxM Axis 1 and Aux Axis 3 Axis 2 and Aux Axis 4 GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 41 24v DC Optically Isolated Output Circuit Servo Axis 1 2 Aux Axis 3 Aux Axis 4 Signal Name Faceplate Auxiliary Servo Identifier Circuit Function Circuit Function Circuit Function Axis 1 listed Pin Terminal Terminal Faceplate 24v Output Faceplate 24v Faceplate 24v OUTIP_A 18 Output Output Faceplate 24v Faceplate 24v Faceplate 24v OUTIM A 36 Output Output Output I O Type 24v DC Optically Isolated Output Circuit Type Isolated Solid State Relay SSR Output Current 125 ma continuous 500 ma for 10 ms resistive or inductive Output Voltage Drop 1 0 v max at 0 125 amps Notes Output is protected by a 30v transzorb and a 0 2 amp Polyswitch If a short circuit occurs the output wil
43. Abort All Moves Jog Plus Minus Move at Velocity and Move use the Jog Acceleration and Jog Acceleration Mode The Feed Hold Q command uses the programmed acceleration and acceleration mode DSM302 Home Cycle A home cycle can be used to establish a correct Actual Position relative to a machine reference point The configured Home Offset defines the location of Home Position as the offset distance from the Home Marker The Enable Drive Q bit must be ON during an entire home cycle However the Find Home Q bit does not need to be held ON during the cycle it may be turned on momentarily with a one shot Note that turning ON the Find Home Q bit immediately turns OFF the Position Valid 1 bit until the end of the home cycle The Abort All Moves bit halts a home cycle but the Position Valid bit does not turn back ON No motion programs can be executed unless the Position Valid bit is ON Home Switch Mode If the Find Home Mode is configured as HOMESW HOME Switch the Home Switch input from the axis I O connector is used first to roughly indicate the reference position for home Then the next encoder marker encountered when traveling in the negative direction indicates the exact location An open Home Switch input indicates the servo is on the positive side of the home switch and a closed Home Switch input indicates the axis is on the negative side of the home switch An GFK 1464C 6 1 6 2 OFF to ON transition of the Find Home Q com
44. Absolute Encoder Mode The Set Position AQ command functions the same way as in incremental encoder mode At the completion of the Set Position operation Actual Position is set to the Set Position value The DSM302 internally calculates the encoder Absolute Feedback Offset needed to produce the commanded Set Position value This Absolute Feedback Offset is immediately saved in the DSM302 non volatile capacitor backup memory Once an absolute position is established by a Set Position command the DSM302 will automatically initialize Actual Position after a power cycle and set the Position Valid 1 bit Absolute Encoder Mode DSM302 Power Up The battery pack attached to the servo subsystem will maintain power to the encoder counter logic Once the encoder has referenced through first time start up the actual position is automatically maintained by the encoder even if the axis is moved during servo power loss The encoder will monitor the status of the battery pack and report loss of battery power or low battery power to the DSM302 The DSM302 will complete a power on diagnostic and when configured for absolute encoder mode interrogate the referenced status of the Digital serial encoder A valid referenced status from the encoder will signal the DSM302 to read the encoder absolute position The DSM302 will report the Actual Position AI status as the sum of the encoder position and the Absolute Feedback Offset established by the initial Find
45. All Moves Q bit ON for at least one PLC sweep Force Digital Servo Velocity Command DIGITAL Servos This command bypasses the position loop and forces a velocity RPM command to the digital servo for tuning purposes Acceleration control is not used and changes in velocity take effect immediately A Force Digital Servo Velocity command value of 4095 will produce a motor velocity of 4 095 RPM and 4095 will produce a motor velocity of 4 095 RPM depending on individual motor maximum velocities The digital servo control loops may limit actual motor speed to a lower value CAUTION Care should be taken not to operate a servomotor beyond its rated duty cycle The Enable Drive Q bit must be active with no other motion commanded for the Force Digital Servo Velocity command to operate The command must remain continuously in the AQ data for proper operation When a Force Digital Servo Velocity command is active for a given axis any other AQ immediate command for that axis will remove the Force Digital Servo Velocity data and halt the servo A one shot Force Digital Servo Velocity command will therefore only operate during the sweep in which it appears Refer to Chapter 5 Motion Mate DSM302 to PLC Interface for more information on this command Note The Force Analog Output command described below is used for analog servos Force Analog Output Command ANALOG Servos In Analog mode the Force Analog Output AQ immediate comm
46. Axis 2 Error 4 Aux Axis 3 Error Sel Int Mstr Axis 2 The following DSM302 items cannot be monitored on the Follower mode Status screen 1 Data Q Data Vo AI Data CTL13 CTL16 OUT 1 Control bits Strobe Position Position Strobe 1 OUT3 Control bits Strobe 2 Position Position Strobe 2 Reset Strobe 2 User Selected Data Torque Limit Execute Program 7 10 Servo Ready Any Aux Axis 3 4 bits New Cfg Received Appendix E Using the APM Motion Programmer Status Screen with the DSM302 E 3 Appendix PF Updating Firmware in the DSM302 The DSM302 operating firmware is stored in on board FLASH memory The firmware update is provided on a floppy disk The PC Loader utility controls downloading the new firmware from the floppy to the DSM302 FLASH memory This utility requires an IBM AT PC compatible computer with at least 640K ram one floppy drive MS DOS 3 3 or higher and one RS 232 serial port In order to run this utility within an MS DOS box under Windows 3 1 Windows 95 or Windows NT the processor should be at least a Pentium 133 If not the computer should be rebooted into MS DOS mode This utility functions optimally with a hard drive with at least 1 MB available space To Install the New Firmware Perform the Following Steps GFK 1464C 1 Save or backup any programs or data resident in the module before performing the update function 2 Place the PLC in STOP NOIO Mode Clear any faults 3 Ensure that the modul
47. Command Generator Master Axis Velocity is summed with the Commanded Velocity Velocity Feedforward output of the axis Command Generator Therefore the servomotor s position and velocity is determined by the sum of the Command Generator output and Master Axis input The Command Generator and Master Axis input can operate simultaneously or independently to create Servo Axis motion The DSM302 allows several sources for the Master Axis input Aux Axis 3 Encoder default Master input to Servo Axis 1 and 2 e Internal Master Axis generator selectable as Master input to Servo Axis or 2 instead of Aux Axis 3 Encoder e Servo Axis 2 Encoder configurable as Master input only to Servo Axis 1 e Aux Axis 3 Analog Input 1 configurable as Master Velocity input to Servo Axis 1 or 2 The ratio at which a Servo Axis follows the Master Axis is programmable as the ratio of two integer numbers For example a Servo Axis can be programmed to move 125 Position Feedback units for every 25 Master Axis Position units Each time the Master Axis Position changed by 1 position unit the Servo Axis would move 125 25 5 Position Feedback units When Aux Axis 3 Analog Input 1 is used as the Master source the Analog Input voltage is converted to a Master Axis Velocity and an equivalent Master Axis Position change In this mode the Servo Axis Velocity not Servo Position is proportional to the Analog Input value MASTER AXIS ENCODER MOTION MO
48. Force Digital Servo Velocity command must remain in the AQ command data area or the servo will be stopped Other Considerations Other considerations when using non programmed motion are as follows The Abort All Moves Q bit when ON will prevent any non programmed motion from starting Turning ON the Abort All Moves Q bit will immediately stop any current non programmed motion at the current Jog Acceleration Set Position AQ command during non programmed motion will cause a status error W Turning OFF the Enable Drive Q bit while performing a home cycle or executing a Move at Velocity AQ command will cause a stop error W The Feed Hold Q bit has no effect on non programmed motion The Rate Override command has no effect on non programmed motion W Changing the Jog Velocity or Jog Acceleration will not affect moves in progress GFK 1464C Chapter 6 Non Programmed Motion 6 7 Chapter Programmed Motion A motion program consists of a group of user programmed motion command statements that are stored to and executed in the DSM302 The DSM302 executes motion program commands sequentially in a block by block fashion once a program is selected to run The motion program is executed autonomously from the PLC although the PLC starts the DSM302 motion program and can interface with it with parameters and certain commands during execution In addition external inputs CTL bits connected directly to the DSM3
49. GFK 1464C The Series servo amplifier integrates a power supply with the switching circuitry Therefore GE Fanuc is able to provide a compact amplifier that is 60 smaller than conventional models In fact the D amplifier has the same height and depth as a GE Fanuc Series 90 30 PLC module This allows efficient panel layout when using the DSM302 motion controller The amplifier is designed to conform to international standards GE Fanuc offers three communication interfaces for the B Series amplifiers pulse width modulated PWM Fanuc Servo Serial Bus FSSB and I O Link Interface Only the pulse width modulated PWM interface may be used with the DSM302 module The PWM interface utilizes the standard GE Fanuc servo communication protocol Position feedback is communicated serially between the DSM controller and the motor mounted serial encoder Chapter 1 Product Overview 1 13 Series FANUC Servo Motors The Series Servomotors are built on the superior technology of the a Series servos They incorporate several design innovations that provide the best possible combination of high performance low cost and compact size Ratings of 0 5 to 12 Nm are offered These motors are up to 15 shorter and lighter than comparable servos New insulation on the windings and an overall sealant coating help protect the motor from the environment The B Series motors conform to international standards IEC The motor protection level is IP65 I
50. Home cycle or Set Position AQ command Absolute Encoder Mode with Continuous Mode C 4 Some restrictions are necessary when Absolute Encoder mode is selected along with Axis Mode set to CONTINUOUS Absolute Encoder mode causes the DSM302 to automatically initialize the Actual Position AI status word from the battery backed absolute encoder after a power cycle Absolute Encoder mode is selected by setting Feedback Mode to ABS in the configuration software CONTINUOUS axis mode allows the DSM302 to create continuous motion in one direction by the use of multiple CMOVE or PMOVE incremental commands As the axis moves Actual Position will reach a High or Low Count Limit then roll over to the other limit The distance between Actual Position rollovers is the Continuous Count Modulus The battery backed absolute encoder has a maximum total absolute counting range of 8192 cts rev x 32767 revs 268 427 264 counts See the calculation in the previous section when using higher resolution position feedback This is the maximum number of counts the encoder can move after a position reference operation Find Home Q or Set Position AQ command and still retain absolute position after a power cycle If the encoder rotates more than this number of counts after a position reference operation the absolute position rolls over and the encoder starts a new counting cycle Motion Mate DSM302 for Series 901M 30 PLCs User s Manual December 2002 G
51. IC693ACC335 axis terminal board to break out user I O such as overtravel or home limit inputs insert the other end of the cable into the connector labeled A for axis 1 or B for axis 2 on the front of the DSM302 If you are using the terminal board insert the other end of the cable into the terminal block connector marked SERVO Next locate the terminal board connection cable IC693CBL324 1 meter or IC693CBL325 3 meter Insert one end of this cable into the terminal board connector marked DSM Insert the other end of the cable into the connector labeled A for servo axis 1 or B for servo axis 2 on the front of the DSM302 module Note Refer to I O Connections in chapter 3 for information concerning the user I O connections available on the IC693ACC335 terminal block GFK 1464C Chapter 2 Getting Started 2 5 2 6 SVU Amplifier Channel Switches Confirm that the Channel Switches dipswitches located behind the SVU amplifier door are set as shown in the following tables Note that the OFF position is to the left and the ON position is to the right Note also that the switches are numbered from bottom to top Switch 1 is the bottom switch For example in Figure 2 3 Switches 1 3 and 4 are shown ON and switch 2 is shown OFF Figure 2 3 SVU Amplifier Channel Switches Table 2 1 SVU Amplifier Channel Switch Settings Amplifier SVU1 80 Amplifier SVU1 130 ee To connect additional amplifiers repeat steps B
52. INCOM C 35 5 OUTI 24 v 125 ma PLC 24v Output OU 18 DC SSR output PLC 24v Output OU 36 Not Used OUT2P_C 13 OUT2 Differential Not Used OUT2M C 31 OUT 5v outputs PLC 5v Output OUT3P C 14 PLC 5v Output OUT3M C 32 24v 30 ma 222 ENBLI 15 SSR output ENBL2 33 is active PLC Analog In AINIP C 7 Differential 10 PLC Analog In AINIM C 25 10v PLC Analog In AIN2P 8 Analog Inputs C Analog int PLC Analog In AIN2M C 26 10v Analog Out PLC Analog Out AOUT C Analog Out com Analog Out Com ACOM C SHIELD Cable Shield Cable Shield SHELDC 14 15 8 RT Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Aux Axis 4 Circuit and Pin Assignments This table identifies all circuits and pin assignments for Aux Axis 4 Connector D The shaded areas indicate GFK 1464C signals which are unused and not available for user connections Table 3 14 Circuit and Pin Assignments for Aux Axis 4 Connector D Aux Axis 4 Circuit Function Not Used Not Used Not Used lov fw oo Circuit Identifier Circuit Type Single ended differential 5v inputs PLC 24v Input PLC 24v Input isolated inputs IN1I PLC 24v Input INCOM 4v Input Common 24v Input Common OUTI 24 v 125 ma PLC 24v Output DC SSR output PLC 24v Output Not Used OUT2 Not Used Differential PLC 5v
53. Impedance 4 7K ohms to 45v Maximum Input Voltage 10 0 v Logic 0 Threshold 0 8 v max Logic 1 Threshold 2 0 v min Input Filtering 1 0 microseconds typical Notes This input must be pulled to Ov to turn on 5v 4700 15000 IN 1 0V 3 38 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Optically Isolated 24v Source Sink Inputs Circuit Servo Axis 1 2 Aux Axis 3 Aux Axis 4 Signal Name Faceplate Auxiliary Servo Identifier Circuit Function Circuit Function Circuit Function Axis 1 listed Pin Terminal Terminal I O Type Optically Isolated 24v Source Sink Inputs Circuit Type Source Sink 5K resistance to INCOM Input Impedance 5 4K ohms to INCOM 24 VDC Maximum Input Voltage 30 0v referenced to INCOM Logic 0 Threshold 6 0 v max referenced to INCOM Logic 1 Threshold 18 0 v min referenced to INCOM Input Filtering 5 milliseconds typical Notes These inputs use bi directional optocouplers and can be turned on with either a positive or negative input with respect to INCOM 5100 1000 0 1 e ji x GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 39 Single Ended 5v Inputs Outputs Analog Servo Axis Axis 1 2 1 2 and Aux Axis 3 Circuit Function Circuit Function Servo PWM Alarm Strobe 1 Input Ov Ov Servo PWM Alarm Strobe 2 Input Ov Ov Servo PWM Alarm Not Used Ov Ov Se
54. Mode is available in Release 1 40 of the DSM302 or later The DSM302 requires PLC firmware release 6 50 or greater and Logicmaster 90 30 20 Micro software release 8 02 or greater 2 The SRDY servo ready Input must be applied connected to Ov or the Motion Mate DSM302 will not operate 3 The ENABLE DRIVE Q control bit must be set continuously to 1 or no motion other than Jog moves will be allowed If no STOP errors see Appendix A for error codes have occurred the DRIVE ENABLED I status bit will mirror the state of the ENABLE DRIVE Q bit A STOP error will turn off the DRIVE ENABLED output bit even though ENABLE DRIVE input bit is still a 1 The error condition must be corrected and the CLEAR ERROR control bit turned on for one PLC sweep to re enable the drive 4 Ifthe ERROR I status bit is 1 and the AXIS ENABLED and DRIVE ENABLED I status bits are 0 then a STOP error has occurred Status LED flashing fast In this state the DSM302 will not respond to any commands other than the CLEAR ERROR Q control bit 5 The CLEAR ERROR Q control bit uses one shot action Each time an error is generated the bit must be set to 0 then set to 1 for at least one PLC sweep to clear the error 6 The CFG OK LED must be ON or the DSM302 will not respond to PLC commands If the LED is OFF then a valid DSM302 configuration has not been received from the PLC Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C
55. Move at Velocity or Execute Program command In Zone will always be off Default 10 2 05 Pos Loop TC Position Loop Time Constant milliseconds The desired servo position loop time constant This value configures the amount of time required for the servo velocity output to reach 63 of its final value when a step change occurs in the Velocity command The lower the value the faster the system response Values that are too low will cause system instability and oscillation Default 1000 Note For accurate commanded velocity profile tracking Pos Loop TC should be 1 4 to 1 2 of the MINIMUM system acceleration or deceleration time For example if the fastest acceleration that must occur occupies 100msec of time the Pos Loop TC should be between 25 to 50msec To maintain system stability use the largest value possible For users familiar with servo bandwidth expressed in rad sec Bandwidth rad sec 1000 Position Loop Time Constant ms For users familiar with servo gain expressed in ipm mil Gain ipm mil 60 Position Loop Time Constant ms Table 4 4 Gain Bandwidth Position Loop Time Constant Gain Bandwidth Position Loop Time 0 o usc 3i 00 9d o 7 E sm deg o mos T For applications that do not require feedback control or employ very crude positioning systems an Open Loop Mode exists Setting a zero Position Loop Time Constant which indicates that the 4 14 Motion Mate DSM302 for Series 90 30
56. Moves sess nnne 7 4 Absolute or Incremental 7 4 Absolute Positioning 7 4 Incremental Positioning esessssesseeeeeeereee ener nennen ene 7 5 TTypes of Accelerdtion 4 2 cente eite etes ee Der iter itera 7 5 L1 cat Acceleration 7 5 S Cutrve AcceleratloDui 7 5 Types of Programmed Move Commands sse 7 6 Positioning Move 7 6 Continuous Move CMOV E 7 6 Programmed MOV Ese eo C Span eee WEE IAE RT eR ET e red 7 8 Example 1 Combining PMOVEs and CMOVESs sss 7 8 Example 2 Changing the Acceleration Mode During a Profile 7 9 Example 3 Not Enough Distance to Reach Programmed Velocity 7 9 Example 4 Hanging the Move When the Distance Runs Out esses 7 9 Dwell Commarid 5 3 eret rh metere ne Rr eene Eae teg 7 10 Exainple 5 Dwelling uU IRE nial eee tus 7 10 Wait Commands e REN 7 10 SUBPOULINES o 7 11 Block Numbers and Jumps essent nre netten 7 11 Unconditional Jumps es cee endete ene iere ien leitete debe een 7 1 Example 6 Unconditional Jump eese 7 12 Conditional Jumps repete tta eet ead
57. PLCs User s Manual December 2002 GFK 1464C GFK 1464C 2 06 2 07 positioning loop is disabled selects this mode Note that in Open Loop Mode the only way to generate motion is to program a non zero Velocity Feedforward The Position Error is no longer used to generate motion because Position Error is based on position feedback and Open Loop Mode ignores all feedback The Position Loop Time Constant will not be accurate unless the Vel at 10 V value is set correctly Vel at 10 V User Units Second All DSM302 and servo functions depend on this value being correct for proper operation For Digital Mode the Velocity at 10 Volts configuration field should be set to a conversion constant value of 139820 multiplied by the decimal value of the User Units to Counts ratio For example with a User Unit value of 1 and a Counts value of 2 the decimal value of their ratio would be 0 5 The conversion constant multiplied by 0 5 yields the value 69910 for the Vel at 10 V 0 5 139820 69910 For Analog Mode the Velocity at 10 Volts configuration field is the Actual Servo Velocity User Units second desired for a 10 Volt DSM302 analog velocity command output to the servo The DMS302 Force D A Output AQ Immediate Command and the Actual Velocity AI status word can be used for a command voltage to empirically determine the proper configuration value if necessary The allowable Vel at 10V range for 1s 400 User Units sec lt Vel at 10V
58. Parameter Immediate 0 255 Parameter Data Range depends on parameter usage Only 00 or FFh are acceptable xx don t care 4 01 Null This is the default AQ Immediate command Since the AQ words are automatically transferred each PLC sweep the Null command should always be used to avoid inadvertent execution of another AQ Immediate command 4 02 Rate Override This command immediately changes the feedrate override value which will modify the commanded velocity for all subsequent programmed moves This new value will become effective immediately when received by the DSM302 It is stored and will remain effective until overwritten by a different value A rate override has no effect on non programmed motion or acceleration Rate Override is set to 100 whenever a program is initiated The Rate Override command can be sent on the same PLC sweep as an Execute Program bit and the Override value will immediately take effect Rate Override can be used to adjust the programmed velocity not acceleration of a particular move or a set of moves on any given axis 4 03 Position Increment Without Position Update User units This command offsets the axis position from 128 to 127 user units without updating the Actual Position or Commanded Position The DSM302 will immediately move the axis by the increment commanded if the servo is enabled Position Increments can be used to make minor machine position corrections to compen
59. Part Number 0 5 3000 IC800CBL064 14 Meter Severe Duty 1 3000 2 3000 83 3000 and 6 2000 IC800CBL065 14 Meter Severe Duty a C12 2000 IC800CBL066 14 Meter Severe Duty GFK 1464C Chapter 2 Getting Started 2 13 Transformer 200 240VAC 1 or 3 Phase Breaker See Notes below PE 2 14 Supply Power 24VDC Power Supply 24VDC 10 10 Spark Arrester ag Discharge Resistor Built in Thermostat KEY with available GE Fanuc cable NOTES Line filter and lightning surge absorber can be used in place of a transformer when 200 240 volts AC is 1 available to the cabinet 245681 GE Fanuc Motion Controller E STOP PB and NC Contacts Series Amplifier CX11 4 on next amplifier Customer s 777 Ground 11 6 Encoder 90VDC Power Supply 2 only for motors with brake option B Series Motor user supplied cable 2 For single phase operation AC line phase L3 is not connected Refer to the Servo System Specifications in the Servo Product Specification Guide GFH 001 for output current de rating Figure 2 10 Connecting the B Series Digital Servo Amplifier Terminal Strip B Attach the other end of the motor power cable to the motor after first removing the plastic cap protecting the motor s connector Note that this cable is keyed and can only be properly
60. Position Strobe 2 The Position Strobe 1 and Position Strobe 2 status bits indicate that an OFF to ON transition has occurred at the associated faceplate Strobe Input When this occurs an axis position is captured and reported in the Strobe n Position AI status word where n is Axis 1 Axis 2 or Axis 3 The Position Strobe l bit is cleared by the associated Reset Strobe n Q bit A maximum of 2 PLC sweeps is required for the Position Strobe 1 bit to be cleared in the PLC after a Reset Strobe n Q bit is turned ON Once the Position Strobe n bit is cleared new data may be captured by another Strobe Input Position data will be captured within 250 microseconds from a Strobe Input Chapter 5 Motion Mate DSM302 to PLC Interface 5 5 5 6 1 12 1 13 1 14 1 15 1 16 Note The Position Strobe bits do not indicate the logic level of the faceplate input they only indicate that an OFF to ON transition has occurred on the input Position Error Limit The Position Error Limit status bit is set when the absolute value of the position error exceeds the configured Position Error Limit value When the Position Error Limit status bit is set commanded velocity and commanded position are frozen to allow the axis to catch up to the commanded position Torque Limit The Torque Limit status bit is set when the commanded torque exceeds the torque limit setting for the configured motor type Servo Ready Servo Axis 1 2 INA C Aux Axis 3
61. SERVO 1C693CBL324 325 Terminal Board Connection Cable Not used if connecting directly from DSM302 to Servo Servo Amplifier CX11 3 connect K1 cable directly from V U Servo Amplifier to DSM302 s w D B IC800CBL001 002 Servo Command Cable K1 ies Ampli Face View 6 Motion Mate DSM302 Figure 2 9 B Series Servo Amplifier Connections For more information refer to the connection section of the Servo Product Specification Guide GFH 001 2 Connect the Motor Power Cable K4 to the D Series Digital Servo Amplifier Note Make connections to the CX 11 connector carefully This connector is not keyed Double check your connections before applying power Incorrect connections could result in equipment malfunction or damage A The size of the motor ordered for your system determines the motor power cable K4 you must use You can choose to purchase prefabricated cables or to build custom cables Refer to the B Series Control Motor Descriptions Manual GFZ 65232EN for information about custom cables or installation for conformance to CE mark The amplifier end of the prefabricated motor power cable is constructed to connect to terminal block CX11 3 on the amplifier Table 2 4 K4 Cable B Series Motor Cable Examples Servo Motor Type K 4 Motor Cable Cable Description
62. Serial Communications Port Configuration Data Motion programs in addition to Program Zero for the DSM302 can be programmed using the APM Motion Programmer software The computer running the Motion Programmer software connects to the Serial Communications Port which supports the SNP protocol on the DSM302 faceplate The DSM s Serial Communications Port is labeled COMM on the module s faceplate The DSM302 s Serial Communications Port must be configured properly to communicate with the Motion Programmer PC Make sure the Motion Programmer configuration parameters and the DSM302 s Serial Communications Port configuration parameters match The DSM302 s Serial Communications Port configuration parameters are described in Table 4 2 Table 4 2 Serial Communications Port Configuration Data Configuration Parameter Description Values Defaults Units Baud rate of SNP Port 300 600 1200 2400 4800 9600 19200 19200 ODD EVEN NONE ODD NA Number of stop bits Number of data bits 7 or 8 Modem TT Modem turnaround time 0 255 1 100 sec Idle Time Maximum link idle time 1 60 0 se sec SNP ID SNP ID 6 characters consisting of A F and 0 A00001 N A 9 First character must be A F Baud Rate The baud rate parameter specifies the transmission rate in bits per second of data through the serial port Parity Specifies whether or not a parity bit is to be used NONE if not and if so whether
63. Standard 2 11 Follower Velocity Loop Gain 0 255 A Standard 2 12 Follower A Reversal Compensation 0 255 00 ABSOLUTE Follower Follower units sec sec Follower S CURVE Follower Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Table 4 3 Continued Axis Configuration Data Configuration Logicmaster Valid Ref Parameter Description Values Defaults Units Modes Axis Mode Axis Mode CONTINU CONTINU N A Standard 2 17 LINEAR Follower ROTARY 1 See Note 2 ROTARY 2 See Note 2 p p Follower MN NAME T EM Follower M Follower laci ctun ic NN NAE Follower Hi Limit Lo Limit Home Positn Follower Follower pur n ou M Follower mc M EE Follower Follower Follower MOVE Follower MEME eet 7 pee REPE ERE Oodd pi Pos EOT Positive End of Travel 8 388 608 8 388 607 8 388 607 Neg EOT Negative End of Travel 8 388 608 8 388 607_ 8 388 608 Ratio A Val Follower A B Ratio A 32768 32767 not 0 NA 231 Ratio B Val Follower A B Ratio B 1 32767 SA rte 231 Mstr Source Master Axis Source ENC3 INT E Follower 2 32 ENC2 ANALOG Master Velocity Limit 0 1000 1000 Master Velocity Limit 1000 0 1000 FollwrEnInp Follower Enable Input 0 16 02 Follower 2 35 Follwr Mode Follower Mode NORMAL NORMAL N A Follower 2 36 ACC RAMP WINDER WINDER L WINDER R CAM 1 See Note
64. This status bit is set when faceplate signal IN4 of the associated connector A B or C is ON active low ON Ov OFF 5v For Servo Axis 1 and Servo Axis 2 this input reports the Servo Ready state of the servo amplifier For Aux Axis 3 The INA C input is a spare input to the PLC Follower Enabled This status bit indicates when the Follower is enabled for the axis The Enable Follower Q bit and an optional CTL01 CTL16 faceplate trigger input enable the Follower function If follower ramp acceleration control is active when Follower Enabled turns on the axis will accelerate to the master velocity command and when it turns off the axis will decelerate to zero master velocity command Both acceleration and deceleration during the ramp process will utilize the currently active Jog acceleration Follower Velocity Limit The Follower Velocity Limit status bit is set if the velocity requested by the external or internal master input exceeds the configured Velocity Limits Therefore Follower Velocity Limit is an indication that the follower axis is no longer locked to its master input The error is reported in the associated Servo Axis n Error Code AI word when Follower Velocity Limit 1s set An exception exists when one of the Velocity Limits is set to 0 A zero Velocity Limit indicates unidirectional following motion so no error is generated for the limit that is set to zero For example if the Velocity Limit 0 and Counts are input th
65. VELOC 15000 PMOVE 120000 ABS LINEAR DWELL 4000 P1 ABS LINEAR V 245262 Figure 7 9 Dwell Command Example The WAIT command is similar to the DWELL command Instead of generating no motion for a specified period of time a WAIT stops program motion until a specified CTL bit turns ON Thus motion stops any time a WAIT is encountered even if the CTL bit is ON before the WAIT is reached in the program The trigger to continue the program can be any of the twelve CTL bits Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Subroutines If in the previous example WAIT was substituted for DWELL the motion profile would be the same except the second PMOVE would not start until the CTL bit turned ON If the CTL bit was ON when the program reached the WAIT the second PMOVE would begin immediately after the first PMOVE finished Also if WAIT was used instead of DWELL in the previous example CMOVEs and PMOVEs would generate similar velocity profiles The WAIT will stop motion whether the previous move is a CMOVE or PMOVE The DSM302 can store up to ten separate programs and forty subroutines Subroutines can be defined as two types single axis and multiaxis Subroutines are available for all motion programs created with the Motion Programmer software However Program 0 in the configuration software does not support subroutines Commands within single axis subroutines do not contain an
66. a high velocity when the distance runs out In the following example the first CMOVE accelerates to a high velocity The second CMOVE has an identical velocity However the distance specified for the second CMOVE is very short Thus the axis is running at a very high velocity and must stop in a short distance If the programmed acceleration is not large Chapter 7 Programmed Motion 7 9 enough the following profile could occur The DSM302 attempts to avoid overshooting the final position by commanding a zero velocity This rapid velocity change is undesirable and can cause machine damage ACCEL 500 VELOC 3000 CMOVE 9000 ABS LINEAR ACCEL 600 CMOVE 4800 INC LINEAR 9000 t Figure 7 8 Hanging the DSM302 When the Distance Runs Out Dwell Command Wait Command A DWELL command is used to generate no motion for a specified number of milliseconds A DWELL after a CMOVE will make the CMOVE perform similar to a PMOVE even if the specified dwell duration is zero milliseconds A DWELL P command uses the value stored in the designated parameter It is treated as a NULL command and skipped CMOVE continues to the next Move following the DWELL P if the parameter value has a special flag value of 65000 This does not occur with a DWELL command that has a constant value of 65000 Example 5 Dwell A simple motion profile which moves to a specific point waits and returns to the original point 1s shown below ACCEL 30000
67. a per axis basis which will allow the flexibility necessary for future growth of the DSM product Ladder programs created for current products that use name references will only require editing of the named reference locations GFK 1464C Appendix G Answers to Frequently Asked Questions G 11 Appendix DSM302 Revision History Firmware Release 1 40 Features Introduced in Firmware Release 1 40 DSM Analog Mode The current DSM module is enhanced in firmware version 1 40 to provide an analog servo interface The controller provides a 10 volt analog velocity command interface signal The analog interface supports third party motor amplifier sets that support a 10 volt velocity command and a quadrature encoder position feedback interface The function is currently implemented in the APM product line and allows the DSM to support the same motors and amplifiers as the existing APM controller Enhanced Follower Accuracy The DSM follower feature accuracy is enhanced in DSM firmware version 1 4 In Follower mode the master axis position is sampled 1 0 mSec to 1 5 mSec prior to using the data within the control This sampling delay causes the follower slave axis to have a measurable and predictable based upon motor velocity following error To address the delay a master axis position delay compensation has been added in release 1 4 The delay compensation uses the master axis velocity to correct the follower master position and eliminate
68. allowed when the DSM302 is controlling a servo Position Error Limit should normally be set to a value 10 to 20 higher than the highest Position Error encountered under normal servo operation Default 4096 The Position Error Limit range formula is 256 x user units counts lt Position Error Limit lt 60 000 x user units counts If Velocity Feedforward is not used Position Error Limit can be set to a value approximately 20 higher than the Position Error required to produce a 4000 rpm command The Position Error User Units required to produce a 4000 rpm command with 0 Velocity Feed forward is Position Error user units Position Loop Time Constant ms x Servo Velocity 4000 rpm user units sec 1000 Example The user units counts ratio is 2 1 and the Position Loop Time Constant is 50 ms Step 1 Calculate servo velocity at 4000 rpm 2 user units count x 8192 counts rev x 4000 revs minute 60 seconds minute 1 092 266 user units second Step 2 Calculate Position Error at 4000 rpm 50 milliseconds x 1 092 266 user units second 1000 milliseconds second 54613 user units If Velocity Feedforward is used to reduce the following error a smaller error limit value can be used but in general the error limit value should be 10 20 higher than the largest expected following error Note An Out of Sync error will occur and cause a fast stop if the Position Error Limit Value is exceeded by more than 1000
69. apply any external voltage to this connection HIROSE 20 Pin PCR Type Connector Pin Configuration Pins as viewed from connection side 139 NC Contact for E Stop 129 circuit Pins as viewed from connector side NC Contact O for E Stop circuit Figure 2 13 20 Pin PCR Connector Pin Out 6 Connect 24V DC Cable K12 to the D Series Digital Servo Amplifier A connector for the external 24 VDC supply is included with the amplifier package as a part of kit A06B 6093 K301 and should be connected to CX11 4 The other end of the cable must be connected to a 24VDC source capable of supplying at least 450 milliamps of current for each B Series amplifier The GE Fanuc IC690PWRO024 power supply is recommended Do not apply power at this time 7 Connect Cable K8 Jumper or External Regeneration Resistor to the Series Digital Servo Amplifier Without External Regeneration Resistor Using a Jumper If you do not have an external regeneration resistor you must leave the connections on CX11 2 DCP and DCC open However you must jumper the CX11 6 TH1 and TH2 terminals shown in the figure below This jumper completes the circuit that would otherwise be completed by the normally closed thermal over temperature switch in the external regeneration resistor unit If you do not have this jumper installed the amplifier will not function The jumper and its connector are included as a part of the connector kit A06B 6093 K301 that is
70. axes in the system Table 2 5 K2 Cable B Series Encoder Cable Examples Motor Type K 2 Encoder Cable Cable Description Part Number 0 5 3000 IC800CBL022 14 Meter Severe Duty 81 3000 B 2 3000 33 3000 and B6 2000 14 Meter Severe Duty 4 Connect the 220 V AC Power Cable to the Series Digital Amplifier The AC power cable is a user supplied cable which connects to CX11 1 on the face of the Series amplifier The connector for the amplifier end of this cable is part of kit A06B 6093 K301 supplied with each amplifier package See the Servo Product Specification Guide GFH 001 for more detailed information An AC line filter will reduce the effect of harmonic noise to the power supply its use is recommended A line filter is not needed if an isolation transformer or separate power transformer is used Two or more amplifiers may be connected to one AC line filter or transformer as long as Its power capacity is not exceeded Figure 2 11 shows how to connect the amplifier to the line filter 248025 CX11 1 To Power Source Series Amplifier Ground Lug Connection Strip Figure 2 11 Connecting the B Series Servo Amplifier to the Line Filter and Power Source GFK 1464C Chapter 2 Getting Started 2 15 Note You must supply the cable for the connection between the line filter and the power source Use 4 conductor 600V 60 C 140 F UL or CSA approved cable between the line filter and the servo amplifier
71. be performed initially or whenever encoder battery power is lost with the servo amplifier also in a powered down state Feedback Mode set to ABSOLUTE must be selected in the configuration software for proper operation with a battery pack Absolute Encoder Mode Position Initialization GFK 1464C When a system is first powered up in Absolute Encoder mode a position offset for the encoder must be established Using the 0 Find Home cycle or the Set Position AQ command can accomplish this Find Home Cycle Absolute Encoder Mode The Find Home Mode can be configured for MOVE PLUS MOVE MINUS or HOMESWHtch operation Refer to Chapter 4 for additional details of Home Cycle operation The Home Offset and Home Position configuration items function the same as in Incremental Encoder mode At the completion of the Home Cycle the Actual Position AI status word is set to the configured Home Position value The DSM302 internally calculates the encoder Absolute Feedback Offset needed to produce the configured Home Position at the completion of the Home Cycle This Absolute Feedback Offset is immediately saved in the DSM302 non volatile capacitor backup memory Once an absolute position is established by successful completion of a Find Home cycle the DSM302 will automatically initialize the Actual Position AI status word after a power cycle and set the Position Valid l bit Appendix C Position Feedback Devices C 3 Set Position Command
72. commands is indicated in Table 9 2 below Table 9 2 Actions Affecting Program Command Position Follower ACTION Enabled ACTION Resulting Updates to Follower Position Registers Updates to Follower Position Registers Home Found Actual Position AI status word is set to Home Value Program Command Position is set to Actual Position Position Error Yes Find Home Q command is Not allowed Status Error is returned Set Position ot Actual Position AI status word is set to AQ Value Command Program Command Position is set to Actual Position Position Error Note Set Position is not allowed if the Moving I bit is ON Execute Program No Actual Position AI status word is NOT affected Program Command Position is set to Actual Position Position Error Yes Actual Position AI status word is NOT affected Program Command Position is set to Reference Position 0 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C 2 Program moves will execute in a continuous fashion such that incremental PMOVE commands past the limits will roll over at the limit and continue Absolute PMOVE or CMOVE commands can also be used for applications that do not require going beyond the high low count limits Any internally generated move command can be immediately terminated by the Abort All Moves Q command The User Selected Data AI status word can be changed to repo
73. configuration is set to CONTINU The High Count Limit should always be set one User Unit smaller than the desired cycle For example a 360 machine would have a High Count Limit setting of 359 At the next count past 359 the count would roll over to the value set in the Low Count Limit parameter 0 in this example See Appendix C for considerations when using an absolute mode encoder Default 8 388 607 Lo Limit Low Count Limit User Units When moving in the negative direction the Actual Position will roll over to the high limit when this value is reached The Count Limits can be used for continuous rotary applications when the Axis Mode configuration is set to CONTINU See Appendix C for considerations when using an absolute mode encoder Default 8 388 608 Home Positn Home Position User Units The value assigned to Commanded Position when a Find Home cycle completes Home Offset Home Position Offset User Units A value added to or subtracted from the servo s final stopping point when a Find Home cycle completes Home Offset adjusts the final servo stopping point relative to the encoder marker See chapter 6 for details on the home cycle Default 0 Home Vel Final Home Velocity User Units second The velocity at which the servo seeks the final Home Switch transition and Encoder Marker pulse at the end of a Find Home cycle This velocity is also used for the home cycle MOVE and MOVE modes See chapter 6 for details on
74. connect the module s faceplate shield to a panel ground Status LED s EN1 EN4 Connector C Aux Axis 3 Follower Master Axis Connector D Aux Axis 4 Figure 3 1 DSM302 Module GFK 1464C COMM 6 pin RJ 11 connector Provides RS 232 connection for motion programmer software Connector A Servo Axis 1 Connector B Servo Axis 2 3 1 LED Indicators There are seven LEDs on the DSM302 module which provide status indications These LEDs are described below STAT ON OFF Normally ON FLASHES to provide an indication of operational errors Flashes slow four times second for Status Only errors Flashes fast eight times second for errors which cause the servo to stop When the LED is steady ON the DSM302 is functioning properly Normally this LED should always be ON When the LED is OFF the DSM302 is not functioning This is the result of a hardware or software malfunction which will not allow the module to power up Flashing When the LED is FLASHING an error condition is being signaled OK ON OFF CFG EN2 EN3 EN4 Constant Rate CFG LED ON The LED flashes slow four times second for Status Only errors and fast eight times second for errors which cause the servo to stop The operational error code will be placed in one of the first four AI status words and the Module Error Present l status bit will be ON Constant Rate CFG LED Flashing If t
75. contains the pulse width modulated PWM output signal of the motion controller the serial data from the motor encoder and diagnostic signals from the amplifier The signals carried in this cable are at data communications voltage levels and should be routed away from other high current conductors C Locate the servo command cable 800 001 1 meter or 800 002 3 meter Insert the mating end of this cable into the connector JS1B located on the front of the Servo Amplifier see Figure 2 9 D If you are not using the IC693ACC335 axis terminal board to break out user I O such as overtravel or home limit inputs insert the other end of the cable into the connector labeled A for servo axis 1 or B for servo axis 2 on the front of the DSM302 If you are using the terminal board insert the other end of the cable into the terminal board connector marked SERVO Next locate the servo command cable IC693CBL324 1 meter or IC693CBL325 3 meter Insert one end of this cable into the terminal block connector marked DSM Insert the other end of the cable into the connector labeled A for servo axis 1 or B for servo axis 2 on the front of the DSM302 To connect additional amplifiers repeat steps B D above for each additional amplifier Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C 1C693ACC335 Axis Terminal Board
76. desired Move at Velocity will not function unless the servo drive is enabled Enable Drive Q command and Drive Enabled 951 status bit are set The listing of AQ immediate commands shows the words in reverse order to make understanding easier For example to command a velocity of 512 user units per second in a DSM302 configured with AQ data starting at AQ1 the following values should be used 0022h 34 decimal in AQI 0200h 512 decimal in 2 and 0 in AQ3 When the DSM302 receives these values if Drive Enabled 1 15 ON Abort All Moves is OFF and no other motion is commanded it will begin moving the axis at 512 user units per second in the positive direction using the current Jog Acceleration and Acceleration Mode The Drive Enabled 1 bit must be ON before the DSM302 receives the immediate command or an error will occur Also if a Move at Velocity command is already in the AQ data the velocity value must change while the Drive Enabled bit is ON for the DSM302 to accept it The DSM302 detects a Move at Velocity command when the AQ values change When the DSM302 is performing a Move at Velocity command it ignores the software end of travel limits Pos EOT and Neg EOT Hardware overtravel limits must be ON if they are enabled Chapter 6 Non Programmed Motion 6 5 A Move at Velocity command can be stopped without causing error two ways a Move at Velocity command with a velocity of zero or turning the Abort
77. in follower mode Axis Mode Linear provides little functionality over Axis Mode Continu Tuning Parameters Tuning Parameters 1 and 2 are generic parameters used to select pre defined tuning parameter settings such as the Enhanced Position Loop Resolution parameter settings described below To avoid tuning parameter value conflicts Tuning Parl and Tuning Par2 should not contain the same non zero value Tuning Par1 Tuning Parameter 1 Specifies axis tuning parameter to be configured Valid range is 0 63 Default 0 Tuning Dat1 Tuning Parameter 1 Data Provides the value for the axis tuning parameter selected by Tuning Parl Valid range is 32768 32767 Default 0 Tuning Par2 Tuning Parameter 2 Specifies axis tuning parameter to be configured Valid range is 0 255 Default 0 Tuning Dat2 Tuning Parameter 2 Data Provides the value for the axis tuning parameter selected by Tuning Par2 Valid range is 32768 32767 Default 0 Table 4 5 Available Tuning Parameter Selections Tuning Parl or Tuning Dati or Description Tuning Par2 Value Tuning Dat2 Value 0 0 Not used default values 1 0 3 Enhanced Position Loop Resolution for Digital Servos see table below Enhanced Position Loop Resolution for Digital Servos For digital servos only enhanced position loop resolution at the expense of maximum supported motor velocity has been added to the product in firmware release 1 20 Prior to this
78. input p Series 24 VDC to Servo Amplifier 2 19 Differential 10v Analog Inputs 3 46 Differential Single Ended 5v Inputs Optically Isolated Enable Relay Output Kl Cable to DSM302 Single Ended 10v Analog Output 3 47 Series Connection 2 6 2 13 Illustration of the DSM302 Module 1 1 K2 Cable Immediate Commands Using the 6Byte Series Connection 2 10 2 17 F ormat 5 17 5 19 Prefabricated Cable Part Numbers 2 17 In Pos Zone In Position Zone 4 16 K3 Cable In Position Zone AQ Immediate Command B Series Connection 2 17 K4 Cable Motor Power In Zone Status Bit 5 5 a Series Connection 2 8 2 15 Incremental Encoder Mode Considerations C Part Numbers 2 15 3 K8 Cable Incremental Positioning 7 5 Incremental Quadrature Encoder C 5 Series External T Resistor or Jumper to Indicators LEDs A 11 Kinematic equations Installation Procedures Firmware Upgrades L Installing the Motion Mate DSM302 Recommended Procedure 3 5 LED Indicators Internal Master Velocity Generator 8 3 description of 3 2 DSM302 Module A 11 Limitations on Total Travel Line Filter AC 2 11 12 17 Linear Acceleration Interpolation G 7 Intgr Mode Integrator Mode Intgr TC Integrator Time Constant Introduction to Follower Winder aid Lo Limit Low Count Limit LOAD Command Program Zero 4 28 IP ratings motors G 1 Load Parameter 7 2 J Load Parameter Immediate AQ Immedi
79. k k k ckckckck ckckck ck ckckck ck ckck ck k k k ck kck ck k X SEND FAULT 0001 M0295 COMM _ S REQ HDR_WDS RO196 FT CONST SYSID 0007 NOTE SYSID HIGH BYTE COMM REQ RACK DESTINATION SYSID LOW BYTE COMM REQ SLOT DESTINATION CONST TASK TASK ALWAYS 0 FOR DSM302 COMM REQ 00000000 Verifying the Data Sent to Parameter 1 In this example the value in DSM Parameter is critical because it specifies a move distance that if incorrect could result in machine damage So the logic in the following two rungs verifies that the Parameter 1 value is correct If not correct contacts not shown from output coil VERIFY in the second rung will prevent the DSM from producing motion E RO208 I1 Q 0000015000 A10021 I2 40000015000 1 0200 M0202 MOVE_ MOVE_ TMR 4 WORD INT 1 0015 CONST IN Q AQ001 CONST IN Q AQ002 CONST PV 1840 LEN 1840 00001 LEN 00001 00045 00001 00001 ipee R0300 00000 M0202 VERIFY Soa CL First Rung The MOVE WORD instruction moves hexadecimal number 1840 into AQ0001 the fi
80. loop and the position loop Always begin with module configuration then proceed to the velocity loop setting and finally the position loop For Analog servo systems there are a series of Start Up Procedures to follow GE Fanuc Start Up and Tuning Information for DIGITAL Servo Systems There are three major sections covered e Validating Home Switch Over Travel Inputs and Motor direction e Tuning the Velocity Loop e Tuning the Position Loop Validating Home Switch Over Travel Inputs and Motor direction GFK 1464C 1 Connect the motor amplifier and DSM302 module following the procedures in Chapter 2 2 IfOver travel Limit switches are used OT Limit SW ENABLED in configuration wire them to the correct 24V terminal board points refer to Chapter 3 The overtravel inputs are operated in the fail safe mode 1 e a normally closed or PNP type switching device should be used Current must be sourced to the input to maintain a logic level 1 on the input while the axis is NOT at the EOT position or an alarm condition Error A9 will be returned Otherwise the Over travel limits Pos EOT and Neg EOT must be disabled using the Logicmaster configuration software 3 Ifa Home switch is used Home Mode HOMESW in configuration wire it to the correct 24V terminal board points refer to Chapter 3 The Home switch must be wired and actuated so that it is ALWAYS ON closed when the axis is on the negative side of home and ALWAYS OFF open
81. lt 1 000 000 User units sec In Digital Mode only if the user sends the DSM302 a velocity command that exceeds the servo system capability the DSM302 will clamp that command value at the appropriate maximum motor velocity boundary Note that no error will be reported back to the DSM302 See Appendix D Start up and Tuning GE Fanuc Digital and Analog Servo Systems for more information on determining the correct value Default 4000 Caution The Velocity at 10V must be configured correctly in order for the Pos Loop TC and VEL FF factors to be accurate Vel FF Velocity Feed forward gain percent The Commanded Velocity percentage that is added to the DSM302 s position loop velocity command output Increasing Velocity Feedforward causes the servo to operate with faster response and reduced position error The optimum value for each system has to be determined individually For Digital Servos a 95 to 100 Vel FF value is a good starting point For analog servos 90 100 is a typical value If Vel FF 6 is changed Pos Err Lim may require adjustment Default 0 Chapter 4 Configuring the DSM302 4 15 4 16 2 08 2 09 2 10 The Vel FF will not be accurate unless the Vel at 10 V value is first set correctly Intgr TC Integrator Time Constant milliseconds This is the position loop position error integrator time constant This value indicates the time required to reduce the position error by 63 For example if the
82. moves To divide the total acceleration or deceleration time in half we calculate the distance at the midpoint of either slope when velocity is 12000 to be 720 000 user units Chapter 7 Programmed Motion 7 21 The distance traveled during acceleration or deceleration is calculated using the formula Change in velocity x Required time Distance traveled 2 12 000 x 120 720 000 2 Since 240 seconds is needed to reach a velocity of 24 000 a velocity of 12 000 can be reached in 120 seconds The initial CMOVE and the final PMOVE both use this distance A second CMOVE takes over at the midpoint of the acceleration slope from the first CMOVE and accelerates to the target velocity of 24 000 A third CMOVE is required for dividing up the deceleration portion of the profile The final move a PMOVE takes over from the third CMOVE at the deceleration midpoint distance 720 000 user units from the final position The third CMOVE as it approaches its final position will automatically decelerate to the PMOVE s velocity of 12 000 The dashed lines in the Example 2 drawing separate the four moves To calculate the distances of the second and third CMOVEs we subtracted the distances we calculated for the first CMOVE and final PMOVE 720 000 each for a total of 1 440 000 from the final distance of 8 000 000 This gave us a remaining distance of 6 560 000 which we divided equally between the second and third CMOVES 3 280 0
83. necessary Three time constants will account for 96 7 of the rise in command Four time constants account for 98 9 of the rise Typically three time constants are sufficient for most motion applications We can use our knowledge of time constants to predict the required system response For instance if we know that the fastest acceleration required in our motion profiles must occur within 200 mSec The 200 mSec response to the change in command will be 98 9 complete in three time constants Simply dividing the 200 mSec by 3 tells us that a time constant will be about 67 mSec The Pos Loop TC configuration field represents one time constant in mSec In the example above one time constant is 67msec Position Loop Proportional Gain Method 2 Similar to the Velocity loop tuning method above Use an oscilloscope and gradually lower the Pos Loop TC value increasing gain Monitor the Motor Velocity analog output for performance characteristics are appropriate GFK 1464C Appendix D Tuning GE Fanuc Digital and Analog Servo Systems D 13 GE Fanuc Start Up and Tuning Information for Analog Servo Systems There are two major sections covered e Validating Home Switch Over Travel Inputs and Motor direction e Velocity at 10V Pos Loop TC and VEL FF determination Analog Mode System Startup Procedures Startup Procedures 1 Connect the analog motor to the servo amplifier according to the manufacturer s recommendations 2 Connect the D
84. of A is determined by the sign of the winder zone position register therefore the user programmed sign of A is ignored in winder mode The Zone Position Register represents the master command zone required to produce the configured winder axis zone therefore when the A B ratio value is changed the size of the Zone Position Register is adjusted proportionately The zone move distance of the winder axis always remains equal to the configured zone length and also any preset position within the zone remains the same 6 14 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Follower Mode Master Axis and Connection Options The diagrams on the following pages illustrate a variety of Master axis and Follower slave axis loop connection options The diagram below illustrates the two axes of the DSM302 connected in cascade with encoder 3 or the internal master as the master source for axis 2 and encoder 2 the master source for axis 1 MASTER a45320 ENCODER FEED FORWARD 3 o MOTOR 2 ENABLE FOLLOWER 2 MOTION JOG INTERNAL MOVE MASTER PROGRAM AT VELOCITY 2 ENCODER SLAVE AXIS 2 FEED FORWARD SLAVE gt o gt MOTOR ENABLE FOLLOWER MOTION JOG PROGRAM MOVE VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 8 14 2 Axis Cascade Master Source Encoder 3 Internal Master The diagram below illustrates the two axes of the DSM302 connected in parallel with encoder 3 or the in
85. release a non configurable position loop resolution of 8192 counts per encoder revolution was provided The table below describes the various selections now supported along with the maximum supported motor velocity for each setting Note that the configuration data is specified by entering a value of 1 to select parameter 1 in the Tuning Parl or Tuning Par2 field of the Axis 1 screen for axis 1 or Axis 2 screen for axis 2 The appropriate resolution setting value 0 3 is then entered in the corresponding Tuning Datl field or Tuning Dat2 field in the Axis 1 screen for axis 1 or Axis 2 screen for axis 2 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 2 22 2 23 2 24 2 25 2 26 2 27 2 28 Table 4 6 Enhanced Position Loop Resolution Tuning Parl or Tuning Tuning Dati or Encoder Resolution Maximum Motor Par 2 Value Taning Dat Counts per Revolution velo Value Revolutions per Minute 17 102 e 78190 etie 4400 rpm 16384 cts rev 3662 rpm 32768 cts rev 1831 rpm 65536 cts rev 915 rpm Default Setting 2 Some motors are restricted to a lower maximum rpm rating Series motors and encoders only Hi Limit High Count Limit User Units When moving in the positive direction the Actual Position will roll over to the low limit when this value is reached The Count Limits can be used for continuous rotary applications when the Axis Mode
86. screw torque which may be applied is 5 inch pounds Note Two of the screw terminals are labeled S for Shield A short earth ground wire should be connected from one of the S terminals directly to a panel earth ground The cable shields for any shielded cables from user devices should connect to either of the S terminals 1 8 45mm a a m s m al s a SOL Height alo O Din Rail Mount Din Rail Mount BO BO 4 95 125mm 1 95 48mm Bro BO son Panel Mount Panel Mount zo QO 5 6 141mm 1 65 42mm eO gt SO o oO s O J Ho O o o O E 70 IC693ACC336 Auxiliary Terminal Board Figure 3 7 Auxiliary Terminal Board with Mounting Dimensions 3 14 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Converting From DIN Rail Mounting to Panel Mounting The following parts are used in either the DIN rail or Panel mount assembly options The auxiliary terminal board is shipped configured for DIN rail mounting The instructions in this section guide you in converting the board to its panel mounting optional configuration The following table and drawings describe the various plastic parts which make up the auxiliary terminal board assembly and shows a
87. shield frame ground for noise suppression The I O terminal points so connected are 6 7 8 14 15 and 16 The I O terminals support a wire gauge of 14 28 AWG Maximum screw torque which may be applied is 5 inch pounds Note Two of the screw terminals are labeled S for Shield A short earth ground wire should be connected from one of the S terminals directly to a panel earth ground The cable shields for any shielded cables from user devices should connect to either of the S terminals Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Mounting Dimensions 3 05 77mm L a Height ae OL o Din Rail Mount Din Rail Mount 2 65 68mm 2 1 52mm 9 Panel Mount OL 3 65 92mm 1 55 39mm o LU 1 0 SERVO IC693ACC335 Servo Terminal Board Figure 3 4 Digital Axis Terminal Board with Mounting Dimensions GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 11 Converting From DIN Rail Mounting to Panel Mounting The following parts are used in either the DIN rail or Panel mount assembly options The axis terminal board is shipped configured for DIN rail mounting The instructions in this section guide you in converting the board to its panel mounting optional configuration The following table and drawings describe the various plastic parts which make up the axis term
88. side view of the board configured for DIN rail mounting Table 3 6 Auxiliary Terminal Board Components Phoenix Contact Part Number UM45 Profil 105 25 PCB Carrier UM 45 SEFE with 2 screws Side element with Foot SES wi UMK 45 SES with 2 screws Side Element UMK BF Parts shipped with auxiliary terminal board for optional panel mounting UM 46 Profil 44 80 105 25 0 25 p UM 45 SEFE UM 45 SES Ve 10 i 1 02 18 25 9 F5 72 183 Figure 3 8 Auxiliary Terminal Board Assembly Drawings 06781 1464 Chapter 3 Installing and Wiring the DSM302 3 15 Figure 3 9 Auxiliary Terminal Board Assembly Side View The following procedure should be used to convert the auxiliary terminal board to it panel mounting form Remember to save all removed parts for possible later conversion back to DIN rail mounting 1 Using a small bladed Phillips screwdriver carefully remove the two screws holding one UM 45 SEFE side element with foot to the UM 45 Profil PCB carrier Save this part for possible future use in converting the terminal board back to its DIN rail mounting configuration 2 Attach one UMK 45 SES side element to the PCB carrier in place of the side removed in step 1 above again using the two screws Be careful to not overtighten the screws 3 Insert one UMK BF mounting ear into the appropriate two holes in the side element
89. such as CMOVE PMOVE VELOC ACCEL etc The variations of these commands can be displayed using the Tab key after pressing the function key for the particular group For example to program a CMOVE IS P Continuous MOVE Incremental S curve acceleration using a Parameter data value first select a command field using the cursor control keys then press the CMOVE function key This causes CMOVE AL to be displayed in the command field of the screen With Logicmaster 90 the variations for the command options are cycled through by pressing the TAB key For example pressing the Tab key for CMOVE AL command cycles the command through CMOVE AL P CMOVE AS etc until the desired CMOVE IS P is displayed To program a JUMP command press F10 MORE and then press F1 JUMP Data Field Paired with each command is a data field In the data field enter either a signed double integer or the number of a parameter 0 255 as appropriate for the configured command Parameters 1 20 can be loaded with data using the LOAD P command Block number parameters can be entered in the data field when paired with Block or Jump instructions The data field of a dwell command indicates the number of milliseconds that the program will pause in execution Axis Field This field is used to set the axis number for commands such as VELOC or PMOVE Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Table 4 4 Program Zero Motion Pro
90. sufficient power level to the encoder Motion Controller To Amplifier Separation Maximum is 50 meters 160 feet Amplifier to Motor Separation Motor Power The motor power wiring is normally not a limitation Wire has to be of sufficient size to not create a great line drop GE Fanuc cables are sized for 14 meters if longer cables are required they should be sized for the increased distance Refer to the servo description manual for details Amplifier to Motor Separation Encoder Feedback The normally recommend maximum separation distance is 50 meters 160 feet Special FANUC approved installations have been used for a maximum amplifier to motor separation of 61 meters 200 feet For distances beyond the standard 14 meters a larger gauge cable wire must be provided for the 5 volt DC encoder power to limit the voltage droop to no more than 0 2 volts The position encoders have a 0 185 amp current requirement There are techniques that can be used to extend the range using fiber optic cable requires adapters to convert the signal over and back The cross sectional size of the serial encoder power wiring can be reduced on long separations by placing a regulated 5 volt DC supply at or near the motor not recommended for Severe Duty applications Can the B Series servomotors be operated on single phase Yes To use the motors with single phase power observe the following Power source specification e Nominal voltage rating 220
91. the Motion Program Store function Flashes fast eight times second during the Write User RAM to EEPROM operation When this LED is ON the servo drive for Servo Axis 1 is enabled When this LED is ON the servo drive for Servo Axis 2 is enabled When this LED is ON the Force Analog Output command for Aux Axis 3 is active When this LED is ON the Force Analog Output command for Aux Axis 4 is active A 10 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Appendix DSM Parameter Download Using the B COMM REQ Instruction This appendix describes how to load DSM Parameter Memory with a Communications Request Abbreviated COMM REQ in this chapter ladder instruction An advantage of the COMM REQ is that it can load up to 16 parameters per instruction compared to 2 parameters per PLC sweep for the Load Parameter Immediate Command Also multiple COMM REQ instructions may be used for this purpose in a ladder program but only one Load Parameter Immediate Command may be used per scan Therefore the COMM is most useful for loading several or many parameters and the Load Parameter Immediate Command is most useful for loading one or two In general COMM REQ is used in a Series 90 30 PLC ladder program to communicate with an intelligent module However this chapter only discusses the COMM as it applies specifically to a DSM module The chapter is divided into four sections e Section 1 The Com
92. the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply The following are trademarks of GE Fanuc Automation North America Inc Alarm Master Field Control Modelmaster Series 90 CIMPLICITY GEnet Motion Mate Series One Genius PowerMotion Series Six CIMPLICITY PowerTRAC Genius PowerTRAC ProLoop Series Three CIMPLICITY 90 ADS Helpmate PROMACRO VuMaster CIMSTAR Logicmaster Series Five Workmaster Copyright 1999 2002 GE Fanuc Automation North America Inc All Rights Reserved Preface Content of This Manual GFK 1464C This manual describes the Motion Mate DSM302 Release 1 40 which is a complete integrated motion control system The Motion Mate DSM302 is an intelligent fully programmable motion control option module for the Series 90 30 Programmable Logic Controller PLC The Motion Mate DSM302 allows a PLC user to combine high performance motion control with PLC logic solving functions in one integrated system This manual consists of nine chapters and seven appendices Chapter 1 Product Overview This chapter provides an overview of the hardware and software used to set up and operate a Motion Mate DSM302 motion control system Chapter 2 Getting Started This chapter provides an introduction to the Motion Mate DSM302 motion control system through a start up guide that outlines the steps required to operate or jog your motio
93. the axis is commanded to be at any instant in time The difference between Commanded Position and Actual Position 1s the Position Error value that produces the Velocity Command to drive the axis The rate at which the Commanded Position 1s changed determines the velocity of axis motion If Commanded Position moves past either of the count limits it will roll over to the other limit and continue in the direction of the axis motion Actual Position Actual Position user units is a value maintained by the DSM302 to represent the physical position of the axis It is set to an initial value by the Set Position Immediate command or to Home Position by the Find Home cycle When digital absolute encoders are used Actual Position is automatically set whenever the encoder reports a valid position The motion of the axis feedback device continuously updates the axis Actual Position If Actual Position moves past either of the count limits it will over to the other limit and continue in the direction of the axis motion Strobe 1 2 Position Strobe 1 Position and Strobe 2 Position user units contain the axis actual position when a Strobe 1 Input or Strobe 2 Input occurs When a Strobe Input occurs the Position Strobe 1 or Position Strobe 2 l bit is set to indicate to the PLC that new Strobe data is available in the related Strobe 1 Position or Strobe 2 Position status word The PLC must set the proper Reset Strobe I or Reset Strobe 2 Fla
94. the configured Follower Enable Input bit CTLO1 CTL16 ACC RAMP means the follower axis velocity is ramped at the active Jog Acceleration rate when the follower is enabled or disabled The winder modes provide a follower cycle that reverses direction at each end of the configured Winder Zone Length If the Winder Zone Length is changed WINDER provides equal taper WINDER R provides taper of the right side only and WINDER L provides taper of the left side only CAMI CAM2 and CAM3 are reserved for future operating modes Refer to Chapter 8 for additional details Default NORMAL MkupTime Follower Acceleration Ramp Makeup Time milliseconds Specifies the time in milliseconds used to make up the master command counts lost during a follower acceleration ramp If the distance correction is not possible in the makeup time too small a value then the correction time is longer and a warning error is reported This setting only has an effect when the FOLLWR MODE is set to ACC RAMP If an acceleration ramp without any correction for lost counts is desired Makeup Time should be set to 0 Chapter 4 Configuring the DSM302 4 21 4 22 2 38 2 39 2 40 2 41 2 42 2 43 Makeup time has a minimum value of 10 so for values entered in the range of 1 10 use 10 instead Default 0 Refer to Chapter 8 Follower Motion Follower Axis Acceleration Ramp Control section for a much more detailed discussion of this feature WinderZnlen Winde
95. the defined input will instantly enable the follower The follower will remain enabled until the Enable Follower Q bit is cleared The faceplate 24v inputs have 5 ms filters that result in a Follower Enable Trigger response time of 5 7 milliseconds The faceplate 5v inputs do not have these filters and will provide an Enable Trigger response time of 1 millisecond or less When the Enable Follower trigger occurs the Commanded Position at that point is captured in a parameter register so that it can be used in a Programmed Move command The position is captured in parameter 226 for Servo Axis 1 or parameter 234 for Servo Axis 2 Follower Enabled status is returned in lI bit offset 28 Servo Axis 1 or 6I bit offset 44 Servo Axis 2 Chapter 8 Follower Motion 8 9 Follower Axis Acceleration Ramp Control For applications where the Follower is enabled when the Master command is already up to speed the Follower Ramp feature can be used to apply a controlled acceleration rate to bring the follower axis up to speed This may be done without losing any Master command counts from the point at which the Follower was enabled During the automatically generated Follower Ramp Control make up move the acceleration deceleration does not exceed the active jog acceleration value and provides a smooth motion When the Follower Ramp feature has been selected FOLLWR MODE is set to ACC RAMP and the follower is enabled the following axis is ramped up to th
96. the devices which normally connect to the IC693ACC335 Digital Servo Terminal Board screw terminals the Terminal Board and Terminal Board Cable IC693CBL324 325 are not needed Instead the Digital Servo Command Cable IC800CBL001 002 can be connected directly from the Digital Servo Amplifier to the DSM302 faceplate A or B connector When this is done the OT Limit Sw configuration parameter must be set to DISABLE in the configuration software or the DSM will not operate GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 17 3 18 The figure below illustrates the Digital Servo Axis terminal board and cables associated with the DSM302 IC693ACC 336 Auxiliary Terminal Board TSTST T TI I T T TT eet st Ts Te T2 T T5 IIIIIIITIIrLiT Iris IC693ACC336 Auxiliary Terminal Board USER I O A SI SA A 1C693ACC335 Servo AxisTerminal Board TO MOTION TO TANUG PROGRAMMER S M Cable 1C693CBL316 Terminal Board to Servo Cables IC800CBL001 1 M IC800CBL002 3 M DSM to Terminal Board Cables IC693CBL324 1M IC693CBL325 3M USER I O IC693ACC335 Servo Axis Terminal Board Figure 3 10 DSM302 Digital Servo Terminal Boards and Connectors Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C
97. the home cycle Final Home Velocity must be slow enough to allow a 10 millisecond filter time delay between the final Home Switch transition and the Encoder Marker pulse Default 500 Find Home Vel Find Home Velocity User Units second The velocity at which the servo seeks the initial Home Switch transitions during the Find Home cycle when the Home Mode is configured for HOMESW If desired Find Home Velocity can be set to a high value to allow the servo to quickly locate the Home Switch Default 2000 Home Mode Find Home Mode The method used to find home during a Find Home cycle HOME SWITCH indicates that a Home Switch is to be monitored to Find Home MOVE and MOVE specify direct positive and negative movement to the next encoder marker at the Final Home Velocity See chapter 6 Non Programmed Motion for details on the Home Cycle Home Switch and Move Modes Default HOMESW Chapter 4 Configuring the DSM302 4 19 4 20 2 29 2 30 2 31 2 32 2 33 Pos EOT Positive Software End of Travel limit User Units If the DSM302 is programmed to go to a position greater than the Positive EOT an error will result and the DSM302 will not allow axis motion In Follower mode the DSM302 internally sets Pos EOT to the HI Limit position rollover value See Note under Axis Mode The Pos EOT limit applies only when the Axis Mode configuration is set to LINEAR Default 8 388 607 Neg EOT Negative Software E
98. the instantaneous velocity generated by the DSM302 s internal path generator Commanded Position the instantaneous position generated by the DSM302 s internal path generator Actual Velocity the velocity of the axis indicated by the feedback Actual Position the position of the axis indicated by the feedback Position Error the difference between the Commanded Position and the Actual Position The DSM302 allows a Position Loop Time Constant in milliseconds and a Velocity Feedforward in percent to be programmed The Position Loop Time Constant sets the Position Loop Gain and determines the response speed of the closed Position Loop The Velocity Feedforward percentage determines the amount of Commanded Velocity that is summed into the Servo Velocity Command MOTION MOVE PROGRAMS AT VEL JOG COMMAND CMD VELOCITY VELOCITY FEEDFORWARD GENERATOR CMD POSITION POSITION FEEDBACK ENCODER Figure 1 2 Simplified Standard Mode Position Loop with Velocity Feedforward GFK 1464C Chapter 1 Product Overview 1 9 Follower Mode Operation Figure 1 3 is a simplified diagram of the Follower mode Position Loop It is similar to the Standard mode Position Loop see previous page with the addition of a Master Axis input The Master Axis input is an additional command source producing a Master Axis Position and Master Axis Velocity Master Axis Position is summed with Commanded Position from the axis
99. the programmed acceleration to zero Then a Jog is performed using the Jog Minus Q bit This is evident because the jog velocity is negative Note that the acceleration used during the Jog is the current Jog Acceleration which is different than the programmed acceleration Note also the Feed Hold Q command must be applied during the entire duration of the Jog After the jog motion has ceased the Feedhold is ended and the program continues to completion V 45269 ACCEL 1000 VELOC 2000 PMOVE 12000 INC LINEAR Feedhold Feedhold Applied Removed Figure 7 19 Feedhold Example Feedrate Override Some applications require small modifications to a programmed velocity to handle outside changes A Rate Override AQ immediate command which is sent to the DSM through ladder logic allows changes to a programmed feedrate velocity during program execution Details about the Rate Override command are found in Chapter 5 When a program begins executing the override rate is initially set to 100 Thus changes to feedrate before the execute program bit is turned ON will be ignored However a rate override commanded on the same sweep as an execute program bit will be effective A percentage can be assigned to the feedrate override of from 0 to 120 When a Rate Override is commanded the DSM302 internally multiplies the feedrate percentage by programmed velocity to obtain a new velocity Ifthe axis is moving the current move s Jog Accel
100. the velocity generated when the Analog Input is 10V Zero velocity is generated when the Analog Input is and the negative of the maximum velocity is generated at 10V Example 3 Following the Analog Input In the graph below the DSM302 is configured with Master Source ANALOG The A B ratio is 1 1 The dotted lines indicate when the Enable Follower Q bit was turned ON and OFF 2345329 Mere Figure 8 3 Following the Analog Input Encoder Servo Axis 2 Master The DSM302 can be configured so that Servo Axis 1 will follow Servo Axis 2 With ENC2 as the Master Source for axis 1 axis 1 will follow axis 2 at the axis 2 velocity multiplied by the A B ratio configured for axis 1 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Example 4 Following Servo Axis 2 Encoder Axis of a DSM302 is configured with Master Source ENC2 With the A B ratio 1 2 axis 2 is commanded to Move at Velocity 12000 and then 0 Axis follows axis 2 at half of the axis 2 velocity and acceleration and moves only half the distance that axis 2 has moved V V 245330 A B Ratio 1 2 Axis 2 Master t Axis 1 Follower t Figure 8 4 Following Servo Axis 2 Encoder A B Ratio A DSM302 axis following a master input can do so at a wide range of slave master A B ratios The A value can be any number from 32768 to 32767 The B value can be anywhere between and 32767 The magnit
101. to 240 VAC Allowable voltage fluctuation 15 to 10 Frequency 50 60 Hz Allowable frequency fluctuation 2 Hz Voltage fluctuation at acceleration deceleration 7 or less Temperature de rating Driving the following motors with single phase power requires temperature de rating 86 2000 and 0 12 2000 3 8 E 5 3 40 55 Ambient temperature C When a motor is powered with a single phase voltage the lifetime of the related servo amplifier may be decreased due to heat generated 1f repeated acceleration deceleration restrictions are not observed If the 86 2000 or 12 2000 is used for applications that require start stop cycles of 20 seconds or less it should be powered with a three phase voltage Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C What are the differences between the Series and the B Series Servo Motors and Amplifiers 5 6 106 in Ib 0 5 12 Nm Medium Compact i __ What are the benefits of a digital servo system Digital System All control loops current velocity and position are closed in the controller High speed microprocessors or digital signal processors DSPs in the motion controller provide loop update times on the order of 250us The servo system can compensate for some machine design limitations yielding faster acceleration deceleration rates and better response to load changes and wide i
102. transfer JUMP CTL12 program execution to the given block Program Zero Motion Command Descriptions GFK 1464C Chapter 4 Configuring the DSM302 4 25 4 26 Each DSM302 command is briefly described below For a comprehensive explanation of Motion Programming on the DSM302 refer to Chapters 7 8 and 9 of this manual See also GFK 0664 The Series 90 APM Programmer s Manual Acceleration ACCEL This modal command is used to specify the axis acceleration and deceleration rate for subsequent moves Once encountered the specified rate will remain in effect until overridden by a later Acceleration command Block Number BLOCK Block numbers are used to monitor and synchronize program execution terminate jump testing and identify jump destinations Block number is an actual command in the Program Zero Editor The default block number is zero Block numbers serve as labels for MOVE DWELL and WAIT commands Cmove CMOVE Continuous Move this command is used when it is not necessary for the axis to be within the configured Position Zone before proceeding to the next command If no previous acceleration or velocity has been specified in a motion program the configured Jog Acceleration and or Jog Velocity will be used Dwell DWELL This command causes motion to cease for a specified time period in milliseconds before proceeding to the next command Jump JUMP This command is used to Branch program execution to ano
103. where it will reverse direction and continue moving within the zone The Zone Position Register always indicates the relative position of the winder axis within the zone If its sign is then it is moving in the same direction as the master command and if its sign is it is moving in the opposite direction of the master command For zone tapering the PLC must send the new zone width at the correct time to produce the desired taper contour If the taper mode selection left or right side the total zone change adjustment will be applied to the designated side of the zone If the taper mode selection both sides the adjustment will be applied equally to each end of the winder zone During the winding operation the PLC may send the Winder Zone Length AQ command to adjust for winder spool taper If the change in the zone length absolute value is greater than the distance from the winder axis position to the end of the zone the DSM302 will wait to perform the update until the axis has moved to an acceptable position Successive zone length change commands before the previous one has been updated will result in a reported error A command for a zone length change gt 25 while the follower is enabled will also result in a reported error Changing A B Ratio in Winder Mode In WINDER mode the A B ratio cannot be changed unless the follower is disabled Any attempt to change it when the follower is enabled will result in a reported error The sign
104. 0 Power Supply is illuminated Place the PLC in the STOP Disabled mode This can be done by using the Logicmaster 90 30 configuration software Alt R hot key or with the Series 90 30 Hand Held Programmer Mode Run keys If using an optional motor mounted holding brake apply applicable power 90 VDC for o and B Series motors and 24 VDC for SL Series motors to brake leads to disengage the holding brake Having accomplished these steps it s time to Configure the Motion Mate 05302 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 4 Configuring the Motion Mate DSM302 The DSM302 Controller is configured using the Logicmaster 90 30 configuration software version 8 02 or later The DSM302 has an extensive set of features that enable it to adapt to many different applications You can easily make adjustments to your motion system Parameter registers in the DSM302 memory allow you to use variables in DSM302 motion programs The DSM302 contains several configuration parameters however only a few need to be set for most applications The remaining configuration parameters are normally set to their default values This section briefly describes the DSM302 configuration fields and how to view and set the configuration parameters required to jog an axis using Logicmaster 90 30 software Using Logicmaster 90 LM90 Program Folders 1 A Logicmaster 90 30 program folder is a
105. 00 each ACCEL 100 VELOC 12000 CMOVE 720000 INC LINEAR Pt a45314a VELOC 12000 CMOVE CMOVE 3280000 INC LINEAR Begins PMOVE VELOC 24000 24000 Begins x CMOVE 3280000 INC LINEAR VELOC 12000 PMOVE 720000 INC LINEAR 12000 720000 4000000 7280000 8000000 t Figure 7 17 Maximum Acceleration Time Example 2 Feedhold with the DSM302 Feedhold is used to temporarily pause program execution without ending the program often to examine some aspect of a system It causes all axis motion to end at the programmed acceleration When Feedhold is ended program execution resumes Interrupted motion will resume at the programmed acceleration and velocity Feedhold is asserted by turning ON the Feed Hold Q bit and lasts until the Q bit is turned OFF The Abort All Moves bit turning ON or an error that would normally cause a stop error will end feedhold as well as terminate the program During Feedhold jogging positive and negative is allowed but no other motion When Feedhold is terminated and program execution resumes the DSM302 remembers and will move to its previous destination Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Example 16 Feedhold The following example illustrates a motion profile when Feedhold is applied The linear move accelerates to the programmed velocity at the programmed rate Feedhold is applied at the dashed line so velocity decreases at
106. 00001 Next highest type 40 50 or 64 words available AI reference Ref Adr Start address for AQ ref 000001 000001 Next highest type 6 9 or 12 words available AQ reference Len Number of PLC AI and 40 6 40 6 AQ references used by the DSM module Fdback Type Feedback Type DIGITAL NCODER ENCODER Ctl Loop Control Loop Type STANDARD TANDARD STANDARD Servo Interface Type DIGITAL NALOG ANALOG 2 8 Motor2 Dir velocity command 19200 Parity Parity 10 O ODD DataBits Numberofdatabits 8 is Modem TT____ Modem turn around time 0 lo 00001 n Idle Time Maximum link idle time SNP ID SNP ID A00001 gt 2 24 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Motor Type Digital Mode Selects the type of FANUC AC servomotor to be used with the DSM302 The DSM302 internally stores default setup motor parameter tables for each of the GE Fanuc servos supported A particular motor for the indicated axis is selected via the Logicmaster 90 30 configuration fields Motor Type for axis 1 or Motor2 Type for axis 2 Supported motor types are listed in the table below FANUC Motor Model Motor model information is in the form series continuous torque in Newton meters maximum rpm Example 82 3000 indicates a Beta series motor of 2 Newton meters continuous torque capability and 3000 RPM maximum continuous
107. 002 GFK 1464C 34 17 16 35 18 36 14 32 27 10 28 Aux 4q C693ACC336 Aux Term Board i DRIVE Terminal AOUT A 55 7 24 l CMD AXIS 1 MOTOR ENBL1_A 15 ENABLE ENBL2_A X 33 ov INA A 5 fem RDY OV A 0 X I gt lt ENCODER FREQUENCY 23 ov 250 KHZ CHANNEL 1 MHZ COUNT RATE S SHIELD WITH DIFFERENTIAL INPUT A QUAD A At 150 KHZ CHANNEL 600 KHZ COUNT RATE 1 WITH SINGLE ENDED INPUT IN1M_A QUAD A 19 QUADRATURE TOLERANCE P IN2P A QUAD B Bs 90 DEGREES 45 DEGREES T IN2M A QUAD B bd VES B 20 INCREMENTAL QUADRATURE A MARKER 3 ENCODER IN3M_A MARKER x lt 21 NOTE FOR SINGLE ENDED 4 BS A Ced ENCODER DO NOT OV A 0V CONNECT A B MKR 22 NEGATIVE OVERTRAVEL POSITIVE OVERTRAVEL LIMIT SWITCH SWITCH LIMIT SWITCH E IN10 A OT 34 IN11 A HOME INPUT amp l BIT 17 OT CTLO1 IN9 A OT OT CTLO2 16 HOME CTLO3 INCOM_A STROBE1 CTLO4 35 OUT1P A SSR OUT R 125 MA 5 24 OUT1M_A SSR OUT VEC 36 LOAD OUT3P_A 14 _ 5V OUT3M A X lt gt DIFFERENTIAL 32 E 2 OUTPUT 105_A STROBE1 9 _A 5V OV A 0 X p SINGLE ENDED 27 DRIVER 106_A STROBE2 10 5V OV A 0 SINGLE E
108. 02 faceplate can be used in motion programs to delay or alter program execution flow The PLC receives status information such as position velocity and Command Block Number from the DSM302 during program execution Program Zero is edited with the Logicmaster configuration software and is incorporated into and stored with the module configuration Motion programs 1 10 and sub routines 1 40 are edited with the Motion Programmer software and must be stored to the DSM302 via its COMM port connector located on its faceplate Please refer to the Series 90 PLC APM Programmer s Manual GFK 0664 for further information Single Axis Motion Programs and Sub Routines A single axis program contains program statements for one axis only The programmed axis is specified as a motion program command operand either axis 1 or axis 2 in the motion program command statements The DSM302 may operate two single axis programs one for each axis independently or simultaneously For example motion program may be written for axis one and motion program 2 written to control axis two Each axis may be home referenced and the motion program for each axis may execute independently without regard to the state of the other axis Alternately program 1 and program 2 may execute simultaneously via the run program Q bits during the same PLC sweep Motion programs 1 10 support the sub routine feature but Program Zero does not Sub routines may include all the availabl
109. 1 11 Refer to publication GFH 001 Servo Product Specification Guide for more information about the o Series servo products Series FANUC Servo Motors The a Series of servomotors incorporate design improvements to provide the best performance possible Ratings up to 56 Nm are offered These motors are up to 15 shorter and lighter than the previous S Series of servomotors New insulation on the windings and an overall sealant coating help protect the motor from the environment The standard encoder supplied with the motor is a 64K absolute unit Holding brakes 90 Vdc and IP67 sealants are options The Series servomotors are approved to conform to international standards for CE EMC and Low Voltage IEC and UL CUL The following table indicates a sample of the Series motors available some aL and also available For more information refer to Chapter 4 of this manual Configuring the DSM302 under the section labeled Motor Type See also the following publications e GFH 001 Servo Products Specification Guide e GFZ 65142E 02 a Series AC Motor Descriptions Manual Table 1 2 Selected o Series Servo Motor Models es 2 3000 fo pe p fo lm e p pe lm e pe pe hm m p pe m m e pe e m m m e pe m m e pe 1 12 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Section 4 B Series S
110. 1 to 1 32 Refer to Chapter 8 for additional information about the A B ratio Velocity Loop Gain VLGN Digital Mode only The velocity control loop gain for a GE Fanuc digital servo axis may be set with the Velocity Loop Gain command The VLGN value is used to match the load inertia Jj to the motor inertia JM VLGN is defined with a default value of 16 representing an inertia ratio of 1 to 1 The VLGN value is calculated assuming that the load is rigidly applied to the motor Therefore in actual machine adjustment the required value may significantly differ from the calculated value due to rigidity friction backlash and other factors A PLC reset or power cycle returns VLGN to the value set in the configuration software A suggested starting point for Velocity Loop Gain is Load Inertia J 16 Velocity Loop Gain Motor Inertia Jm The allowed range of Velocity Loop Gain is 0 to 255 For example The motor inertia JM of a particular servo is 0 10 Ib in s The load inertia Jp in this application is 0 05 Ib in s2 VLGN 0 05 0 10 16 8 The default Velocity Loop Gain 1s set using the Vel Lp Gain setting in the Logicmaster Configuration Software Chapter 5 Motion Mate DSM302 to PLC Interface 5 21 5 22 4 17 4 18 4 19 4 20 4 21 An incorrect VLGN value may cause an axis to be unstable Care should be used when making any change to the VLGN value Torque Limit TRLMT Digital Mode only The Torque Lim
111. 15 Q Discrete Commands Assembly Drawings 3 16 Abort All Move Components 3 16 Clear Error description and mounting dimensions 3 15 CTLO9 CTL12 Output Controls 5 12 Side View 3 17 Enable Drive MCON 5 12 Axis 1 2 Follower Master Error Code AI Status Word 5 8 Enable Follower Axis Configuration Data 4 9 Execute Motion Program 0 10 Feed Hold Off Transition Axis Mode Feed Hold fs n Transition 15 12 DisDly 4 19 Find Home 5 13 Fdback Mode 4 19 1 GFK 1464C Index 1 Index Index 2 4 14 Pos Loop TC Rev Comp 4 18 Tuning 4 20 Tuning Dat2 Tuning Parameter 1 Tuning Parameter 2 4 20 User Units Counts VelLp Gain 4 19 19 Velocity at 10 Volts Velocity FF 4 18 WinderZnlen Axis Connector Pin Assignments Axis Enabled 1 Status Bit 5 4 Axis Field Program Zero Axis Mode Axis Terminal En Assembly Drawings Components 3 13 Side View 3 14 Bandwidth defined D 12 Beta motors running above rated speed G 4 72 Block 7 2 BLOCK Command Program Zero 4 28 Block Numbers and Jump Brake motor holding G 5 C Cable K1 Series Connection 2 6 2 13 Cable K12 24 VDC to Servo Amplifier Cable K2 Series Connection 2 10 2 17 Cable K3 220 VAC Power to B Series Amplifier 2 17 Cable K4 Motor Power to o Series 2 8 Cable K8 External Regeneration Resistor or Jumper f Series 2 19 Cab
112. 15 9 16 9 17 18 19 e ere ejejeje e e e e e OMNDAARWN Terminal Of Servo Amp Phase U Phase V Phase W Ground GFK 1464C 3 Connect the Motor Encoder to the Series Digital Servo Amplifier A Remove the protective plastic cap from the encoder connector on the motor and locate the K2 feedback cable IC800CBL021 The cable is configured so that it can only be attached to one connection on the motor B Plug the opposite end into the connection labeled JF1 on the bottom of the o Series servo amplifier see Figure 2 6 Repeat this procedure for all axes in the system Servo Amplifier JA4 JF1 JS1B FANUC AC SERVO UNIT Front Face OL SERIES IC800CBL021 Motor Encoder Cable K2 Motor Figure 2 6 Connecting the Series Motor Encoder Table 2 3 Prefabricated Servo Motor Encoder Cable K2 for o3 to 40 Models Motor Models Severe Duty Cable Cable Length Note Details on cables can be found in the o Series AC Servo Motor Descriptions Manual GFZ 65142E and in a and Series Product Specifications Guide GFH 001 GFK 1464C Chapter 2 Getting Started 2 9 4 Connect 220 Volt AC 3 Phase Power to the o Series Digital Amplifier An AC line filter will reduce the effect of harmonic noise to the power supply its use is recommended Two or more amplifiers may be connected to one AC line filter if i
113. 2 CAM 2 See Note 2 CAM 3 See Note 2 GFK 1464C Chapter 4 Configuring the DSM302 4 9 Table 4 3 Continued Axis Configuration Data Configuration Logicmaster Valid Ref Parameter Description Values Defaults Units Modes MkupTime Ramp Makeup Time 0 32 000 o ms 7 Follower 237 Winder Znlen Winder Zone Length 100 8 388 607 10 000 Enc3 Hi Lim Aux Axis 3 Position Hi 8 388 607 counts Follower 2 39 Count Limit 8 388 608 8 388 607 Count Limit 8 388 608 8 388 607 bu 8 388 608 8 388 607 Enable DISABLED Anlg Max Vel Analog Maximum Velocity 0 1 000 000 4 10 Note 1 Note 2 2 01 Scaling dependent configuration parameter whose value range depends upon user unit scaling Values shown in table are for default scaling Refer to the descriptions below for calculating the current values when using non default scaling of User Units and Counts parameters These parameters are reserved for future use User Units Counts The User Units to Counts ratio sets the number of programming units for each position feedback count This allows the user to program the DSM302 in application specific units The User Units and Counts values must be within the range of 1 to 65 535 The User Units to Counts ratio must be within the range of 8 1 to 1 32 For example if there is 1 000 inch of travel for 8192 feedback counts a 1000 8192 User Units Counts rati
114. 23A hexadecimal For this value 0033 is the most significant word and E234 is the least significant word The data to be sent to the DSM302 would be Word 2 Word 1 Word 0 Command 0033 E23A 0023 Set Position 3 400 250 Setting up word 0 as a hexadecimal word and words 1 and 2 as a double integer in a LM90 Mixed Reference Table Display will simplify immediate command entry Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C In the following AQ command table only the word offsets for Servo Axis are listed Word offsets for the other axes are computed by adding 3 Servo Axis 2 6 Aux Axis 3 or 9 Aux Axis 4 to the listed word offsets Note that the only Immediate Command that may be used with Aux Axis 3 or 4 is Force Analog Output The Ref column numbers refer to sections in this chapter Table 5 7 AQ Immediate Commands Using the 6 Byte Format Command Definition oon fem ETE 01 RO Rate Override RO 0 12096 Incr Position Increment Without Position Update Incr 128 127 User Units Velocity 22h Move At Velocity Vel 8 388 608 8 388 607 User Units sec Position 23h Set Position Pos 8 388 608 8 388 607 User Units Analog Output 24h Analog Output Analog Output 32 000 32 000 Incr 25h Position Increment With Position Update 4 07 Incr 128 127 User Units XX XX XX In Posn 26h In Position Zone 4 08 Zone Range 0
115. 324 1 meter or IC693CBL325 3 meters connects from DSM connector PL2 to DSM302 faceplate A Servo Command Cable IC800CBL001 1 meter 800 002 3 meters connects from the SERVO connector PL3 to a GE Fanuc series or series Digital Servo Amplifier unit GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 9 3 10 Eighteen screw terminals are provided on the Digital Servo Axis Terminal Board for connections to user devices These terminals have the following assignments Table 3 4 Digital Axis Terminal Board Pin Axis Terminal DSM302 Circuit Servo Axis 1 2 Signal Name Board I O Faceplate Identifier Circuit Function Axis 1 listed Screw Terminal i Single ended Strobe Input 1 A INIP A 5v inputs Strobe Input 2 IN2P ME e A 24v optically Overtravel s ss capt Commen OUTI 24 v 125 ma PLC 24v Output OUTIP ee OUT3 Differential PLC 5v Output OUT3P S bo a uo e our vv Analog Oat PLC Analog Out AOUT A ACOM Analog Analog S 2 pins SHIELD Cable Shield Cable Shield SHIELD A For signal names pertaining to servo axis 2 change all A to The maximum voltage that should be applied to I O terminals 6 8 and 14 16 is 30 VDC The maximum voltage for any other input terminal is 5 VDC Six 130V MOVs are installed between selected I O points and the
116. 4 Constant Rate CFG LED ON The LED flashes slow four times second for Status Only errors and fast eight times second for errors which cause the servo to stop The operational error code will be placed in one of the first four AI status words and the Module Error Present 1 status bit will be ON Constant Rate CFG LED Flashing If the STAT and CFG LEDs both flash together at a constant rate the DSM302 module is in boot mode waiting for a new firmware download If the STAT and CFG LEDs both flash alternately at a constant rate the DSM302 firmware has detected a software watchdog timeout due to a hardware or software malfunction Irregular Rate CFG LED OFF If this occurs immediately at power up then hardware or software malfunction has been detected The module will blink the STAT LED to display two error numbers separated by a brief delay The numbers are determined by counting the blinks in both sequences Record the numbers and contact GE Fanuc for information on correcting the problem The OK LED indicates the current status of the DSM302 module When the LED is steady ON the DSM302 is functioning properly Normally this LED should always be ON When the LED is OFF the DSM302 is not functioning This is the result of a hardware or software malfunction that will not allow the module to power up This LED is ON when a valid module configuration has been received from the PLC Flashes s ow four times second during
117. 4 COMTI SUT ALON SERIE 8 14 Operation StS PS arcere retro e Ph RET dence RUD ena eee tee e edet 8 14 Operation Description 8 15 Contents ix Contents Changing Ratio in Winder Mode 0 ccccccccsssesseceseceeceseceeceeeeseeeseeeeseeeseeeeneeenneeenes 8 15 Follower Mode Master Axis and Connection 8 16 Follower Control Loop Block Diagram essere 8 19 Chapter 9 Combined Follower and Commanded Motion eee 9 1 Example 1 Follower Motion Combined with 9 Follower Motion Combined with Motion Programs essen 9 2 Example 2 Follower Motion Combined with Motion Program sss 9 5 Control Sequence oeni e e HE e HH a dd 9 5 Appendix A Error se eese se tete se tee sette se eee e A 1 DSM3092 Error Codes ena a iie edis ride eed ters 1 Error C de Format urne EA a E 2 Response Methods uec emet ieee ct tren A 2 DSM Digital Servo Alarms ener enne A 7 LED Indicators irana Wet een tdeo Oso RE LE ERR Reed A 11 Appendix B DSM Parameter Download Using the COMM REQ Instruction B 1 Section 1
118. 464C L Series FANUC Servo Motor L3 3000 L6 3000 L9 3000 L25 3000 L50 2000 C3 2000 a 6 2000 C12 2000 a 22 1500 HV Series FANUC Servo Motor Motor Type Code Motor Model Motor Specification 12HV 3000 a 22HV 3000 30HV 3000 DSM firmware revision 1 10 or later is required for HV Series Motors M Series FANUC Servo Motor Motor Type Code Motor Model Motor Specification 3 3000 6 3000 9 3000 Series FANUC Servo Motor Motor Type Code Motor Model Motor Specification B 0 5 3000 B 1 3000 B 2 3000 B 3 3000 B 6 2000 GFK 1464C Chapter 4 Configuring the DSM302 4 5 1 06 Motor Dir For all GE Fanuc digital servos a configured motor direction of POS Positive defines the positive axis direction as counter clockwise CCW motor shaft rotation when viewed looking into the motor shaft A configured Motor direction of NEG Negative defines the negative axis direction as clockwise CW shaft rotation For analog servos a configured analog motor direction of POS Positive defines the positive axis direction as encoder channel A leading channel B A configured analog motor direction of NEG Negative defines the negative axis direction as encoder channel B leading channel A In practice the motor direction configuration allows the user to easily reverse the motion caused by all commands without having to change the motion program
119. 64C GFK 1464C Motion Program Example 1 Begin Program BLOCK JUMP JUMP CMOVE BLOCK CMOVE BLOCK PMOVE BLOCK DWELL End Program 1 CTLO1 2 This JUMP command will be ignored CTL02 3 This JUMP command will be recognized 1 40000 INC LINEAR 2 1 20000 INC LINEAR 3 1 100000 ABS LINEAR 4 1 100 When a new Block Number becomes active AFTER a Conditional JUMP command Jump testing will occur one final time Motion Program Example 2 Begin Program BLOCK CMOVE JUMP BLOCK PMOVE BLOCK DWELL End Program 1 1 20000 ABS LINEAR CTLO1 3 2 1 40000 ABS LINEAR CTLO1 tested only once 3 1 100 In the example above The CTL01 bit test occurs just once because the PMOVE following the JUMP contains a new Block Number 2 Changing the location of Block Number 2 causes CTL bit testing throughout the PMOVE following the JUMP Motion Program Example 3 Begin Program BLOCK CMOVE BLOCK JUMP PMOVE BLOCK DWELL End Program 1 1 20000 ABS LINEAR 2 CTLO1 3 1 40000 ABS LINEAR CTLO1 tested throughout PMOVE 3 1 100 Chapter 7 Programmed Motion 7 13 Jump Testing The DSM302 can perform a Conditional JUMP from an active CMOVE to a program block containing a CMOVE or PMOVE without stopping For the axis to jump without stopping the distance represented by the CMOVE or PMOVE in the Jump block must be greater than the servo stopping distance The servo stoppin
120. 7 15 Jumping After the Midpoint of Acceleration or Deceleration 7 19 Figure 7 16 Jumping before the Midpoint of Acceleration or Deceleration sess 7 19 Figure 7 17 Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating 5 aec eee PE eid eee t 7 20 Figure 7 18 Maximum Acceleration Time Example 1 essen 7 2 Figure 7 17 Maximum Acceleration Time Example 2 7 22 Figure 7 19 Feedhold Example entente enne teen inrer nennen 7 23 Figure 7 20 Feedrate Override Example sees entente nnne 7 24 Figure 7 21 Multiaxis Programming Example sese 7 25 Figure 7 22 Trapezoidal Move n cs ounces ere tele eet ederet uen 7 29 Figure 7 23 Triangular Velocity Profile essere ethernet nennen nennen 7 30 Figure 7 24 S Curve Acceleration n eoo tee fite e os de cte rede 7 30 Figure 8 1 Following Encoder Master 1 140100 2020 0400 0000000 000000000000000000 8 2 Figure 8 2 Following the Internal Master ssesssssseseseeseeeeeneeen enne nre treten ens 8 3 Figure 8 3 Following the Analog Input erret rene ener t n enr ern rir rtu 8 4 Figure 8 4 Following Servo Axis 2 Encoder oe prm ie rro ERR APERIRE buy 8 5 Motion Mat
121. AI Length in the module configuration is set to 64 words the values of all eight analog inputs are reported in word offsets 50 57 of the AI table The data is scaled so that 32000 10 00v When Servo Axis 1 2 Connectors A and B control a digital servo the analog inputs are connected through the servo command cable to the servo amplifier These inputs detect the AC servo phase feedback currents and are not available for general use If a Servo Axis is not used to control a digital servo an Auxiliary Terminal Board IC693ACC336 and associated cable may be used to allow analog input connections to user devices Chapter 5 Motion Mate DSM302 to PLC Interface 5 9 For Aux Axis 3 4 Connectors C and D the analog inputs are available for connection to user devices An Auxiliary terminal board IC693ACC336 and associated cable must be used for this purpose On each faceplate connector and Auxiliary Terminal Board Analog Input 1 connects to pins 7 and 25 Analog Input 2 connects to pins 8 and 26 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 3 0 Discrete Commands The following Q Outputs represent Discrete Commands that are sent automatically to the DSM302 from the CPU each PLC sweep A command is executed simply by turning on the Output Bit of the desired command The actual addresses of the Discrete Command bits depend on the starting address configured for the Q refer
122. AOUT C ACOM C E COM Referenced to Ov ENBL1 C ENBL2 C AC DC Solid State Relay Note See Chapter 6 for home switch information Figure 3 21 Aux Axis 3 Follower Master Axis Connections GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 33 INCREMENTAL QUADRATURE ENCODER FOR SINGLE ENDED ENCODER DO NOT SHIELD_C CONNECT A B MKR ENCODER FREQUENCY 250 KHZ CHANNEL 1 MHZ COUNT RATE WITH DIFFERENTIAL INPUT 150 KHZ CHANNEL 600 KHZ COUNT RATE WITH SINGLE ENDED INPUT QUADRATURE TOLERANCE 90 DEGREES 45 DEGREES Figure 3 22 Aux Axis 3 Follower Master Axis Encoder Connections 3 34 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Aux TB Terminals on IC693ACC336 Aux Terminal Board Terminal 105 SHIELD D P5V D 5V OV D 0V IN9 D IN10 D IN11 D INCOM D D SSR OUT OUT1M D SSR OUT OUTSP D OUTS3M D SHIELD D AIN1P D AIN1 AIN1M D AIN1 AIN2P D AIN2 AIN2M D AIN2 SHIELD D AOUT D ACOM D ENBL1 D ENBL2 D Figure 3 23 Aux Axis 4 Connections Chapter 3 Installing and Wiring the DSM302 7 24V INPUT 24V INPUT 24V INPUT 24 VDC ON E 1 NF DRIVER 5V ov D lt lt enen VJ INPUT BIT OFFSET IN10 D IN11 D BRAS 125 MA 5 24 LOAD VDC 5V DIFFERENTIAL OUTPUT A
123. Appendix H DSM302 Revision History H 3 4 Firmware Release 1 20 Features Introduced in Release 1 20 Expanded Follower A B Ratio The A B slave master follower ratio has been expanded from the original range of 32 1 to 1 32 toa range that supports 32 1 to 1 10 000 Existing AQ command 2Dh can be used to specify an expanded range at runtime Specifying the expanded range ratio greater than 1 32 at configuration time requires release 9 0 or higher of the MS DOS Programming Software or Windows based Programming Software release 2 11 or higher Enhanced Position Loop Resolution Enhanced position loop resolution at the expense of maximum supported motor velocity was added to the product in firmware release 1 20 Prior to this release a non configurable position loop resolution of 8192 counts per encoder revolution was provided The table below describes the various selections now supported along with the maximum supported motor velocity for each setting Note that the configuration data is specified by entering a value of 1 to select parameter 1 in the Tuning Parl or Tuning Par2 field of the Axis 1 screen for axis 1 or Axis 2 screen for axis 2 The appropriate resolution setting value 0 3 is then entered in the corresponding Tuning Dat1 or Tuning Dat2 field in the Axis 1 screen for axis 1 or Axis 2 screen for axis 2 Enhanced Position Loop Resolution Selections Supported Encoder Resolution Maximum Moto
124. Before JUMP GFK 1464C Chapter 7 Programmed Motion 7 15 Jumping Without Stopping Jump Stop If the Type 3 command following a conditional jump is a CMOVE and the Type 3 command at the destination is a move command with sufficient distance to fully decelerate to zero when completed the jump will be executed without stopping This is the only way to sustain motion when a jump is performed Example 9 JUMP Without Stopping This is a simple example of a conditional jump from one CMOVE to another While jump testing the CTLO3 bit the first CMOVE accelerates to the programmed velocity Before the dashed line the CTLO3 bit is OFF but at the dashed line the C7TL03 bit turns ON Program execution is immediately transferred to block 3 and the CMOVE there begins Because the velocity at the jump destination is different the velocity changes at the acceleration programmed of the jump destination block Finally as the second CMOVE completes velocity is reduced to zero and the program ends BLOCK 1 ACCEL 2000 V a45264a VELOC 10000 JUMP CTLO3 3 CMOVE 120000 INC LINEAR BLOCK 3 ACCEL 20000 A VELOC 5000 CTLO3 ON CMOVE 15000 INC LINEAR Figure 7 12 JUMP Without Stopping A jump stop is a stop that is caused by a jump When a jump stop occurs the Jog Acceleration and Jog Acceleration Mode are used instead of any programmed acceleration Note that s curve motion will achieve constant velocity before using the Jog Acceleration and beginn
125. D 8 Velocity Loop Step Response Velocity vs Time VLGN 64 sss D 10 Figure D 9 Velocity Loop Step Response Torque Command vs Time VLGN 64 D 10 Figure D 10 Velocity Loop Step Response Velocity vs Time VLGN 208 D 11 Figure D 11 Velocity Loop Step Response Torque Command vs Time VLGN 208 D 11 GFK 1464C Contents xv Contents xvi Table 1 1 Digital Servo Loop Update Times essere enne nnns 1 5 Table 1 Analog Servo Loop Update Times eene enne ener innen nns 1 5 Table 1 2 Selected Series Servo Motor 1 1 12 Table 1 3 Selected Series Servo Motor Models sss eene 1 14 Table 2 1 SVU Amplifier Channel Switch Settings essen enne 2 7 Table 2 2 Prefabricated Servo Motor Power Cable K4 Part Number 2 9 Table 2 3 Prefabricated Servo Motor Encoder Cable K2 for o3 to 40 2 10 Table 2 4 K4 Cable B Series Motor Cable Examples 2 15 Table 2 5 K2 Cable B Series Encoder Cable Examples 1 2 200224 2 0200110008 01000000000000005000 2 17 2 6 Grounding Systems uo eret reete decetero raten eate eno e nin 2 23 Table 2 7 Module Digital Mode Configuration Data Screen 1
126. DSM302 to PLC Interface 5 7 5 8 2 01 2 02 2 03 2 04 2 05 2 06 Module Status Code Module Status Code indicates the current operating status of the DSM302 When the Module Error Present 1 flag is set and the error is not related to a specific axis an error code number is reported in the Module Status Code that describes the condition causing the error For a list of Motion Mate DSM302 error codes refer to Appendix A Servo Axis 1 Servo Axis 2 Aux Axis 3 Error Code The Servo Axis 1 Error Code Servo Axis 2 Error Code and Aux Axis 3 Error Code words indicate the current operating status of Servo Axis 1 Servo Axis 2 and Aux Axis 3 Follower Master respectively When the Module Error Present l flag is set and the error is related to a particular axis an error code number 15 reported which describes the condition causing the error For a list of Motion Mate DSM302 error codes refer to Appendix A Command Block Number Command Block Number indicates the block number of the command that is presently being executed in the active Program or Subroutine It changes at the start of each new block as the program commands are executed and thus identifies the present operating location within the program Block numbers are displayed only if the motion program uses them Additionally the most recently used block number will be displayed until superseded by a new value Commanded Position Commanded Position user units is where
127. December 2002 GFK 1464C maximum travel of 32 768 motor shaft revolutions The maximum travel originates at the Actual Position zero and can move the number of maximum travel revolutions plus or minus of the zero position There is no restriction on maximum travel for CONTINUOUS mode Refer to Chapter 4 for additional information on LINEAR and CONTINUOUS Mode Incremental Encoder Mode Considerations The digital serial encoder can be used as an incremental encoder returning 8192 counts per shaft revolution with no revolution counts retained through a power cycle The equivalent of a marker pulse will occur once each motor shaft revolution All Home Modes HOMESWitch MOVE Move and Set Position AQ commands reference the axis and set the Position Valid 1 bit upon successful completion The configured High Count Limit and Low Count Limit are valid and the Actual Position AI status word as reported by the DSM302 will wrap from high to low count or from low to high count values This is an excellent mode for continuous applications that will always operate via incremental moves in the same direction Home Offset and Home Position configuration items allow simple referencing to the desired location Absolute Encoder Mode Considerations The GE Fanuc Digital serial encoder can be used as an absolute type encoder by adding a battery pack to retain servo position while system power is off A Find Home cycle or Set Position AQ command must
128. ER 90 30 THE MOTION CONFIGURATION PROGRAMMER PACKAGE SOFTWARE PACKAGE e ENCODER 3 FOLLOWER MASTER Figure 1 1 Hardware and Software Used to Configure Program and Operate a DSM302 Servo System GFK 1464C Chapter 1 Product Overview 1 3 The Series 90 30 PLC and the DSM302 The DSM302 and Series 90 30 PLC operate together as one integrated motion control package The DSM302 communicates with the PLC through the backplane interface Every PLC sweep data such as Commanded Velocity and Actual Position within the DSM302 is transferred to the PLC in and AI data Also every sweep and AQ data is transferred from the PLC to the DSM302 The Q and AQ data is used to control the DSM302 Q bits perform functions such as initiating motion aborting motion and clearing strobe flags AQ commands perform functions such as initializing position and loading parameter registers Besides the use of I AI Q and AQ addresses an additional way to send parameters to the DSM302 is with COMM instruction Details about using the COMM REQ instruction with the DSM can be found in Appendix B DSM Parameter Download Using the COMM REQ PLC Data Latency and DSM302 Latencies The DSM302 is an intelligent module operating asynchronously to the Series 90 30 CPU module Data is exchanged between the CPU and the DSM302 automatically For information about the operation of the Series 90 30 sweep refer to the Series 90 30
129. Eee ta ae EV acest Ss 3 37 Figure 4 1 Example of a Logicmaster Program Zero esses eene rennen retener 4 25 Figure 6 1 Home Switch Example eene ee etie e een Rue ei de eite eee 6 3 Figure 6 2 Move Minus Home Position Example 6 4 Figur 7 1 Sample Lin ar Moun ctetu ee ATA 7 5 Figure 7 2 Sample S Curve Motion sessi 7 6 Figure 7 3 Example 1 Before Inserting 0 7 7 Figure 7 4 Example 2 After Inserting CMOVE 0 essent 7 7 Figure 7 6 Changing the Acceleration Mode During a Profile esee 7 9 Figure 7 7 Not Enough Distance to Reach Programmed Velocity eese 7 9 Figure 7 8 Hanging the DSM302 When the Distance Runs 7 10 Figure 7 9 Dwell Command Example esses nennen 7 10 Figure 7 10 Unconditional Jump sese enne entren nn en rennen re nennen enn 7 12 Figure 7 11 Normal Stop Before JUMP ccceceescsseseseeseeeeceseeseeeceaecaeeeceesecaceesecnaeeaeseeceaecaeeeeeeaecnaeeneeeees 7 15 Figure 7 12 JUMP Without 22 eee ener entente enne ennt 7 16 Figure 7 13 Jump Stops a eese ener el ve a eth e oe p Rabe than 7 17 Figure 7 14 Jump Followed by PMOVE isset enne 7 18 Figure
130. FANUC GE Fanuc Automation Programmable Control Products Motion Mate DSM302 for Series 90 30 PLCs User s Manual GFK 1464C December 2002 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for
131. FK 1464C Restrictions when Absolute Encoder Mode is used with Continuous Mode 1 Ifthe Continuous Count Modulus in counts is a power of 2 then no restrictions exist on continuous travel This means the distance defined as Hi Count Limit Low Count Limit 1 in counts must be a number which is a power of 2 such as 128 256 512 8192 16384 and so forth Under this condition the DSM302 will always initialize the Actual Position AI status word to the correct continuous position after a power cycle 2 Ifthe power of 2 condition for Continuous Count Modulus is not met the continuous motion must be limited to a range of 268 427 264 counts using the default 8192 CountsPerRev for the position feedback after a Set Position AQ or Find Home Q position reference operation This restriction can be handled in some systems by periodically performing a Set Position when the axis is stopped and holding a known continuous position Note Performing a Set Position AQ command or Find Home Q cycle in ABSOLUTE encoder mode causes the DSM302 to recalculate the encoder Absolute Feedback Offset and automatically save the offset data in non volatile memory Incremental Quadrature Encoder Incremental Quadrature Encoders provide three output signals to the DSM302 Channel A Channel B and Marker The Channel A and Channel B signals transition as the encoder turns allowing the DSM302 to count the number of signal transitions and calculate th
132. Input 1 10 8 19 Master Source Encoder 3 Internal Master 8 18 Cascade Master Source Analog Input Cascade Master Source Encoder 3 Interna Master Master Source Analog Input Parallel Master Source Encoder 3 Internal Master 8 16 G Ground Connection Faceplate Shield 3 4 Grounding Cable Shield Ground Clamp Grounding Systems Frame Ground System Ground H Hardware Description 3 1 Help GE Fanuc FAX back system 2 35 GE Fanuc Web site 2 35 Help Numbers telephone number table 2 35 Hi Limit High Count Limit 4 21 Hi Lo Limits C 2 Hints System ubleshooting Home Cycle 6 1 Home Mode Find Home Mode Home Positn Home Position Offset Home Positn Home Position Home switch startup validation ID 1 Home Switch Mode 6 1 Hot Line telephone help numbers 2 35 Cable Grounding 3 21 GFK 1464C Index I O Circuit Function and Pin Assignments 3 JUMP Command Program Zero 4 28 25 Jump Stop 7 16_ I O Circuit Identifiers and Signal Names 3 25 Jump Testing 7 14 I O Circuit Types Jumping Without Stopping Connectors 3 3 Jumps and Block Numbers 7 11 Link G 6 Jumps Conditional 7 12_ I O Specifications Jumps S CURVES 7 18 7 19 20 24v DC Optically Isolated Output Jumps Unconditional 5v Differential Outputs JX5 Connector Single Ended 5v Inputs Outputs K12 Cable 5v Power 3 48 Optically Isolated 24v Source Sink Inputs Single Ended 5v Sink
133. Integrator Time Constant is 1000 1 second the Position Error would be reduced to 37 of its initial value after 1 second A value of zero turns off the integrator If used the Integrator Time Constant should be 5 to 10 times greater than the Position Loop Time Constant to prevent instability and oscillation Default 0 Intgr Mode Integrator Mode Position loop position error integrator operating mode OFF means the integrator is not used CONTINU means the integrator runs continuously even during servo motion IN ZONE means the integrator only runs when the Moving 1 status bit is OFF Intgr Mode should normally be set to OFF Continuous CONTINU may be used for Follower mode operation only when a constant or slowly changing master velocity is expected This parameter should not be used to dampen disturbances in the position loop feedback Never select continuous CONTINU for Standard mode applications Default OFF Rev Comp Reversal Compensation User Units A compensation factor that allows the servo to reverse direction and still provide accurate positioning in systems exhibiting backlash Backlash is exhibited by a servomotor that must move a small amount lost motion before the load begins moving when direction is reversed For example consider a dead bolt door lock Imagine the servo controls the key in the lock and the feedback reports bolt movement When the servo turns the key counterclockwise the bolt moves left However as the ser
134. LED will flash an error code which should be reported to GE Fanuc See section LED Indicators later in this chapter for more details GFK 1464C 4 1 A 2 Error Code Format All error codes are represented as hexadecimal data with the following format High Byte Bits 0 7 Error Number 0 FFh Bits 8 11 Axis Number low nibble 0 Axis Independent 1 Servo Axis 1 2 Servo Axis 2 3 Aux Axis 3 Bits 12 15 Response Method high nibble 0 Status Only 1 Stop Normal 2 Stop Fast Figure A 1 Status Code Organization Response Methods 1 Status Only Errors Set the Module Error Present 1 bit and Module Status Code or Axis Error Code AI word but do not affect motion Note Unless otherwise noted any command which causes a Status Only Error is ignored 2 Stop Normal Errors Perform an internal abort of any current motion using current Jog Acceleration and Jog Acceleration Mode LINEAR or S CURVE The Drive Enabled and Axis Enabled l bit are each turned OFF after the configured Drive Disable Delay 3 Stop Fast Errors Instantly abort all motion by setting the servo velocity command to zero The Drive Enabled and Axis Enabled 1 bits are each turned OFF after the configured Drive Disable Delay Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Table A 1 DSM302 Error Codes Error Number Response Description Error Type Hexadecimal 00 None
135. M302 System Before discussing specific assembly details let s first review these general guidelines Always make sure that the connectors lock into the sockets The connectors are designed to fit only one way Do not force them W Do not overlook the importance of properly grounding the DSM302 system components including the DSM302 faceplate shield ground wire Grounding information is included in this section All user connection except for the grounding tab are located on the front of the DSM302 module The grounding tab is located on the bottom of the module Refer to the figure below and take a few minutes now to familiarize yourself with these connections For instructions about installation of the DSM302 when IEC and other standards must be observed see Installation Requirements for Conformance to Standards GFK 1179 Motion Mate DSM302 Connections Figure 2 2 provides an overview of the faceplate and labels on the DSM302 module For additional information and a complete connection diagram please refer to chapter 3 Installing and Wiring the Motion Mate DSM302 COMM Status LED s 6 pin RJ 11 connector STAT Provides RS 232 OK connection for motion CFG programmer software EN1 ENA Connector C Aux Axis 3 Follower Master Axis Connector A Servo Axis 1 Connector D Aux Axis 4 Connector B Servo Axis 2 Motion Mate DSM302 Grounding Tab Figure 2 2 Face Plate Conn
136. MOTION JOG PROGRAM MOVE T VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 8 17 2 Axis Parallel Master Source Analog Input Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C The diagram below illustrates the two axes of the DSM302 connected with encoder 3 or the internal master as the master source for axis 2 and the analog input the master source for axis 1 MASTER a45324 ENCODER FEED FORWARD 770 5 FOLLOWER 2 SLAVE MOTOR 2 MOTION JOG PROGRAM MOVE VELOCITY INTERNAL MASTER ENCODER SLAVE AXIS 2 FEED FORWARD SLAVE ANALOG INPUT Nm MOTOR ENABLE FOLLOWER MOTION JOG PROGRAM MOVE VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 8 18 Axis 2 Master Source Encoder 3 Internal Master Axis 1 Master Source Analog Input The diagram below illustrates the two axes of the DSM302 connected with the analog input the master source for axis 2 and encoder 3 or the internal master as the master source for axis 1 ANALOG INPUT ENABLE FOLLOWER 2 FEED FORWARD 245325 SLAVE MOTOR 2 MOTION JOG PROGRAM MOVE VELOCITY 2 ENCODER SLAVE AXIS 2 MASTER ENCODER FEED FORWARD SLAVE MOTOR 1 ENABLE FOLLOWER 1 MOTION JOG INTERNAL MOVE NTERNA PROGRAM MOV VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 8 19 Axis 2 Master Source Analog Input Axis 1 Master Source Encoder 3 Internal Master GFK 1464C Cha
137. MP A conditional jump command is similar to Type 2 commands in that jump testing does not start until the Type 3 command immediately after the JUMP is executed If this Type 3 command would normally stop motion then motion will stop before jump testing begins Type 3 commands that will stop motion are DWELL WAIT End of Program and moves in the opposite direction Thus even though the CTL bit may be ON before the block with the conditional JUMP and Type 3 command is executed axis motion will stop before program execution continues at the jump destination This stopping is NOT a Jump Stop which is described in Example 10 Example 8 Normal Stop Before JUMP The following example contains a jump followed by a DWELL command The DSM302 because it processes ahead knows it must stop after the CMOVE command Thus it comes to a stop before the DWELL is executed Since jump testing does not begin until the DWELL is executed testing begins after motion stops Jump testing ends when the following CMOVE begins due to the associated BLOCK command The dashed lines in the velocity profile indicate when jump testing takes place In this example the 03 bit does not turn ON during the program execution BLOCK 1 ACCEL 5000 VELOC 10000 CMOVE 60000 INC LINEAR BLOCK 2 JUMP CTLO3 4 DWELL 4000 v a45310 BLOCK 3 ACCEL 10000 Testing VELOC 5000 CMOVE 15000 INC LINEAR BLOCK 4 NULL Figure 7 11 Normal Stop
138. NALOG O INPUT ANALOG O INPUT OUT ANALOG OUTPUT COM Referenced to Ov ENABLE RELAY AC DC Solid State Relay 3 35 I O Specifications The specifications and simplified schematics for the module s I O circuits are provided on the following pages The I O circuits described are as follows Differential Single Ended 5v Inputs IN1 IN2 IN3 Single Ended 5v Sink Input IN4 Optically Isolated 24v Source Sink Inputs IN9 IN10 IN11 INCOM Single Ended 5v Inputs Outputs 105 IO6 107 108 5v Differential Outputs OUT2 OUT3 24v DC Optically Isolated Output OUT1 Optically Isolated Enable Relay Output OUT4 Differential 10v Analog Inputs AIN1 AIN2 Single Ended 10v Analog Outputs AOUTI 5v Power 5 0V Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Differential Single Ended 5v Inputs Digital Servo Axis 1 2 Circuit Function Circuit Identifier Analog Servo Axis 1 2 and Aux Axis 3 Circuit Function Servo Terminal Aux Axis 4 Circuit Function Auxiliary Terminal Signal Name Axis 1 listed Faceplate Pin 1 INI Strobe Input 1 Encoder Chan A Not Used INIP_A Strobe Input 1 Encoder Chan A Not Used INIM A 19 IN2 Strobe Input 2 4 Encoder Chan B Not Used Strobe Input 2 Encoder Chan B Not Used Not Used Not Used IN3 er Encoder Data Ser Encoder Data
139. NDED 28 7 DRIVER 8 SHIELD_A 4 A AIN1 5 ANALOG AIN1M A AIN1 NBC 25 AIN2P A AIN2 ANALOG AIN2M A AIN2 INPUT 26 1464 NOTES Denotes negated signal See Chapter 6 for home switch information Figure 3 19 Analog Servo Axis 1 Connections Chapter 3 Installing and Wiring the DSM302 3 31 Faceplate Aux tq C693ACC336 Aux Term Board DRIVE Pin Terminal AOUT B 6 CMD AXIS 2 MOTOR ENBL1_B 15 15 ENABLE ENBL2_B 33 33 ov INA B E 5 5 OV B 0 AX ENCODER FREQUENCY 23 200 E 250 KHZ CHANNEL 1 MHZ COUNT RATE S SHIELD B WITH DIFFERENTIAL INPUT IN1P B QUAD A 150 KHZ CHANNEL 600 KHZ COUNT RATE 1 1 WITH SINGLE ENDED INPUT IN1M_B QUAD A 19 19 QUADRATURE TOLERANCE IN2P_B QUAD B 1 90 DEGREES 45 DEGREES IN2M_B QUAD B 20 20 INCREMENTAL QUADRATURE E IN3P_B MARKER ENCODER IN3M B MARKER bd 21 21 NOTE FOR SINGLE ENDED 4 4 5 5 ENCODER DO NOT OV B 0V CONNECT A B MKR 22 22 NEGATIVE OVERTRAVEL POSITIVE OVERTRAVEL LIMIT SWITCH SWITCH Core 46 LIMIT SWITCH L D z xm IN10 B OT 34 34 IN11_B HOME INPUT l BIT 17 17 OT
140. Output OUT3 5v outputs PLC 5v Output ENBL ao cd je ies Pm SSR output alog MAQ Differential 10v Cmd is active s PLC Analog In PLC Analog In ACOM Analog Out com Analog Out Com SHIELD Cable Shield Cable Shield 24v optically IN2 IN3 P5V OV IN4 105 PLC 5 Input 106 Single ended IO7 108 OV IN9 IN10 Chapter 3 Installing and Wiring the DSM302 Aux Term Pin Board Terminal 1 1 p 2 3 3 NE 18 18 T2P_D 13 13 OUT3P_D OUT3M_D ENBLI D ENBL2 D 14 14 15 15 AINIPD 7 7 RR 8 8 66 O 18 OU OU OU 19 AIN2P_D AIN2M D AOUT D ACOM D SHIELD D 3 27 Connection Diagrams The following diagrams illustrate typical user connections to the DSM302 Terminals on IC693ACC335 Axis Terminal Board Pin Terminal IN1P A STROBE1 1 1 Al 4 5V STROBE1 DIFFERENTIAL 19 9 D DRIVER l IN2P A STROBE2 pul IN2M A STROBE2 SINGLE ENDED 20 10 i DRIVER ov P5V_A 5V 5224 4 3 22 11 A 0V INPUT OT CTLO1 SHIELD A OT CTLO2 5 HOME CTLO3 STROBE1 CTLO4 PH M POSITIVE LIM HOME OVERTRAVEL SWITCH SWITCH Creare LIMIT SWITCH O S4 _ L zn IN10 A OT a 34 14 IN11 A HOME 17 7 IN9 A OT 16 6 INCOM A 35 15 24 VDC OUT1P_A SSR OUT 18 8 Rus OUT1M_A SSR OU
141. P67 may be made available through special order A 32K absolute encoder is standard with each Series servo An optional 90 Vdc holding brake is also available with each model For more information refer to Chapter 4 of this manual Configuring the DSM302 under the section labeled Motor Type See also the following publications e GFH 001 Servo Products Specification Guide e GFZ 65232E f Series AC Motor Descriptions Manual Table 1 3 Selected B Series Servo Motor Models Model Torque Output Max Speed Number Nm KW RPM 2000 1 Continuous 10096 Duty Cycle Note The 12 motor is listed with the motors due to similar attributes Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Section 5 SL Series Servos Analog Mode Starting with firmware release 1 40 support for analog servos was added to the DSM302 This allowed the DSM302 to be matched with the GE Fanuc SL Series of analog servos to produce complete high performance analog servo systems For details on the GE Fanuc SL Series Servo amplifiers motors and accessories please see the SL Series Servo User s Manual GFK 1581 GFK 1464C Chapter 1 Product Overview 1 15 Chapter 2 GFK 1464C Getting Started Objectives of this chapter W To help you become familiar with the components and cables used in a DSM servo system as well as show you how they connect together To show you how to veri
142. PU sweep certain data is automatically transferred both ways between the DSM302 and the CPU CPU Interface data references the starting locations for the automatic transfers The configuration parameters in Module Configuration Data are described in Table 4 1 All Reference Section designations shown in the tables pertain to this chapter Table 4 1 Module Configuration Data Configuration Description Values Logicmaster Defaults Units Reference Parameter Section Ref Adr Start address for I ref type 64 CPU Dependent 6100001 or next higher reference bits Ref Adr Start address for Q ref type 64 CPU Dependent 000001 or next higher reference se bits Ref Adr Ref Adr AI AQ Len Start address for AI ref type CPU Dependent 100001 or next higher reference N A 40 words for typical standard mode applications 50 words for typical follower mode applications 64 words for special applications Start address for AQ ref type CPU Dependent 000001 or next higher reference N A 6 words for typical standard mode applications 9 words for typical follower mode applications 12 words for special applications N A 1 01 Selects appropriate length 40 6 40 6 combinations of the AI and 50 9 AQ reference addresses 40 6 64 12 for typical standard mode 50 9 for typical follower mode and 64 12 for special applications Motion Mate DSM302 for Series 90 30 PLCs User s Manual Dece
143. Parl Tuning Parameter Tuning Par2 Tuning Parameter Tuning Procedure for a Digital Servo Types of Acceleration E U Update rate DSM302 G 8 Updating Flash Memory in the DSM302 F 1 Upgrading Firmware SE User Connections User ET Analog Input AI Status Word 5 9 User Selected Data AI Status Word 5 9 User Units Counts Using the APM Motion Programmer with the DSM302 E 1 V Vel Lp Gain Velocity Loop Gain 4 19 VELOC Command Program Zero 4 28 8 Clamping 8 7 Generator Internal Master Velocity at 10 Volts 4 17 pauses Velocity Command Move at 6 6 5 Velocity Feedforward AQ Immediate Command 323 Velocity Velocity Feed Forward Gain 4 18 8 Velocity Loop Gain AQ Immediate Command 5 23 W Wait 7 2 Wait Cann WAIT Command Program Zero 4 29 Winder Follower 8 14 8 19 GFK 1464C Index WinderZnlen sions ES length 4 24 Wiring Connections 3 30 GFK 1464C Index Index 9
144. Programmable Controller Reference Manual GFK 0467 The following information specifies timing considerations as applied to the DSM302 module e Motion program control or branching via faceplate inputs is a worst case 2 ms position loop execution delay p us the input filter delay 5 ms typical for 24 volt CTL inputs or 0 5 micro second input filter delay for 5 volt CTL inputs of the input based functions may retrieve DSM status I and AJ information from the DSM data memory asynchronously The DSM will internally refresh all status data except Actual Velocity at a 2 millisecond data memory refresh rate Actual Velocity is updated in the DSM data memory every 128 milliseconds The DSM performs averaging to generate an accurate Actual Velocity reading and is therefore not intended for high speed control purposes e The PLC requires 2 4 milliseconds back plane overhead when reading and writing data to the DSM internal memory The PLC will normally read input data from the DSM and write output data to the DSM once per PLC sweep At worst case the PLC may have just missed the DSM 2 millisecond internal data update and will need to complete a sweep and begin another to read data from the DSM The result is that DSM status data is available at a typical 4 6 millisecond rate or a PLC sweep whichever is largest The DSM302 may be configured for three different lengths of AI and data A PLC CPU requires time to read and write the d
145. SM302 Drive Enable Relay and Velocity Command outputs to the servo amplifier Connect the position feedback device Incremental Quadrature Encoder to the Motion Mate DSM302 encoder inputs Note If these connections are incorrect or there is slippage in the coupling to the Feedback Device an Out of Sync error condition can occur when motion is commanded 3 Connect the servo amplifier Ready output if available to the DSM302 SRDY input IN 4 If the servo amplifier does not provide a suitable Ready output this input to the DSM302 must be connected to Ov If a Home switch is used 24 Vdc wire it to the correct DSM302 input The Home switch must be wired so that it is ALWAYS ON when the axis is on the negative side of home and ALWAYS OFF when the axis is on the positive side of home 4 Use the Series 90 30 PLC Configuration Software to set the desired configurable parameters Store the configuration to the PLC 5 Turnon the Q Enable Drive bit and place the command code for Force D A Output equal to 0 in the AQ table Confirm that the servo amplifier is enabled the motor should exhibit holding torque If the motor moves adjust the amplifier command offset adjustment until the motor stops moving Note The Q Enable Drive bit must be maintained ON in order for the Force D A Output command to function 6 Send the command code for Force D A Output equal to 3200 1 0v Confirm that the motor moves in the desired POSITIVE direction b
146. Servo Axis 1 Error 3 Servo Axis 2 Error 4 Aux Axis 3 Error The following DSM302 items cannot be monitored on the Standard mode Status screen I Data Q Data AI Data CTL13 CTL16 control bits Strobe 2 Position Position Strobe 2 OUT3 control bits User Selected Data Torque Limit Servo Ready Any Aux Axis 3 4 bits New Cfg Received E 2 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Follower Mode Status Screen Not supported by DSM302 Execute Program 4 6 Reset Strobe 1 Execute Program 0 3 GFK 1464C The figure below indicates the Follower mode Status screen items that have a different interpretation for the DSM302 Follower Enabled Follower Enabled Axis 1 Axis 2 PROGRM FILES SETUP FOLD R UTILTY PRINT 1 2 Axis Axis Enabl Block Pos Valid D sition Drive Enab Acyg al Pos Prog Activ Error Moving Enc3 Pos Vel In Zone Cmd Velocity Actual Veloc Status Code Vel Limit Abort Movs reserved reserved Enab Drive reserved Find Home Jog Plus Jog Minus reserved reserved eserved En Followr y Clr Err MONITOR APM REV CTRL PLC 10 Sel Int Mstr Axis 1 Non zero Status Code Axis 3 Analog Input 1 Displayed in Following Priority Order 1 Module Status 2 Servo Axis 1 Error 3 Servo
147. Set Follower Winder Zone Length Counts This command sets the Winder Zone length when the follower axis is operating in WINDER mode An error will be reported if a previous Zone Length change has not yet been processed An error will also be reported if the follower is enabled and the Zone Length change is greater than 25 Refer to Chapter 8 Follower Motion for a detailed explanation of the WINDER mode Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C 4 25 Select Analog Output Mode Digital Mode only For GE Fanuc digital servos this command lets you choose what analog signals will be sent to the Analog Output pins pins 6 and 24 on the four DSM faceplate connectors The Select Analog Output Mode command uses a Signal Code to specify the signal to be sent and a Connector Code to specify the DSM connector to receive the signal This command is particularly useful for servo tuning Use the following structure to set up your 6 byte AQ Immediate Command described in Table 5 7 Byte 0 contains the Select Analog Output Mode command code 47h e Byte 1 contains the Connector Code a hex number e Byte 3 contains the Signal Code a decimal number Bytes4 5 and 6 are not used and should contain Zeroes Connector Codes Connector Code Connector Selected Connector Pins Olh Connector A Pin 6 OUT Refer to the I O Connection h t un Diagrams in Cha
148. T 125 MA ed 36 16 LOAD OUT3P A p 14 5 5V OUT3M_A aay DIFFERENTIAL 32 13 E OUTPUT SHIELD A S AOUT A ACOM A EI POUT ANALOG E OUTPUT 24 12 OM REFERENCED TO OV Note See Chapter 6 for home switch information Figure 3 16 Digital Servo Axis 1 Connections 3 28 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Axis TB Terminals on IC693ACC335 Ais Tentinal Board Terminal B STROBE1 db 5 INIM STROBEI DIFFERENTIAL DRIVER B STROBE2 T SINGLE ENDED DRIVER P5V B 69 INPUT BIT CTLOS SHIELD B CTLOB 9 NEGATIVE OVERTRAVEL OVERTRAVEL mul SWITCH CQ LMIT SWITCH oe ee Wesce n 0 B IN11_B HOME IN B 0 24 VDC OUTIP B SSR OUT 125 MA 5 24 OUTIM_B SSR OUT LOAD j voc OUT3P B 5V DIFFERENTIAL OUT3M_B Cae NU SHIELD B ADUT B ka ACOM_B OUTPUT COM 4 REFERENCED 0 Note See Chapter 6 for home awitch information Figure 3 17 Digital Servo Axis 2 Connections Chapter 3 Installing and Wiring the DSM302 3 29 Pins on IC693ACC335 Axis Terminal Board PL3 Connector IN3P A ENCD SHIELD_A Shield Shield Denotes a negated signal Figure 3 18 and BSeries Digital Servo Command Cable IC800CBL001 002 Connections 3 30 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2
149. Table 3 3 Maximum Number of DSM Modules per System Power Supply Voltage Power Supply Current Draw by DSM Available 5V Current Module to supply external encoder if used Maximum Number of modules system Model 311 313 321 323 PLCs 5 or 10 slot CPU baseplates Model 331 PLC 5 and 10 slot CPU baseplates 5 and 10 slot expansion or remote baseplates 5 total baseplates per system Model 340 341 PLC 5 and 10 slot CPU baseplates 5 and 10 slot expansion or remote baseplates 5 total baseplates per system Model 350 364 PLC 5 and 10 slot CPU baseplates 5 and 10 slot expansion or remote baseplates 8 total baseplates per system 5 VDC from PLC backplane 800 mA plus encoder supply current see next item 500 mA if used must be added to module 5v current draw 1 DSM302 module in CPU baseplate 2 DSM302 modules in CPU baseplate with PWR321 322 3 DSM302 modules in CPU baseplate with PWR330 331 3 DSM302 modules in expansion remote baseplate 3 total DSM302 modules per PLC system 2 DSM302 modules in CPU baseplate with PWR321 322 6 DSM302 modules in CPU baseplate with PWR330 331 3 DSM302 modules in expansion remote baseplate with PWR321 322 7 DSM302 modules in expansion remote baseplate with PWR330 331 8 total DSM302 modules per PLC system with PWR321 322 6 total DSM302 modules per PLC system with PWR330 331 2 DSM302 modules in CPU baseplate with PWR321 322 6 DSM302 modules in CPU baseplate
150. The Communications 2 2 B 1 Structure of the Communications Request sess B 1 Corrective AGH Ome secedere e eris B 3 Monitoring the Status Word sese B 4 Error Detection and Handling B 4 Verifying that the DSM Received Correct Data B 4 Section 2 The COMM REQ Ladder Instruction eere B 7 DSM COMM REQ Programming Requirements and Recommendations B 8 Section 3 The COMM REQ Command Block e 2 B 10 Section 4 DSM COMM REQ Example ee eeee eese eren ener enne rta se tnnue B 13 Appendix Position Feedback 0 netten C 1 Digital Serial Encoder First Time Use or Use After Loss of Encoder Battery Power C 1 Digital Serial Encoder Modes sese C 2 Limitations on Total Travel for Linear Axis Mode c ccccccccsccsssccesssecesececsssceessseceeees C 2 Incremental Encoder Mode Considerations C 3 Absolute Encoder Mode Considerations eene C 3 Absolute Encoder Mode Position Initialization esee C 3 Find Home Cycle Absolute Encoder C 3 Set Position Command Absolute Encoder Mode sse C 4 Absolute Encoder Mode DSM302 0
151. The example below illustrates how to meet the requirements that the User Units and Counts values be within the range of to 65 535 and the User Units to Counts ratio be within the range of 8 1 to 1 32 The basic equation we need to satisfy is Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C User Units Load Movement Per Motor Rotation Desired Resolution Counts EncoderCounts Per Motor Rotation The numerator and denominator must each fit within the RANGE limits The reduced fraction must fit between the RATIO limits The decimal point is always implied not used The User Units to Counts ratio is always expressed as an integer ratio Example Application Use the User Units to Counts ratio to configure the DSM302 so you can program in engineering units rather than encoder counts As an example assume a machine has a motor with a motor mounted quadrature encoder connected through a gear reducer to a spur gear The spur gear is mounted to the end of a pinch roller shaft The pinch roller feeds sheet material for a cut to length application The motion program will specify the length of cut sheets The programmer wishes to program in 0 01 inch resolution The following data is given e 2000 line encoder x4 8000 counts per encoder revolution e 20 1 gear reduction e 14 336 inch diameter spur gear e inch desired programming unit Although several approaches are possible the most straightforwar
152. The gauge of wire used for connecting the line filter to the power source must be sized based on the size of the circuit breaker between the power source and the line filter and the number of servos connected to the line filter The power connectors and terminals are supplied as part of the amplifier package 5 Connect the Machine Emergency Stop to the Series Digital Servo Amplifier E STOP B Series Amplifier Front Face View 24 ole Normally Closed Machine E STOP Device s 20 JX5 Of First B Series Amplifier 20 JX5 Of Second B Series 17 Amplifier Up to 6 Amplifiers can be connected JX5 Connector in series Part of Kit A02B 0120 K301 Figure 2 12 Connecting the E STOP to the B Series Servo Amplifier Note You must supply the cable for this connection package The JX5 connector and connector cover is included with the amplifier as part number 02 0120 K301 If no E STOP circuit is required this connection must be made with a wire jumper or the amplifier will not enable Connector JX5 Pin 20 supplies 24V DC for the E STOP circuit Wire Pin 20 through a normally closed contact or switch so there is 24V DC to JX5 Pin 17 when not in E STOP GE Fanuc uses two brands of connectors for the JX5 connector See figure 2 13 for proper connection to each type CAUTION Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Do not
153. The module indicated that the Verify the COMM REQ data sent was not in the correct parameters sequence IOB NOT RDY 5 The RDY bit in the module s Retry Check DSM module status was not active IOB TIMEOUT The maximum response time Check DSM module Verify elapsed without receiving a the COMM REQ parameters response from the module IOB BAD PARAM 7 One of the parameters passed Verify the COMM REQ was invalid parameters IOB BAD CSUM The checksum received from the Retry Check installation for DMA protocol module did not proper grounding shielding match the data received noise suppression etc IOB OUT LEN CHGD The output length for the module Verify the COMM REQ was changed so normal parameters processing of the reply record should not be performed Corrective Action The type of corrective action to take depends upon the application If an error occurs during the startup or debugging stage of ladder development the advice to Verify the COMM REQ parameters is appropriate The same is true if an error occurs right after a program is modified But if an error occurs in a proven application that has been running successfully the problem is more likely to be hardware related The PLC fault tables should be checked for possible additional information when troubleshooting Status Word errors GFK 1464C Appendix DSM Parameter Download Using the COMM Instruction B 3 B 4 Monitoring the Status Word Error Dete
154. The only problem is the velocity overshoot GFK 1464C Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 D 8 48 Velocity Loop Step Response Velocity vs Time VLGN 1 1 1 1 1 AHENK be pes sess 1 1 1 1 ais ee Sal ee ae Shaye Safe ee 4 AeA 05 04 0 3 0 2 0 1 Time Sec 48 Figure D 6 Velocity Loop Step Response Velocity vs Time VLGN 48 Velocity Loop Step Response Torque Command vs Time WLGN isdwyi puewwon enbuo Time Sec 48 Figure D 7 Velocity Loop Step Response Torque Command vs Time VLGN The response shown in Figures D 6 and D 7 is good D 9 Appendix D Tuning GE Fanuc Digital and Analog Servo Systems GFK 1464C Velocity Loop Step Response Velocity vs Time vi GN 64 Velocity RPM 0 2 0 1 0 0 1 0 2 0 3 04 0 5 Time Sec Figure D 8 Velocity Loop Step Response Velocity vs Time VLGN 64 Velocity Loop Step Response Torque Command vs Time VL GN 64 2 Torque Command Amps 0 2 0 1 0 0 1 0 2 0 3 0 4 0 5 Time Sec Figure 0 9 Velocity Loop Step Response Torque Command vs Time VLGN 64 The response shown in Figures D 8 and D 9 is acceptable Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C
155. URVE ACCEL 1500 245258 VELOC 2800 CMOVE 6000 INC LINEAR V VELOC 1200 CMOVE 23000 ABS SCURVE ACCEL 1000 6000 23000 t VELOC 2800 PMOVE 5000 INC LINEAR Figure 7 5 Combining PMOVEs and CMOVEs The move types are indicated under the corresponding move for example P L indicates linear PMOVE The first PMOVE accelerates to program velocity moves for a distance and decelerates to a stop This is because motion stops after all PMOVEs When the first move stops it is at the programmed distance The second move is an s curve PMOVE It like the first accelerates to the programmed velocity moves for a time and decelerates to zero velocity because it is a PMOVE The next move is a linear CMOVE It accelerates to program velocity moves for a time and then decelerates to a lower velocity using linear acceleration When a CMOVE ends it will be at the programmed position of the move just completed and at the velocity of the next move Thus when the fourth move begins it is already at its programmed velocity The fourth move is a CMOVE so as it approaches its final position it accelerates to be at the velocity of the fifth move when it completes The graph shows the acceleration of the fourth move 1S S curve Finally the fifth move begins and moves at its programmed velocity for a time until it decelerates to zero Any subsequent moves after the fifth would begin at zero velocity because the fifth move is a PMOVE Motion M
156. VE PROGRAM ATVEL MASTER MASTER AXIS AXIS POSITION POSITION VELOCITY TO VELOCITY COMMAND CMD VELOCIT GENERATOR CMD POS POSITION ERROR MOTOR POSITION FEEDBACK ENCODER Figure 1 3 Simplified Follower Mode Position Loop with Master Axis Input 1 10 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 3 a Series Servos Digital Mode The GE Fanuc Digital pronounced Alpha Series Servo features include m World leading reliability m Low maintenance no component drift no commutator brushes m All parameters digitally set no retuning required m Absolute encoder eliminates rehoming m An optional brake is available m Optional IP67 environmental rating is also available for most motors m High resolution 64K count per revolution encoder feedback incremental or absolute The GE Fanuc Servo motors proven on over three million axes installed worldwide offer the highest reliability and performance The latest technologies such as high speed serial encoders and high efficiency Integrated Power Modules IPM s further enhance customer benefits The GE Fanuc servo system is unique in that all the control loops current velocity and position are closed in the motion controller This approach reduces setup time and delivers significant throughput advantages even in the most challenging applications The servo drives are less costly to integrate and maintain Con
157. Valid values 1 16 The value in this word impacts the value of Word 8 Parameter Data Words 13 44 The size of this Parameter Data area depends on the value in Word 12 Number of Parameters to Send Two words 4 bytes of data are required for each parameter Since the valid number of Double Integer parameters is 1 through 16 the Parameter Data area can be between 2 and 32 words COMM_REQ Memory Type Codes The codes in the following table are used in Word 3 Status Word Pointer Memory Type and Word 9 Parameter Data Memory Type Table B 4 COMM_REQ Memory Type Codes COMM_REQ Memory Type Codes Memory Type Code Number to Enter 70 Discrete input table Discrete output table Register memory Analog input table Analog output table Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 4 DSM COMM REQ Example In this example the following specifications are given e The DSM module is mounted in Rack 0 Slot 7 of the PLC The Command Block s starting address is RO196 Status Word is located at 0195 e 16 parameters are to be sent COMM REQ s FT fault output drives a Set Coil e DSM Parameter 1 is considered critical in this application The last two rungs of the example verify that Parameter 1 received the correct value via the COMM REQ The next figure provides an overview of the COMM REQ example GFK 1464C Appendix DSM Para
158. ack input mode CUSTOM and CUSTOM2 configure the DSM302 inputs for special applications DIGITAL selects GE Fanuc Digital AC servo encoder input mode If DIGITAL is selected the Servo Cmd configuration parameter must also be set to DIGITAL LM90 Default ENCODER Note Normally only DIGITAL or ENCODER feedback option should be selected The RESOLVR and 2 options not currently supported The LINEAR option is reserved for special applications in conjunction with CCL2 Ctl Loop STANDARD selects the normal DSM302 motion control loop The STANDARD loop provides a velocity command Analog mode or velocity position command Digital mode proportional to position error with optional Velocity Feed forward FOLLOWER selects a control loop that allows ratio tracking of a master input CCL and CCL2 Custom Control Loops are individually designed for special applications and should not be selected Default STANDARD Servo Cmd This parameter defines the type of command output provided to the servo sub system DIGITAL selects a special digital output for GE Fanuc Digital servo drives ANALOG selects a 4 10 volt velocity command for standard analog servo drives DUAL is not supported LM90 Default ANALOG Chapter 4 Configuring the DSM302 4 3 4 4 1 05 Motor Type Selects the type of FANUC AC servomotor to be used with the DSM302 in Digital Mode ONLY The DSM302 internally stores setup motor paramet
159. ain value that meets the system requirements the more robust the control You should carefully observe the velocity feedback signal In some applications running the Velocity Loop Gain high enough to create instability can cause machine damage If in doubt adjust the Velocity Loop Gain to be no greater than the value calculated in equation 1 If oscillations are observed in the Motor Velocity feedback signal prior to this point decrease the Velocity Loop Gain and continue with step 7 below 7 The velocity loop is tuned at this point However the robustness of the loop must be checked To perform this test introduce velocity command steps in increments of 20 Rated Machine Speed 40 Rated Machine Speed 60 Rated Machine Speed 80 Machine Rated Speed and 100 Rated Machine Speed Observe the Motor Velocity and Torque Command signals for any instability If an instability or resonance is observed reduce the Velocity Loop Gain and repeat the test NOTE For Digital servos the AQ Force Analog Output command can provide Torque Command or Commanded Motor Velocity Velocity 750 rpm volt and TqCmd 100 1 111111 Volt X Volt or Torque 100 Torque Command 1 111 Volts 10096 TqCmd MaxCur Amplifier For instance Beta 0 5 MaxCurAmp 12 amps gt 1 111111Volt 12 amps Sample Velocity Loop Tuning Session A sample velocity loop tuning session is shown in the plots that follow D 6 Motion Mate DSM302 for Series 90 30 PLCs U
160. al If you still cannot solve the problem you may contact the GE Fanuc number for your area listed in the table below Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Telephone Numbers GE Fanuc Telephone Numbers North America Canada Mexico Technical Toll Free 1 800 GE Fanuc Support Hotline Direct Dial 804 978 6036 Latin America for Mexico see above Direct Dial 804 978 6036 France Germany Luxembourg Switzerland Toll Free 00800 433 268 23 and United Kingdom GE Fanuc web site http www gefanuc com support plc Fax Link System GFK 1464C Help is also available in the form of Fax documents that you can order from the GE Fanuc Fax Link System To access please call 804 978 5824 Follow the instructions for obtaining by Fax a master list of the available subjects You may also download a master list called Document 1 or print a set of Fax Link instructions from the following web address http www gefanuc com support plc fax htm When you receive the master list select a document then call and specify the document number and it will be Faxed to you Once you have successfully moved an axis it s Mission Accomplished Chapter 2 Getting Started 2 31 2 32 Section 7 Next Steps to Take After successfully moving an axis what s next This startup chapter does not cover all aspects of the DSM302 motion system For this reason you shou
161. always uses the NOWAIT mode WAIT NOWAIT flag always set to zero this Idle Timeout Value parameter is not used for the DSM Set it to zero Maximum Communication Time Word 6 Since the DSM always uses the NOWAIT mode WAIT NOW AIT flag always set to zero this Maximum Communication Time parameter is not used for the DSM Set it to zero Command Code Word 7 This is always E501 hexadecimal for the DSM To enter this value directly as a hexadecimal value use a Word type MOVE instruction Also since this value is 58 625 in decimal an Integer type MOVE instruction limited to a maximum decimal value of 32 767 because bit 16 is used for the sign does not have the capacity to contain it A Word type MOVE instruction can hold a decimal number up to 65 535 FFFF in hex Parameter Data Size Word 8 Specifies the Parameter Data size in bytes This value depends on the value in Word 12 which specifies the number of parameters to be loaded This value may be between 8 and 68 It is equal to 4 bytes for the first two words of the Parameter Data section plus 4 additional bytes for each parameter loaded For example if you wish to load 16 parameters the maximum per COMM REQ multiply 4 times 16 to arrive at 64 Add 4 to 64 for a total of 68 bytes Parameter Data Memory Type Word 9 This word specifies the memory type that will be used for Parameter Data Each memory type has a unique code number shown in the Memory Type Codes table below S
162. ammed Motion GFK 1464C The following conditions must be satisfied before a motion program can be initiated for a multiaxis program the conditions must be met for BOTH axes W The Enable Drive Q bit must be ON The Drive Enabled 1 bit must be ON W The Position Valid ol bit must be ON W The Moving I bit must be OFF Chapter 7 Programmed Motion 7 3 The Program Active l bit must be OFF W The Abort All Moves Q bit must be OFF The axis position must be within the configured end of travel limits Pos EOT and Neg EOT unless the Axis Mode is configured as CONTINUous The overtravel limit switches must be ON 24V input is high if enabled Force Digital Servo Velocity command must not be active W The program to be executed must be a valid program stored in the DSM302 Conditions That Stop a Motion Program A motion program will immediately cease when one of the following conditions occurs The Abort All Moves Q bit turns ON W The Enable Drive bit turns OFF An Overtravel Limit Switch turns OFF when OT Limit Switch is ENABLED via configuration H The next programmed move either PMOVE or CMOVE will pass a software end of travel limit unless the axis mode is configured as Continuous A Stop Normal or Stop Fast Response Method Error occurs See Appendix A Error Reporting Parameters for Programmed Moves Programmed moves have three parameters 1 The distance data to move or po
163. ance manual will describe the procedure for monitoring motor current signals IR and IS If the waveforms are abnormal replace the amplifier If excessive noise 1s observed check grounds and especially the cable shield grounds for the command cable K1 to the amplifier 4 The motor may be operating in violation of duty cycle restrictions Calculate the amount of cooling time needed based on the duty cycle curves published for the particular motor 5 motor may be over loaded Check for excessive friction or binding in the machine For all the above problems allow ten minutes cooling of the amplifier with minimum or no motor loading then cycle amplifier power to reset GFK 1464C Appendix A Error Reporting A 9 LED Indicators There are seven LEDs on the DSM302 module which provide status indications These LEDs are described below STAT Normally ON FLASHES to provide an indication of operational errors Flashes slow four times second for Status Only errors Flashes fast eight times second for errors which cause the servo to stop ON OFF When the LED is steady ON the DSM302 is functioning properly Normally this LED should always be ON When the LED is OFF the DSM302 is not functioning This is the result of a hardware or software malfunction that will not allow the module to power up Flashing When the LED is FLASHING an error condition is being signaled OK ON OFF CFG EN2 EN3 EN
164. and operates the analog output on the DSM faceplate connectors A B C or D A Force Analog Output value of 32000 will produce 10 00 Vdc and a Force Analog Output value of 32000 will produce 10 00 Vdc Force Analog Output operates only while the AQ data is active When a Force Analog Output command is active for a given axis any other AQ immediate command for that axis will remove the Force Analog Output command and turn off the associated analog output Refer to Chapter 5 Motion Mate DSM302 to PLC Interface for more information on this command 6 6 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C 5 Position Increment Commands To generate small corrections between the axis position and the DSM302 tracking the Position Increment AQ commands can be used to offset Actual Position by a specific number of user units If the Drive Enabled 1 bit is ON the axis will immediately move the increment amount If the position increment without position update is used command 21h the Actual Position AI status word reported by the DSM302 will remain unchanged If the Position Increment With Position Update is used AQ command 25h the Actual Position and Commanded Position AI status words reported by the DSM302 will be changed by the increment value Position Increment can be used at any time though simultaneous use with the Force Digital Servo Velocity command is impossible because the
165. ands can come from one of the stored motion programs 0 through 10 and any stored subroutines they may call The Move AQ command is treated as a single line motion program which uses the present Jog Velocity and Jog Acceleration Program execution is started by the PLC setting an Execute Program n Q bit or sending a Move command If there is no master command the axis can be commanded solely from the stored motion program data Thus with no master input to Servo Axis 2 and Encoder 2 selected as the master source for Servo Axis 1 a stored program can be used to control Servo Axis 2 with Servo Axis 1 following per the designated ratio When PMOVEs are executed with Follower not enabled the Jn Zone 1 bit must be set at the end of the move before programmed motion will continue When Follower is enabled since n Zone may not turn on while also following a master command the n Zone indication will not be required to continue The next Move will take place when the commanded distance for the previous move has completed Zone l bit will always indicate the true in zone condition The active commanded position updated and used by the stored motion program is referred to as Program Command Position Each time a program is selected for execution this position register 1s initialized in one of the two ways listed below 1 Ifthe follower is not enabled the Program Command Position is set to the current Commanded Position Act
166. as the default velocity for motion programs Jog Acceleration User units sec sec This command sets the acceleration value used by Jog Move at Velocity a Find Home Cycle Move at Velocity Follower Ramp Control and Abort All Moves Additionally the Jog Acceleration is used as the default acceleration for motion programs A PLC reset or power cycle returns this value to the configured data Note A minimum value after scaling is used in the DSM302 This value is determined by the rule Jog Acc user units counts gt 32 counts sec sec Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 4 12 4 13 4 14 4 15 4 16 Position Loop Time Constant Milliseconds This command allows the servo position loop time constant to be changed from the configured value The lower the Position Loop Time Constant value the faster the system response Values that are too low will cause system instability and oscillation For accurate tracking of the commanded velocity profile the Position Loop Time Constant should be 1 4 to 1 2 of the MINIMUM system acceleration or deceleration time The Vel at 10 V configuration value must be set correctly for proper operation of the Position Loop Time Constant A PLC reset or power cycle returns this value to the configured data Velocity Feedforward This command sets the Velocity Feedforward gain percent It is the percentage of Commanded Velocity that is add
167. ased on the Motor Dir configuration parameter setting and the Actual Velocity reported the DSM302 AI table is POSITIVE If the motor moves in the wrong direction consult the servo amplifier manufacturer s instructions for corrective action The Motor Dir parameter in the Configuration Software can also be used to D 14 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C n swap the positive and negative axis directions If the motor moves in the POSITIVE direction but the DSM302 reports that Actual Velocity is NEGATIVE then the encoder channel A and channel B inputs must be swapped 7 Record the actual motor velocity reported by the Motion Mate DSM302 with a 1 0 volt velocity command Multiply this velocity by 10 and update the Vel a 10V entry in the DSM302 configuration if necessary Initially set the Pos Loop TC configuration parameter to a high value typically 100 to 1000 ms 8 Turn on Q Jog Plus bit Confirm that the servo moves in the proper direction and that the Actual Velocity reported by the Motion Mate DSM302 in the AI table matches the configured jog velocity 9 With the Drive Enabled bit ON and no servo motion commanded adjust the servo drive command offset adjustment for zero Position Error The integrator should be OFF during this process 10 Check for proper operation of the Find Home cycle by momentarily turning on the Q Find Home bit the Drive Enabled Q bit mu
168. ata across the backplane with the DSM302 The Series 90 30 Programmable Controller Reference Manual GFK 0467 version L when available will document the PLC sweep impact by CPU model group when the different configurations of AI and AQ data are selected commands to the DSM Q AQ are normally output to the DSM at the end of the PLC sweep within one PLC sweep delay The DSM will process the command within 4 5 milliseconds after receipt 1 4 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C DSM302 Servo Loop Update Times When controlling a GE Fanuc digital AC servo the DSM302 uses these loop update times Table 1 1 Digital Servo Loop Update Times Motor Current Torque Loop 250 microseconds Motor Velocity Loop 1 millisecond Motor Position Loop 2 milliseconds When controlling an Analog servo the DSM302 uses this loop update time Table 1 x Analog Servo Loop Update Times Motor Position Loop 2 milliseconds DSM302 Position Strobes Each Position Feedback Input Quadrature Encoder or GE Fanuc Serial Encoder to the DSM302 includes two Position Strobe inputs A rising edge pulse on a Strobe input causes the encoder Actual Position to be captured with a 250 microsecond maximum delay and within 2 ms is updated in the DSM data memory associated Strobe Position AI data The Strobe Position data is also stored in a DSM Parameter Register that can be used as an operand for Mo
169. ate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Example 2 Changing the Acceleration Mode During a Profile The following example shows how a different acceleration and an even acceleration mode can be used during a profile using CMOVEs The first CMOVE accelerates linearly to the programmed velocity Because the second CMOVE s velocity is identical to the first the first CMOVE finishes its move without changing velocity The acceleration of the second move is S curve as it decelerates to zero velocity v a45259 ACCEL 2000 VELOC 6000 CMOVE 13000 ABS LINEAR ACCEL 4000 CMOVE 15000 INC SCURVE Figure 7 6 Changing the Acceleration Mode During a Profile Example 3 Not Enough Distance to Reach Programmed Velocity CMOVES and PMOVES can be programmed that do not have enough distance to reach the programmed velocity The following graph shows a CMOVE that could not reach the programmed velocity The DSM302 accelerates to the point where it must start decelerating to reach the programmed position of C1 at the velocity of the second CMOVE ACCEL 2000 v 879260 VELOC 8000 CMOVE 7000 INC LINEAR ACCEL 10000 VELOC 2000 CMOVE 4400 INC LINEAR Figure 7 7 Not Enough Distance to Reach Programmed Velocity Example 4 Hanging the Move When the Distance Runs Out A serious programming error involves hanging i e leaving no desirable options for the command generator the move at
170. ate Command 5 28 Logicmaster 90 30 Configuration of Controller Module 4 1 Logicmaster 90 30 Configuration Software 1 Jerk Limited Acceleration Equations JF1 Connector Jog ACC Jog Acceleration Rate Jog ACC Mod Jog Acceleration Mode 5 0 Jog Se AQ Immediate Command Loss of Encoder Battery Po 1 Jog Minus Q Discrete Command 5 13 Jog Plus Q Discrete Command 5 33 M Jog Vel Jog Velocity Jog Velocity AQ Immediate Command Machine Control 2 1 Jogging with the DSM302 Emergency Stop JS1B Connector 2 6 2 13 In Jump 7 2 BO GFK 1464C Index Index 5 Index Index 6 Sources 8 1 Velocity Limit Velocity Limit 14 22 Master Axis Source 422 Master Source Configuration Data Analog Input Maximum Veloci Encoder 3 ome Position Encoder e Encoder 3 Position Low Count Limi Maximum Acceleration Time 7 21 MCS300 being obsoleted 10 8 MkupTime Makeup Time 424 8 10 Mode Home Switch Modes Move and Mess Modes Serial Encoders Module Configuration DSM302 4 1 Module Configuration Data DSM302 4 2 Module ErrorPresent I Status Bit 5 3 Module Status Code AI Status Word Modules per System Restrictions 3 5 Motion Mate differences G 8 Motion Mate DSM302 Motion Mate DSM302 Configuration Data Additional Information 2 30 Motor Model 2 28 Motor Specification Motion Mate DSM302 System Controller Modu
171. attery installed which maintains position if system power is cycled In ABSOLUTE mode encoder battery alarms will be reported See appendix C Position Feedback Devices for more information This parameter is not used for Analog Servo Mode Default INC Jog Vel Jog Velocity User Units second The velocity at which the servo moves during a Jog Find Home Move at Velocity Follower Ramp Control and Abort operation The Jog Velocity is the default value used by motion programs when there is no programmed velocity Default 1000 Jog Acc Jog Acceleration Rate User Units second second The acceleration rate used during Jog Find Home Move at Velocity Follower Ramp Control and Abort operations The Jog Acceleration is the value used by motion programs when there is no programmed acceleration Default 10000 Note A minimum value after scaling is used in the DSM302 This value is determined by the rule Jog Acc user units counts gt 32 counts sec sec Jog Acc Mod Jog Acceleration Mode LINEAR or S CURVE The acceleration mode for Jog Find Home Move at Velocity and Abort operations LINEAR constant acceleration causes commanded velocity to change linearly with time S CURVE jerk limited acceleration causes commanded velocity to change more slowly than the linear mode at the beginning and end of acceleration intervals Motions using S Curve acceleration require twice the time and distance to change velocity compared to motions u
172. avel Limit and the drive enable signal was immediately turned OFF due to the error the servo may continue moving until it coasted to a stop Thus to allow the DSM302 to command and control a fast stop the Drive Disable Delay should be longer than the deceleration time of the servo from maximum speed Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 2 12 2 13 2 14 2 15 2 16 2 17 The disable delay may be used to control when torque is removed from the motor shaft Applications using an electro mechanical brake may need time for the brake to engage prior to releasing servo torque Default 100 Vel Lp Gain Velocity Loop Gain Used to set velocity loop gain This applies to GE Fanuc Digital Servos only This parameter is not used for Analog Servo Mode The formula Load Inertia J1 16 Velocity Loop Gain Motor Inertia Jm can be used to select an initial velocity loop gain value The allowable value range is 0 to 255 The value of 0 should be used if the motor shaft is not attached to a load Default 16 load inertia equals motor inertia Fdback Mode Feedback Mode Only used in Digital Mode Used to configure Incremental or Absolute feedback type for the serial encoder INC means the serial encoder is being used as an incremental encoder and encoder battery alarms will not be reported ABSOLUTE means the serial encoder is being used as an absolute encoder encoder backup b
173. axis number this allows single axis subroutines to be called from any single axis program written for either axis or axis 2 Commands within multiaxis subroutines contain axis numbers just like commands within multiaxis programs Multiaxis subroutines can only be called from multiaxis programs or subroutines Single axis subroutines can only be called from single axis programs or subroutines A single axis program for axis and a single axis program for axis 2 can call the same single axis subroutine simultaneously Each subroutine must be assigned a unique number between 1 and 40 Subroutines are programmed using the CALL command which specifies the subroutine number to be called When a CALL is encountered during program execution program execution is redirected to the subroutine When the subroutine completes program execution resumes at the command after the CALL command Subroutines can be called from another subroutine but once a subroutine has been called it must complete before it can be called again for the same axis Thus recursion is not allowed Block Numbers and Jumps Block numbers are used as reference points within a motion program and to control jump testing A data word displays the current block number which can be monitored to ensure correct program execution or to determine when events should occur A block number can also serve as a JUMP command destination Jumps are divided into unconditional and conditional An
174. be home referenced prior to program execution Only multi axis program may be active at a time PROGRAM 0 PAGE 1 Command Data Axis ACCEL 0000000800 VELOC 0000004000 VELOC 0000007500 PMOVE AL 0000000000 NULL 0000000000 N A NULL 0000000000 N A 1 1 PMOVE AL 0000010000 1 1 1 Figure 4 1 Example of a Logicmaster Program Zero The Program Zero commands are entered using the Function keys F1 F9 The cursor can be moved from field to field in Program Zero by using the Cursor Control arrow keys Many Command fields have more than one choice To choose place the cursor on the desired Command field then use the TAB key to toggle through the list of choices for that Command field Paired with each command is a Data field for entering either a signed double integer constant or the number of a DSM302 data parameter variable value as appropriate for the configured command Logicmaster Program Zero Programmer Instruction Format GFK 1464C A Program Zero instruction line consists of a command and the associated data describing the command The command and data are entered into areas on the program editor screen called fields These fields are described below Chapter 4 Configuring the DSM302 4 23 4 24 Command Field The English language designation for the command To enter a command position the cursor on a command name field then press the desired function key F1 F9 Most of the commands fall into groups
175. bles the Follower axis to start following the master Aux Axis 3 encoder inputs The Follower Enabled I bit indicates when the axis is Chapter 9 Combined Follower and Commanded Motion 9 5 following the master command Note that the Accel Ramp and Make Up Time feature could be used to allow the follower axis to catch up to the master axis if required Once the follower is enabled the PLC sends the Execute Motion Program n Q bit to start execution of the selected program for the follower axis At the time the program is selected Program Command Position will be set to program reference position 0 because the follower is enabled Program execution is then relative to the moving part edge as the follower axis tracks the part Program Command Position now contains the position of the follower axis relative to the part edge and Actual Position indicates the total distance the follower axis has moved from the Home point master program commands At the end of program the PLC turns Enable Follower Q bit OFF and loops back to step 1 to repeat for next part Note Since the DSM302 saved the Follower enable input trigger Commanded Position in a parameter register 226 for axis 1 234 for axis 2 step 1 this time could be used to execute another program with an absolute move command back to the parameter value position and continuing with step 2 In this case the In Zone 1 bit indication could be used to indicate when step is complet
176. cessful Set Position command See Appendix C for considerations when using absolute mode encoders The Set Position command is commonly used to set the starting position reference point to zero or another value without homing the axis Note When a GE Fanuc digital servo system is first powered up after removal or replacement of the encoder battery the digital encoder must be rotated past its internal reference point If this is not done the Set Position command will be ignored and Error Code 53h Set Position before encoder passes reference point will be reported Force Analog Output The Force Analog Output immediate command operates one of the analog outputs on DSM faceplate connector C or D in Digital mode or in Analog mode on connector A B C or D Multiple Force Analog Output commands can be used to operate outputs on different connectors by using the appropriate AQ word offsets see the paragraph before Table 5 7 A Force Analog Output value of 32000 will produce 10 00 Vdc and a Force Analog Output value of 32000 will produce 10 00 Vdc Note that in Digital mode a Force Analog Output signal can be overridden if another signal is routed to the same connector by the Select Analog Output Mode command However the Select Analog Output Mode command can also be used to restore an overridden Force Analog Output signal See Section 4 25 Select Analog Output Mode Force Analog Output must remain continuously in the AQ data for pr
177. complete listing can be found in the o Series AC Servo Motor Descriptions Manual GFZ 65142E Chapter 2 Getting Started 2 7 Table 2 2 Prefabricated Servo Motor Power Cable K4 Part Number Examples Motor Type 03 3000 06 3000 012 3000 022 2000 030 1200 030 3000 040 2000 Severe Duty Cable Catalog Number IC800CBL061 IC800CBL062 IC800CBL063 Cable Description Elbow MS Connector Elbow MS Connector Elbow MS Connector Cable Length 14 Meters 14 Meters 14 Meters B One end of this cable has four wires labeled U V W and GND which connect to screw terminals 9 12 on the servo amplifier Connect these four wires to the terminal strip as shown in Figure 2 5 C Attach the other end of the cable to the motor after first removing the plastic caps protecting the motor s connector Note that this cable is keyed and can only be properly attached to one of the motor s connection points Repeat this procedure as needed for any other axes in the system For the most current information on the motor power cables or wiring custom motor power cables please refer to the latest version of the Series Servo Motor Description Manual GFZ 65142E Figure 2 5 Connecting the Motor to the Series Servo Amplifier Terminal Strip 2 8 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 JS1B MIR H p E 48015 13 14
178. conds Motor Velocity Loop 1 millisecond Motor Position Loop 2 milliseconds How quickly can the DSM302 respond to input events and initiate a move The DSM faceplate inputs motion program CTL bits are available on the DSM module connectors e Strobe data may be captured with a maximum 250 Us position update rate or jitter from the serial encoder plus 0 5 us input filter delay e Motion program control or branching is a worst case 2 ms position loop delay plus the input filter delay 5 ms typical for 24 volt CTL inputs or 0 5 us input filter delay for 5 volt CTL inputs e PLC based functions may receive DSM status 1 and information except AI Actual Velocity which 128ms from the DSM asynchronously at 2 ms refresh rate plus 2 4 ms PLC back plane overhead The PLC will normally read input data once per sweep At worst case the PLC may have just missed the DSM update and will need to complete a sweep and begin another to read data from the DSM The result is that DSM status is available at a 4 6 ms rate or a PLC sweep whichever is largest e PLC commands to the DSM Q AQ are normally output to the DSM with one PLC sweep delay The DSM will process the command in 4 5 ms after receipt How many moves can performed simultaneously Both the Motion Mate DSM302 and the Motion Mate APM302 allow for two moves to be performed simultaneously These moves can be independent or synchronized with a block start command What p
179. counts The DSM302 attempts to prevent an Out of Sync error by temporarily halting the internal command generator whenever position error exceeds the Position Error Limit Halting the command generator allows the position feedback to catch up and reduce position error below the error limit value If the feedback does not catch up and the position error continues to grow the Out of Sync condition will occur Possible causes are 1 Erroneous feedback wiring GFK 1464C Chapter 4 Configuring the DSM302 4 13 2 Feedback device coupling slippage 3 Servo drives failure 4 Mechanically forcing the motor encoder shaft past the servo torque capability 5 Commanded motor acceleration or motor deceleration that is greater than system capability 2 04 In Pos Zone In Position Zone User Units When the Moving 1 bit is OFF and Position Error is less than or equal to the active In Position Zone value the Zone bit will be ON This condition occurs at the end of each Positioning Move PMOVE command or any time the axis commands are halted and Actual Position has caught up to Commanded Position e g for Wait Dwell Feedhold or Feedrate Override 0 In Follower mode n Zone is ON under the same conditions described above If the Follower Enabled 1 bit is ON and the slave axis is following a master axis input In Zone will be controlled only by the Position Error value as long as Moving is OFF If Moving is ON due to a superimposed Jog
180. crements the A B ratio by 1 16th every second until it reaches 1 1 The dotted lines represent ratio changes the dashed line indicates when the Follower Enable Q bit is turned OFF a45333 Following Axis t Figure 8 7 Ratio Stepping Velocity Clamping GFK 1464C Velocity clamping is available using the Velocity Limits set in the Configuration software When the master velocity exceeds the configured limit the following axis will continue to move at the limit velocity multiplied by the A B ratio The n Velocity Limit I bit is set and a status error is generated to indicate that the slave axis is no longer locked to the master input positioning The slave axis has essentially fallen behind the master input The Velocity Limit units are counts per millisecond Thus a limit of 400 cts ms will limit velocity to 400 000 cts sec Chapter 8 Follower Motion 8 7 Example 8 Velocity Clamping The Velocity Limits are set to 100 and 100 in this example Thus the master input velocity is clamped at 100 000 cts sec in either direction When the master axis peaks greater than the limits the following axis stays at the limit After the master slows to under the limit the following axis continues tracking the master axis velocity Counts generated in excess of the Velocity Limits are lost to the follower The horizontal dashed lines indicate the velocity limits The shaded area indicates the times when the n Velocity Limit bit is ON and the follo
181. ction and Handling As shown in the table above a value of 1 is returned to the Status Word 1f communications proceed normally but if any error condition is detected a negative value is returned If you require error detection in your ladder program you can use a Less Than LT compare instruction to determine if the value in the Status Word is negative less than zero An example of this is shown in the following figure If an error occurs the Less Than s output Q will go high A coil driven by the output can be used to enable fault handling or error reporting logic ae INT FAULT STATUS 00000 The FT output of the COMM REQ described later in this appendix goes high for certain faults and can be used for fault detection also Additionally the Status Word can be monitored by error messaging logic for display on an Operator Interface device In this case certain Status Word codes would correspond to appropriate error messages that would display on the operator screen For example if 1 were detected in the Status Word a message could be displayed that says something like Error communicating with the DSM module in expansion rack 2 To dynamically check the Status Word write a non significant positive number 0 or 99 are typically used into the Status Word each time before its associated is executed Then if the instruction executes successfully the CPU will write the number 1 ther
182. d executes user defined control logic The machine control PLC and the servo control DSM302 interface and exchange data over the Series 90 30 backplane 2 1 SNP RS 232 a45636 SNP RS 232 RS 232 to RS 485 Converter I Series 90 30 PLC E S LI DIDI PWM Serial Encoder amp Diagnostic Signals EUM Enn Diagnostic Signals Motion Programmer Power and Digital CPU Programmer Servo Amplifier Digital Servo Encoder Encoder Feedback Encoder Feedback Encoder 1 oat Battery Pack Optional Pack Optional N 7 N Axis 1 Axis 2 Figure 2 1 Typical 2 Axis Motion Mate DSM302 Digital Motion Control System 2 2 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Section 1 Unpacking the System The DSM302 Digital Servo Amplifiers and Motors are packed separately This section describes how to unpack the hardware and perform a preliminary check on the components Unpacking the DSM302 Carefully unpack the DSM302 and PLC system components Verify that you have received all the items listed on the bill of material Keep all documentation and shipping papers that accompanied the DSM302 motion system Unpacking the Digital Servo Amplifier There are two digital amplifier and servo subsystem packages shipped for use with the DSM302 the Series or the D Series The digital servo amplifier is shipped i
183. d guarantee synchronization but then axis 1 would stop at 30 000 counts GFK 1464C Chapter 7 Programmed Motion 7 25 Parameters P0 P255 in the DSM302 The DSM302 maintains 256 double word parameters 0 through 255 in memory Note that parameter 0 is not supported in all configuration or motion program software packages These values can be used as a parameter in ACCEL VELOC DWELL PMOVE and CMOVE motion commands Be aware that range limits still apply and errors may occur if a parameter contains a value out of range The last few parameters are special purpose parameters The DSM302 can load data into these parameters that might overwrite user data The following table describes the function of the special purpose parameters Table 7 1 Special Purpose Parameters Parameter Special Purpose Function Axis Units Number Commanded Position at Follower Enable Trigger 23 23 23 24 24 5 E Commanded Position at Follower Enable Trigger 0 1 Position Strobe 1 Parameters are all reset to zero after a power cycle or after a DSM302 configuration is stored by the PLC Parameters can be assigned in three ways e The motion program LOAD command e Load Parameter Immediate command e The COMM REQ function block This is the preferred way if you need to send multiple parameters per scan The COMM REQ function block is described in Appendix B Assigning a value to a parameter overwrites any previous value Parameter val
184. d 1s to base the calculations on a single spur gear revolution First determine the number of User Units per spur gear revolution 14 336 inch diameter pi 45 0378 inches circumference 45 0378 inches 0 01 inch desired programming units 4503 78 User Units per revolution of spur gear Then determine the number of encoder counts per spur gear revolution 2000 lines 4 20 160 000 encoder counts per spur gear revolution The 4 results from the quadrature encoder generating 4 counts per line The 20 results from the 20 1 gear reduction Then check the value of the User Units to Counts ratio The ratio must be in the 8 1 to 1 32 range and the two numbers must be in the 1 to 65535 range 4503 78 User Units 160 000 encoder counts 0 02815 or 1 35 5 This ratio is too small so something must be changed Any of the following system components could be changed to solve the problem GFK 1464C Chapter 4 Configuring the DSM302 4 11 4 12 2 02 The spur gear diameter to 15 92 inch or larger The encoder lines per revolution to 1800 or less The gear reduction to 18 1 or less The desired programming unit to 0 001 inch By far the easiest component to change is the desired programming unit to 0 001 inch Now recalculate to determine the revised User Units per revolution using 0 001 inch programming unit 14 336 inches diameter pi 45 0378 inches circumference 45 0378 inches 0 001 inch programming unit 45 037 8 Use
185. d Block It should be set to 4 for the DSM The Data Block header is stored in Words 7 through 10 of the Command Block Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C WAIT NOWAIT Flag Word 2 This must always be set to logic zero for the DSM Status Word Pointer Memory Type Word 3 This word specifies the memory type that will be used for the Status Word Each memory type has its own specific code number shown in the Memory Type Codes table below So for example if you want to use R memory for the Status Word you would put either the decimal code number 8 or the hexadecimal code number 08h in this word Note that if you select a discrete memory type I or Q 16 consecutive bits will be assigned to the Status Word beginning at the address specified in the Status Word Pointer Offset word described below Status Word Pointer Offset Word 4 This word contains the offset within the memory type selected Note The Status Word Pointer Offset is a zero based number In practical terms this means that you should subtract one from the address number that you wish to specify For example to select 0001 enter a zero 1 1 0 Or if you want to specify R0100 enter a 99 100 1 99 Note that the memory type in this example is specified by the previous word see the Status Word Pointer Memory Type explanation above Idle Timeout Value Word 5 Since the DSM
186. d as connector X and terminal connector pins are included with the 2 10 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C amplifier package You must install this connection as a switch or jumper for the amplifier to operate Do not apply any external voltage to this connector Front Face R a48026 JV1B _ JA4 Bottom View exi Normally Closed Machine E STOP Device s CX4 olo 3 Of First ESP Series SVU Amplifier CX4 Of Second o Series SVU Amplifier Up to 6 Series SVU AMPs can be connected N in series Figure 2 8 Connecting Emergency Stop to the o Series Servo Amplifier For more information refer to the 0 Series Servo Amplifier SVU Descriptions Manual GFZ 65192EN GFK 1464C Chapter 2 Getting Started 2 12 Connecting the Series SVU Digital Servo Amplifier The Series Digital Servo Amplifier does not contain any user adjustments To connect the Series Servo Amplifier follow the steps outlined below Refer to the previous section for Series Amplifiers 1 Connect the Series Digital Servo Amplifier to the DSM302 A Before connecting the servo command cable make sure the DSM302 faceplate shield ground wire is connected This wire is shipped with the DSM302 module and must be connected from the inch blade terminal on the bottom of the module to a suitable panel earth ground B The servo command cable
187. d velocity exceed the active Vlim Configuring the Master Velocity Limit to zero disables error reporting for the positive direction and provides unidirectional follower operation in the negative direction Default 1000 Refer to Chapter 8 Follower Motion for additional information Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 2 34 2 35 2 36 2 37 Viim Master Velocity Limit counts ms The maximum negative master velocity command in counts per millisecond allowed for the master axis input to the follower If the master velocity command exceeds the Vlim value the master velocity command will be clamped at the active Vlim value an error F2h will be reported and the Follower Velocity Limit I Status Bit will be set The Master Velocity Limit value is used for an additional function if Follower Ramp Acceleration Control is active The Follower Ramp Acceleration Control function has the capability to create a unique motion profile automatically that will be combined with the master command velocity The calculated velocity used for this automatic profile generation will not exceed 80 of the Master Velocity Limit The 80 limitation allows the remaining 20 of the Vlim value to be used to respond to changes in the master source velocity See the description for Follower Make Up Time and Chapter 8 Follower Motion for more information Superimposed motion progra
188. de Moving is ON for the conditions described above and is not affected by the enabled or disabled state of the Master Axis input Moving is also ON whenever the Follower Acceleration Ramp feature is active Refer to Chapter 8 Follower Motion for additional information on the Follower Acceleration Ramp In Zone n Zone can be used to determine when the servo has arrived at its destination Operation of the Jn Zone bit depends on the Position Error value and the state of the Moving I bit Table 5 3 In Zone Bit Operation Cmd Generator Active Position Error lt In ee EE bit ON In ae EN Zone eee eens eet In Zone will be ON whenever Moving is OFF and Position Error is less than or equal to the configured In Position Zone value This condition occurs at the end of each Positioning Move PMOVE command or any time the axis commands are halted and Actual Position has approached Commanded Position e g for Dwell Feed Hold or Feedrate Override 0 In Follower mode Jn Zone is ON under the same conditions described above If the Follower Enabled 961 bit is ON and the slave axis is following the master axis input with no superimposed motion In Zone is ON if Position Error is lt Zone value i e the following axis is closely following the master If Moving is ON due to a superimposed Jog Move at Velocity Accel or Decel Ramp or Execute Program command Zone will always be off Position Strobe 1
189. deceleration Torque y x k X acceleration distance P 0 5t tt t 0 5t X slew distance T Vu _ Fs Xi deceleration distance t ty Figure 7 22 Trapezoidal Move Once the move segment outline is drawn we need to examine specifications or physical restrictions applicable to the move For instance the move may have to complete in a certain time interval t t ta or move a fixed distance X The maximum velocity of the servomotor is one example of a physical limitation Given any two known values of the acceleration portion of the move segment a remaining variable can be found using the kinematic equations as illustrated in the example below Trapezoidal Velocity Profile Application Example Let s assume that a complete move of 16 inches must be made in three seconds and the maximum motor velocity translated through the gearing is 15 inches per second Using our rule of thumb we divide the move s time into thirds t 1sec t 1sec and ty 1sec We can also subdivide the 16 inch move into three distances The slew X section of an equally divided trapezoidal velocity profile represents 1 2 of the distance moved and the acceleration X and deceleration portions each represent 1 4 of the total distance X 4 in X 8 in and X 4 in To calculate peak Velocity V the first acceleration portion of the move must travel a given distance X in a given time t From the above Kinematic Velocit
190. ds PMOVE AS P 6 ABS SCURVE Final stop position value in Parameter 6 GFK 1464C Chapter 7 Programmed Motion 7 27 Calculating Acceleration Velocity and Position Values One method of determining the value for APM or DSM motion program variables such as Acceleration Velocity or Position is to plot the desired move or move segment as a velocity profile A velocity profile plots time on the horizontal axis of a graph and velocity on the vertical axis The key to understanding profile generation is to break the complete move into smaller segments that may be analyzed geometrically Most applications will use the economical trapezoidal move velocity profile as illustrated below To move as quickly as possible use a triangular velocity profile if the servo has sufficient speed range A triangular move would accelerate half the distance then decelerate the remaining half Another alternative is to use a trapezoidal profile with a shorter slew segment Kinematic Equations Kinematics is the branch of mechanics that studies the motion of a body or a system of bodies without consideration given to its mass or the forces acting on it The following table includes transformations of the basic linear equations as applied to the acceleration portion of motion profiles Use these formulae to calculate the velocity and acceleration for the acceleration portions of the move Table 7 2 Linear Equation Transformations ae T Acceleration vw vx
191. e This method is possible because the Program Command Position is set to the Actual Position Position Error when execute motion program is commanded with the follower disabled Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Appendix Error Reporting A DSM302 Error Codes The DSM302 reports error codes in these AI Table locations AI Table Location Data Reported Module Status Code Errors not related to a specific axis Servo Axis 1 Error Code Errors related to Servo Axis 1 Servo Axis 2 Error Code Errors related to Servo Axis 2 Aux Axis 3 Error Code Errors related to Aux Axis 3 Each error code is a hexadecimal word which describes the error indicated when the Module Error Present 6 status bit is set The Module Status Code AI status word reports module errors that are not related to a specific axis Examples of such errors would be a self test detected hardware failure or an error while storing a user program to the flash memory All motion related errors are reported in the proper Axis Error Code AI status word Whenever the Module Error Present 1 status bit is set all four error words should be checked for a reported error Note The STAT LED on the faceplate of the module flashes slow four times second for Status Only errors and fast eight times second for errors which cause the servo to stop In the case of a fatal hardware error being detected at power up the STAT
192. e DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Figure 8 5 Figure 8 6 Figure 8 7 Figure 8 8 Figure 8 9 Figure 8 10 Figure 8 11 Figure 8 12 Figure 8 13 Figure 8 14 Figure 8 15 Figure 8 16 Figure 8 17 Figure 8 18 Figure 8 19 Contents Sample A B RAtOS tite etii edt att dete tha e oth monn 8 6 Changing the A B Ratio sse enne ennt nennen nennen nennt 8 7 satio Stepping raare A e cett fe cele oe 8 7 mate ern e ier v NE 8 8 Unidirectional Operations 8 9 Encoder and Internal Master Synchronization 2 0120 20200020 00201000 00100000000 8 0 Follower Ramp Up Ramp Down Cycle Case 2 8 12 Follower Ramp Up Ramp Down Cycle Case 2 with make up time too small 8 12 Follower Ramp Up Ramp Down Cycle case with active velocity 8 13 2 Axis Cascade Master Source Encoder 3 Internal Master ccccccccesssccceesssscecessseceesenes 8 16 2 Axis Parallel Master Source Encoder 3 Internal Master see 8 16 2 Axis Cascade Master Source Analog enne 8 17 2 Axis Parallel Master Source Analog 8 17 Axis 2 Master Source Encoder 3 Internal Master Axis 1 Master Source Analog Input 8 18 Axis 2 Master Source A
193. e s SNP serial port baud rate is set to 19200 baud 4 Using a Station Manager to PC cable IC693CBL3106 connect the appropriate serial port of your computer master to the DSM302 module to be updated slave 5 Insert the supplied firmware upgrade floppy disk into your A or B drive 6 At the C gt prompt type A install or B install if your floppy drive is B The install program will copy several files to the hard drive then invoke the PC Loader Install can also be run from the floppy drive directly if there is no hard drive or not enough space on the hard drive To run from the floppy type install at the A gt or B gt prompt 7 default the PC Loader communicates through the COMI serial port A different serial port may be selected by pressing the F3 key Press the TAB key to toggle through the selections and press ENTER to accept the displayed choice 8 From the main menu press the F1 key to attach to the DSM302 slave device 9 Once the slave device is attached the boot mode menu will appear press F1 to enter BOOT MODE and press the Y key to confirm the operation The STAT and CFG LED s on the front of the module should now be flashing in unison 10 Once in boot mode press the F1 key to download the new firmware F 2 11 Press the Y key to confirm the operation The download time is approximately 4 minutes If the download fails refer to Restarting An Interrupted Firmware Upgrade 12 When the down
194. e This method lets you know that 1f the number 1 is present it truly indicates that the last COMM REQ executed successfully and that the 1 was not just left over from a previous execution In the example presented at the end of this appendix the number 99 is moved into the Status Word R0195 in a rung prior to the rung that contains the COMM REQ instruction When multiple DSM COMM are used it is recommended that each be verified for successful communications before the next is enabled Monitoring the Status Word is one way to accomplish this Verifying that the DSM Received Correct Data For critical applications it may be advisable to verify that certain parameter values were communicated correctly to the DSM module before operation is allowed to continue To accomplish this first program the Select Return Data AQ Immediate Command to specify a DSM parameter number to be read into the applicable User Selected Data AI double word there is one User Selected Data AI double word for each axis Note that at least three PLC sweeps or 20 milliseconds which ever represents more time must elapse before the new User Selected Data is available in the PLC This requires programming some time delay logic to ensure that this requirement is met Then program a Double Integer Equal instruction to compare the value returned in the User Selected Data double word with the value sent Section 4 of this appendix shows an example of this Also
195. e 351 352 360 363 and 364 CPUs were provided with configurable AI memory in firmware release 9 0 The range of this configurable memory is 128 to 16 384 words using Logicmaster software In versions of these CPUs containing earlier firmware the number of AI references was fixed at 2048 Note 2 Theoretical number of 64 axes 32 modules See discussion in paragraph before this table Can I change the end position or velocity of a move already in process In the Motion Mate controls the Position Increment immediate command can be used to generate small corrections by a specific number of user units between the axis position and the controller tracking The Feedrate Override immediate command allows changes to a programmed velocity during program execution from 0 to 120 It is possible to change a data variable parameter used in the motion program if timing considerations are accounted for The DSM utilizes a look ahead buffer to pre process motion commands Only position parameters later in the program sequence than the active command in the buffer may be changed Since PLC logic is required to change a data value the PLC timing must be accounted for For more information see the FAQ entry How quickly can the DSM302 respond to input events and initiate a move What dedicated I O is available for each axis on the DSM302 The DSM includes positive and negative over travel limits as well as a home input for each axis The
196. e 6 01 or later and may be located in any CPU local expansion or remote expansion base plate 8 Series 90 30 high capacity power supply IC693PWR330 30 watt used to calculate rack power capacity to support maximum number of DSM302 modules 9 The maximum number of DSM302 modules per Series 90 30 system is limited by Number of available AI and QI references supported by CPU model e Maximum number of racks supported by CPU model Power Supply capacity per rack Maximum of 7 modules per rack with PWR330 30 watt 3 modules per rack maximum with PWR321 15 watt e Maximum number of available module slots per rack e Available PC memory for Logicmaster Configuration Software Qv di duc usc The table below represents theoretical maximums and may utilize all of a particular PLC data type For example the 64 axes 32 modules 2 axes per module maximum for the 351 364 CPUs use all available I and references in the CPU The practical number of axes must consider I O use and sweep impact of the entire system Logicmaster may not have enough memory depending on the configuration of the computer it s installed on to even configure all 32 possible modules for the 351 364 CPUS GFK 1464C Appendix G Answers to Frequently Asked Questions G 9 340 350 351 352 360 Available QI 512 512 512 512 2048 2048 Total Racks supported 1 1 5 5 8 8 2 2 Note 1 Th
197. e DSM302 3 11 Reset Strobe 1 2 Flag The Position Strobe n 1 status bit flag informs the PLC that a Strobe Input has captured an axis position that is now stored in the associated Strobe n Position AI status word When the PLC acknowledges this data it may use the Reset Strobe n Flag Q command bit to clear the Position Strobe n Vol status bit flag Once the Position Strobe n 1 bit is set additional Strobe Inputs will not cause new data to be captured The flag must be cleared before another Strobe Position will be captured As long as the Reset Strobe n Flag Q command bit is set the Position Strobe n bit flag will be held in the cleared state In this condition the latest Strobe Input position is reflected in the Strobe n Position status word although the flag cannot be used by the PLC to indicate when new data is present GFK 1464C Chapter 5 Motion Mate DSM302 to PLC Interface 5 13 5 14 3 12 3 13 3 14 3 15 OUT1 A B C D Output Control Each axis connector has a 24 vdc solid state relay SSR output rated at 125 ma The OUTIA OUTI B OUTI C and OUTI D Output Control Q bits control the state of the associated output For each axis the following connector terminals are assigned Faceplate Auxiliary TB Servo TB Connector IC693ACC336 IC693ACC335 Pin Terminal Terminal OUTI SSR terminal 18 18 8 OUTI SSR terminal 36 36 16 A B C D Output Control Each axis connector has a differential 5 vdc output
198. e Follower Velocity Limit Status bit is set but no Status Error code is reported If one of the Follower Control Loop Velocity Limits is set to zero the position error integrator is inhibited from generating motion in the direction of the Velocity Limit This feature allows unidirectional systems to operate properly with the position error integrator enabled Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Section 2 AI Status Words The following AI Status Words are transferred automatically from the DSM302 to the CPU each sweep The total number of the AI Status Words is configured with the Configuration Software to be a length of 40 50 or 64 The actual addresses of the Status Words depend on the starting address configured for the AI references See Table 4 1 Module Configuration Data The word numbers listed in the following table are offsets to this starting address All reference section designations pertain to this chapter All AI data except Actual Velocity is updated within the DSM302 once every 2 milliseconds Actual Velocity is updated once every 128 milliseconds Table 5 4 Al Status Words Word Word C erap sorar 00 Module Status Code N A 201 03 Reserved dT 4829 Reserved ss 11 Congr or seme p ulmi n 1 H A H A Rue 18 19 Actual Velocity GFK 1464C Chapter 5 Motion Mate
199. e Tet ede edel eaae va qp adeat 7 12 Motion Program Example 7 13 Motion Program Example 2 eter E PH epe 7 13 Motion Program Example 7 13 MN UD EI 7 14 Example 7 Jump Testing ciet diee etes 7 14 Normal Stop Before JUMP Prenn naear e ener 7 15 Example 8 Normal Stop Before 7 15 Jumping Without 1 enn enne enne enne 7 16 Example 9 JUMP Without Stopping sese 7 16 Jump NES ees 7 16 Exaimple 10 J mp Stop 5 e neret tinet deti tee Het tei te iir 7 17 Example 11 Jump Followed by PMOVE sese 7 18 S2CUR VE JUMPS frei ede pe 7 18 S CURVE Jumps after the Midpoint of Acceleration or Deceleration 7 18 Example 12 S CURVE Jumping After the Midpoint of Acceleration or Deceleration M 7 18 S CURVE Jumps before the Midpoint of Acceleration or Deceleration 7 19 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter 8 GFK 1464C Contents Example 13 S CURVE Jumping Before the Midpoint of Acceleration or Deceleration i ocean pere ere eee env esempio ond Do se eee ERES 7 19 S CURVE Jumps to a higher Acceleration while Accelerating or a lower Deceleration while
200. e Velocity at 10 Volt value as described in the configuration chapter Set the Integrator Mode selection to OFF Set the Feed Forward to zero Set the Position Error Limit to near maximum value The maximum is 60 000 User Units Counts SD Setting the Position Loop Gain The position control loop is primarily a PI Proportional Integral algorithm with optional Feed Forward We begin tuning the position loop by setting the proportional gain Pos Loop TC to provide a stable response with sufficient gain bandwidth to meet the motion profile requirements By setting the Integrator Mode to OFF as requested in the previous section we create a proportional only control loop There are two suggested methods of setting the proportional gain Pos Loop TC Position Loop Proportional Gain Method 1 Calculating the position loop proportional gain assumes that the mechanical design of the machine will have sufficient bandwidth to remain stable and that any resonant frequencies are higher than the bandwidth required by the motion profile Terminology A large mismatch between the load and motor inertia can cause a RESONANCE in the system Resonance is oscillatory behavior caused by mechanical limitations and aggravated by gearing backlash or torsion windup of mechanical members like couplings or shafts Resonance is eliminated by improving the mechanics reducing load motor inertia mismatch or reducing servo gains reduce perfo
201. e and axis error code words Appendix B Parameter Download Using a COMM REQ This appendix describes how to use the COMM function block to load Data Parameter Memory from the PLC to the DSM302 iii Preface Appendix C Position Feedback Devices This appendix provides information needed to use Fanuc serial encoders and incremental quadrature encoders with the DSM302 Appendix D Startup and Tuning a GE Fanuc Digital Servo System This appendix provides a procedure for starting up and tuning a GE Fanuc digital servo system Appendix E Using the APM Motion Programmer Status Screen with the DSM302 This appendix describes how the APM Motion programmer may be used to monitor the operation of a DSM302 module Appendix F Updating Firmware in the DSM302 This appendix describes the procedure for updating firmware in Flash memory in the DSM302 Appendix G Answers to Frequently Asked Questions This appendix contains answers to the most frequently asked motion questions Related Publications For more information refer to the following publications Series 90 30 Programmable Controller Installation Manual GFK 0356 Logicmaster 90 Series 90 30 20 Micro Programming Software User s Manual 0466 Series 901TM 30 20 Micro Programmable Controller s Reference Manual GFK 0467 Installation Requirements for Conformance to Standards GFK 1179 Series 90 PLC APM Programmer s Manual GFK 0664 a Series Servo Amplifier SVU
202. e engaging the baseplate notch 5 Connect the faceplate shield wire from the 1 4 inch blade terminal on the bottom of the module to a suitable panel earth ground 6 Refer to Figures 3 10 through 3 23 and Tables 3 7 through 3 14 for I O wiring requirements 7 Power up the PLC rack The Status LED of the Motion Mate DSM302 will turn ON when the controller has passed its power up diagnostics 8 Repeat this procedure for each DSM302 module in your PLC system 9 Configure the DSM302 module s as described in Chapter 4 The following table lists the DSM302 module current draw and defines the number of modules that can be installed in a particular PLC system The number of modules in a system may be restricted by W PLC rack power supply capacity PLC I O Table space The DSM module requires the use of 4I AI and AQ memory in the I O Table with the AI type usually being the most restrictive of the four W PLC Configuration data storage capacity W PLC Configuration software memory The absolute limits for each PLC type must not be exceeded because in some cases they are based on PLC I O Table and Configuration data capacity The practical number of axes must consider I O use and sweep time of the entire system The number of DSM302 modules might be additionally limited by the memory available in the personal computer running Logicmaster 90 30 configuration software Chapter 3 Installing and Wiring the DSM302 3 5
203. e latest encoder position change and direction of rotation Incremental Quadrature Encoders are incremental feedback devices they do not provide a continuous indication of absolute shaft angle as the input shaft rotates For this reason the DSM302 s Actual Position AI status word must be initialized with a known physical position before positioning control is allowed This position alignment can be accomplished using the Set Position AQ Immediate command or the Q Find Home cycle The home cycle makes use of the encoder marker channel which is a once per revolution pulse produced at a known encoder shaft angle Successful completion of the Q Find Home cycle or a Set Position AQ command causes the DSM302 to set the axis Position Valid vol bit Position Valid must be set before motion programs will be allowed to execute Position Valid is only cleared by an encoder Quadrature Error Channel A and Channel B switching at the same time or by turning on the Find Home and Abort Q bits simultaneously Note In Digital Mode only incremental quadrature encoders are supported for the Follower mode master axis GFK 1464C Appendix C Position Feedback Devices C 5 Appendix D Start Up and Tuning GE Fanuc Digital and Analog Servo Systems This appendix provides a procedure for starting up and tuning a GE Fanuc Digital or Analog servo system For Digital servos systems there are two control loops in the DSM302 that require tuning the velocity
204. e master velocity at the active Jog Acceleration rate This function is most useful when the master source is in motion before the follower mode is enabled In addition to the PLC Enable Follower Qbit a PLC initiated control bit CTL9 CTL12 or a high speed DSM302 module input CTL01 CTLO8 CTL13 CTL16 may be configured as the enable follower signal for position registration functions When the Enable Follower Qbit is ON then the CTL bit chosen acts as a rising edge trigger to enable follower mode After Follower is enabled only the PLC Enable Follower Qbit controls the active state of the following function When the follower axis is enabled to a moving master source some master source counts cannot be used immediately The master counts that accumulate during acceleration of the follower axis are stored When the follower axis reaches the master velocity they will be inserted during make up distance correction motion This motion has an automatically calculated trapezoidal velocity profile determined by the Follower Ramp Distance Makeup Time the amount of accumulated counts and the active jog acceleration at the beginning of the correction Set the Follower Follower Ramp Distance Make up Time to the desired time in the configuration software or it can be changed with the PLC AQ Command 42h If the Follower Ramp Distance Makeup Time is too short then the automatically generated velocity profile is triangular in profile If during the distance co
205. e motion program commands including the CALL command The BLOCK SYNC command is reserved for multiaxis programs and sub routines Sub routine nesting using CALL statements is supported to a maximum of 8 levels Single axis sub routines similar to motion programs contain commands for only one axis The difference is that a single axis sub routine does not specify the axis number as an a motion program operand command A single axis motion program may CALL any single axis sub routine stored in module memory For example single axis motion program 1 operating axis one may include a CALL statement to single axis sub routine 1 Additionally single axis motion program 2 operating axis two may include a CALL statement to single axis sub routine 1 Single axis motion programs cannot CALL multiaxis sub routines The motion program and sub routine structure allow flexibility in execution and axis control in the DSM302 module The practical limitation is that an axis may only execute one program at a time GFK 1464C 7 1 7 2 For example if motion program is enabled to run it must either complete or abort prior to enabling motion program 2 Multiaxis Motion Programs and Sub Routines A motion program or sub routine is designated multiaxis when it contains commands for both axis one and axis two Both axes must be home referenced and meet the remaining prerequisites see the section Prerequisites for Programmed Motion in this chapter b
206. e shown with the labels Configuration Diagrams HIROSE and HONDA incorrectly reversed The labels were switched Grounding Bars and Chapter 3 The I O Cable Grounding section did not specify the part numbers for the Clamps Need to Be grounding bars and clamps needed for proper installation These have been Documented added to the manual Quadrature Specs Chapter 3 The technical specifications for quadrature devices used as a follower Undocumented master axis were not documented These have been added to the manual Incorrect Part Numbers Chapter 3 incorrect part numbers were given for the Terminal Board Connection Listed for Terminal cables The incorrect part numbers listed were IC800CBL324 and Block Connection IC800CBL325 These part numbers should have been IC693CBL324 and Cables IC693CBL325 respectively and have been corrected Input 134 C Wiring Not Chapter 3 The appropriate wiring for input INA C was not described The description Described has been added Final Home Velocity Chapter 4 The Configuring the DSM302 section incorrectly specified the valid Valid Command Range range as 1 8 388 607 The range is actually 1 65535 and has been Incorrectly Specified corrected in the manual Select Return Data Chapter 5 Section incorrectly stated that information is returned in the Commanded Command Incorrectly Position AI word for each axis Data is actually returned via the User Described Selected Data AI wo
207. e velocity loop at this point in our tuning process The Force Digital Servo Velocity AQ command allows the user to generate a step change in the velocity The velocity command step is then used to generate the velocity loop step response The user should note that when a velocity command step change is performed the acceleration is limited only by the bandwidth of the velocity loop In some applications this can cause damage to the controlled device due to the high acceleration rate Method 2 In some applications method 1 introduces too large a shock to the device under control In these cases another method to generate a velocity command is needed The method requires that the user set the position loop to an open loop configuration The position loop is set to open loop by setting the Position Loop Time Constant to zero and the Velocity Feedforward Gain to 100 percent You can then use the Move at Velocity Command or a motion program to generate velocity commands to the servo drive The first parameter that needs to be adjusted is the Velocity Loop Gain The parameter adjusts the velocity loop bandwidth As a starting point use the following formula also reference the Velocity Loop Gain Section Equation 1 J Velocity Loop Gain i 16 m Where J Load Inertia J Motor Inertia The Velocity Loop Gain calculated in equation in many cases will not need to be altered However due to the application for example machine resona
208. eases to gt 80 of the velocity limit The amount of accumulated counts and the active makeup time value will determine if the makeup move will complete in the specified makeup time A status only error F2h will occur if the combined master command velocity and the makeup move velocity reach 100 of the velocity limit The master command velocity will not exceed 100 of the Vlim value Accumulated counts may be lost and the makeup move will not complete When the Follower is enabled by the Enable Follower bit and an optional Trigger input the Follower Axis Velocity will be ramped up at the Jog Acceleration rate When the Enable Follower Q bit is turned off the axis velocity will ramp down at the same rate The Moving l bit indication is turned on while the ramp control is in effect for both the ramp up make up and ramp down The Follower Enabled and Moving 1 bits can be monitored by the PLC to determine which part of the follower ramp up ramp down cycle is active The following figure shows the state of Follower Enabled and Moving during a follower cycle Follower Disabled Make up distance a Follower Enabled Moving Figure 8 11 Follower Ramp Up Ramp Down Cycle Case 2 GFK 1464C Chapter 8 Follower Motion 8 11 The programmed make up time can be too short for the required distance correction In this case a warning error is reported in the point B of the trajectory but system continues accele
209. ections on the Motion Mate DSM302 Motion Control System Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Connecting the Series SVU Digital Servo Amplifier Skip to the next section if you are connecting a B Series amplifier The Series Digital Servo Amplifier does not require tuning adjustment during initial startup or when a component is replaced It also does not need adjustment when environmental conditions change To connect the amp Series Digital Servo Amplifier follow the steps outlined below Connect the Series Servo Amplifier to the DSM302 A Before connecting the servo command cable make sure the DSM302 faceplate shield ground wire is connected This wire is shipped with the DSM302 module and must be connected from the inch blade terminal on the bottom of the module to a suitable panel earth ground B The servo command cable contains the pulse width modulated PWM output signal from the DSM the serial data from the motor encoder and diagnostic signals from the amplifier The signals carried in this cable are at data communications voltage levels and should be routed away from other conductors especially high current conductors C Locate the servo command cable 800 001 1 meter or ICS00CBL002 3 meter Insert the mating end of this cable into the connector JS1B located on the bottom of the Servo Amplifier see Figure 2 4 D If you are not using the
210. ects an individual data item for some modes Setting the mode to 00h causes the default Torque Command to be reported The following Return Data selections are allowed Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Analog Selected Return Data Data Mode Data Offset lt Z Torque Command not used DSM Firmware Revision not used DSM Firmware Build ID No hex not used Absolute Feedback Offset cts not used Parameter Data Parameter Number 0 255 Analog Inputs Axis 1 not used Analog Inputs Axis 2 not used Analog Inputs Aux 3 not used Analog Inputs Aux 4 not used Commanded Position user units not used Y Y Y Y Y Y Y Y Y Y RRETA Follower Program Command not used Position cts Follower Winder Zone Position not used cts lt lt Torque Command is scaled so that 7282 100 torque DSM Firmware Revision is interpreted as two separate words for major minor revision codes DSM Firmware Build ID is interpreted as a single hex word Absolute Feedback Offset is the position offset in counts that is used to initialize Actual Position when a GE Fanuc digital Absolute Encoder is used Actual Position Absolute Encoder Data Absolute Feedback Offset Analog Inputs provides two words of data for each axis low word AINI and high word AIN2 The data is scaled so that 32000
211. ed which gives quick response to a slowdown command from the control Regenerative braking consists of momentarily treating the motor as a generator and electronically directing its generated current into a power resistor called a regeneration or discharge resistor This removal of Appendix G Answers to Frequently Asked Questions G 5 G 6 electrical energy from the motor causes a reduction in its speed GE Fanuc servo amplifiers use regenerative braking in the following speed reduction situations e When the control commands a reduction in motor speed e When the control commands a motor stop e When the control commands a reversal in motor direction Dynamic Braking Dynamic Braking is used in non controlled stops and involves shorting the motor power lines through low value resistances This braking is possible due to the fact that in a coasting permanent magnet servomotor the rotating magnetic fields from its rotor magnets are cutting across the motor s stator stationary windings and generating a voltage in them The dynamic braking circuit conducts the electric current generated in the stator windings into resistors which convert the current into heat which dissipates into the air This electric current creates a torque which opposes motor rotation causing the motor to rapidly decelerate to a stop Be aware that this feature cannot be used to positively hold a motor motionless since the braking torque is proportional to
212. ed If A is negative the following axis will move with the direction of motion reversed GFK 1464C Chapter 8 Follower Motion 8 5 Example 5 Sample A B Ratios All of the following samples are following the master source input at various A B ratios V 245331 Master Source Follower Axis A B Ratio 1 2 Follower Axis Follower Axis A B Ratio 2 1 A B Ratio 1 3 Follower Axis Follower Axis A B Ratio 4 3 A B Ratio 5 6 Follower Axis Follower Axis A B Ratio 1 1 A B Ratio 2 3 Figure 8 5 Sample A B Ratios 6 6 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Example 6 Changing the A B Ratio One example of variable A B ratios is to use one ratio while moving positive and another when moving negative Note that determination of positive and negative velocity and update of the A B ratio must be done in the PLC In the profile below the following axis uses a 2 1 ratio when moving positive and a 1 2 ratio when moving negative a45332 Ratio 2 1 Ratio 1 2 Master Source Following Axis Figure 8 6 Changing the A B Ratio Example 7 Ratio Stepping Another example of variable A B ratios is step up the ratio as a type of acceleration control Initially setting a ratio 1 32 and incrementing the numerator after a delay would step the following axis from 1 32 to 2 32 to 3 32 and so forth all the way to 32 32 which is 1 1 In this example the PLC in
213. ed by the Home Offset value from the home reference position 9 The axis decelerates and is stopped 10 The DSM302 sets the Commanded Position and Actual Position AI status words to the configured Home Position value Finally the DSM302 sets the Position Valid Vol bit to indicate the home cycle is complete Home Switch Example Many different home switch designs are possible The switch may be normally open or normally closed and may be mounted in one of several possible locations The example given in this section illustrates a fairly common arrangement used for linear axes In the following picture the home switch is a normally open proximity switch mounted near the end of the machine slide s travel range in the negative direction The imaginary line that divides the home switch s positive and negative sides is the home switch s operating point located approximately on the switch s centerline If the machine slide travels in the negative direction far enough so that the right hand edge of the home switch cam causes the home switch to close we consider the machine slide as having crossed over to the negative side of the home switch The home switch cam is long enough so that while the machine slide is on the negative side of the home switch it will keep the normally open home switch closed Note the relationships of the home position the negative overtravel position and the positive stop position A small amount of dista
214. ed to the DSM302 velocity command output Increasing Velocity Feedforward causes the servo to operate with faster response and reduced position error Optimum Velocity Feedforward values are 90 100 The Vel at 10 V configuration value must be set correctly for proper operation of the Velocity Feedforward gain factor A PLC reset or power cycle returns this value to the configured data Integrator Time Constant Milliseconds This command sets the Integrator Time Constant for the position error integrator The value specifies the amount of time in which 63 of the Position Error will be removed The Integrator Time Constant should be 5 to 10 times greater than the Position Loop Time Constant to prevent instability and oscillation It is recommended that the position error integrator only be used in continuous follower applications Use of the integrator in point to point positioning applications may result in position overshoot when stopping Follower A B Ratio This command allows the PLC to update the slave master A B ratio used in each follower loop A is a 16 bit signed integer with a minimum value of 32 768 and a maximum value of 32 767 B is a 16 bit integer with a minimum value of 1 and a maximum value of 32 767 The magnitude of the A B ratio must be in the range 32 1 to 1 10 000 or a status error will be generated Applies to firmware version 1 2 or later For earlier firmware versions the ratio must be in the range of 32
215. ee enne erinnern entere nennen nns 4 2 Table 4 2 Serial Communications Port Configuration Data sess 4 7 Table 4 3 Axis Configuration Data sessssssssseseseeeeeeeene nennen ener ener enne eren nennen nennen 4 9 Table 4 5 Available Tuning Parameter Selections 4 20 Table 4 6 Enhanced Position Loop Resolution esses eee nennen 4 21 Table 4 4 Program Zero Motion Program Commands esses enne 4 27 5 12 Yol Status Bits ert mee re ene aro pea E 5 2 Table 5 2 Faceplate Input ol Status Bits ccc cceccccccsseesseesseeseeesseceeceseeeseecsaecssecssecesecesaecsaecseceeeseeeseaeeenes 5 4 Table 5 3 InzZone Bit Operation tine tle reos get oer evene ase e Eee tabu 5 5 Table S4 SAT Status Words eere etre toot ere ee ee o ere 5 7 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Table 5 5 Table 5 6 Table 5 7 Table 7 1 Table 7 2 Table 9 1 Table 9 2 Table A 1 Table A 1 Table A 2 Table B 1 Table B 2 Table B 3 Table B 4 Table C 1 GFK 1464C Contents MAO Discrete Commands e o r cada ed oe eka ETT ELT NI TR 5 11 MAO Word Assignments nece rhe river Te e ra cet docs be Husa dass P eee ehe eno 5 15 AQ Immediate Commands Using the 6 Byte Format sese 5 17 Special Purpo
216. efore a program can be executed A multiaxis motion program may CALL only multiaxis sub routines One motion program instruction BLOCK SYNC is available only in a multiaxis motion program Sub routine nesting limitations are the same as for a single axis motion program In a multiaxis program there are two categories of moves 1 Axis moves and 2 Axis moves 1 Axis moves When two consecutive moves are programmed the second move will begin execution within 2 milliseconds after the first move finishes 2 Axis moves A 2 Axis move is programmed with two consecutive blocks one for each axis The first of the two blocks must contain the BLOCK SYNC command When the BLOCK SYNC command is executed the two moves will be started together within 2 milliseconds Note that only the start of the moves is synchronized More information about multiaxis programming program block structure flow control JUMP and the BLOCK SYNC command is provided later in this chapter Motion Program Command Types The motion program commands are grouped into three categories Type 1 Commands Call Subroutine W Jump Type 2 Commands Block Block SYNC Load Parameter Null Acceleration Velocity Type 3 Commands Positioning Move Continuous Move Dwell Wait End of Program Type 1 commands can redirect the program path execution but do not directly affect positioning Call Subroutine executes a subroutine before returning execution t
217. eleration of the first CMOVE This value is held as the axis continues to accelerate until it s curves back to constant velocity Constant velocity the second dashed line indicates the beginning of the second CMOVE This move continues until it decelerates to zero at the end of the program ACCEL 50000 VELOC 30000 BLOCK 1 M JUMP CTLO2 2 CMOVE 150000 INC SCURVE BLOCK 2 VELOC 90000 ACCEL 25000 CMOVE 500000 INC CTLO2 ON C2 Begins SCURVE a45267a Figure 7 17 Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Other Programmed Motion Considerations Maximum Acceleration Time GFK 1464C The maximum time for a programmed acceleration or deceleration is 131 seconds If the time to accelerate or decelerate is computed to be longer than this time the DSM302 will compute an acceleration to be used based on 131 seconds To obtain longer acceleration times multiple CMOVEs with increasing or decreasing velocities must be used Example 15 Maximum Acceleration Time The following two program examples show a hypothetical problem with a very long acceleration time in Examplel and a possible solution in Example 2 In Example 1 below 240 seconds is required to reach the programmed velocity of 24 000 at an acceleration rate of 100 24000 100 240 Since this is greater than the DSM s limit of
218. ements for Conformance to Standards GFK 1179 DSM 302 Y 90 30 ao Faceplate Shield Ground Always Required HIGH CAPACITY POWER SUPPLY J UU Grounding Bar 44B295864 001 and Grounding Clamp A99L 0035 0001 Required for CE Mark Installation DSM302 to Axis Terminal Block Shielded Cable Axis al z Grounding Bar Termina 44B295864 001 Block Grounding Clamp 991 0035 0001 Always Required Strobe and Limit Switch Signals Terminal Block to Servo Amp Shielded Cable Ground Wire to S Terminal Always Required Figure 3 15 DSM302 I O Cable Grounding 3 22 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C I O Circuit Identifiers and Signal Names 1 O circuit identifiers provide a consistent method of naming the I O circuits For example IN1 refers to the first of three differential single ended 5v inputs for each axis Signal names are assigned to the circuit identifiers for each axis The signal name consists of the circuit identifier followed by a suffix A D to identify the axis connector Differential circuits also have suffixes P positive and M minus to identify the and signal for each differential pair Example OUT is the circuit identifier for the first differential 5v output
219. ences See Table 4 1 Module Configuration Data The Bit Offsets listed in the following table are offsets to this starting address All reference section designations pertain to this chapter Table 5 5 Q Discrete Commands Abort All Moves 3 04 O Abort All Moves 5 3 05 3 06 3 07 S S Reset Strobe 2 S S Uo Go Go c OUT1_B Output Control OUT3_B Output Control 10 22 4 Reserved Reserved pe Reserved Reserved Reserved 95 tw Go Go AR 3 07 Aux 3 A 95 oo Nn 3 09 Reserved 3 10 3 11 ES 3 Reserved Reserved 9 Reserved 3 12 30 Reserved 62 Reserved 31 Reserved 2 6 Reserved tw Go 92 Go wN 1464 Chapter 5 Motion Mate DSM302 to PLC Interface 5 11 5 12 3 01 3 02 3 03 3 04 3 05 3 06 Clear Error When an error condition is reported this command is used to clear the Module Error Present 1 status bit and the associated Module Status Code Servo Axis 1 Error Code Servo Axis 2 Error Code and Aux Axis 3 Error Code status words Error conditions that are still present such as an End of Travel limit switch error will not be cleared and must be cleared by some other corrective action If the Clear Error bit is maintained ON a Jog command can be used to
220. ental positioning move example PMOVE 5000 INC LINEAR In this example the axis will move from its current position to a position 5000 user units greater With an incremental move the first parameter specifies the actual number of user units the axis moves Types of Acceleration GFK 1464C Linear Acceleration A sample linear move profile that plots velocity versus time is shown in Figure 7 1 As illustrated a linear move uses constant linear acceleration The area under the graph represents the distance moved ACCEL 1000 V 245256 VELOC 2000 PMOVE 6000 INC LINEAR Figure 7 1 Sample Linear Motion S Curve Acceleration An S Curve motion sample plotting velocity versus time is shown below As illustrated S Curve acceleration is non linear When the move begins the acceleration starts slowly and builds until it reaches the programmed acceleration This should be the midpoint of the acceleration Then the acceleration begins decreasing until it is zero at which time the programmed velocity has been reached An S Curve move requires twice the time and distance to accelerate and decelerate that a comparable linear move needs The area under the graph represents the distance moved Chapter 7 Programmed Motion 7 5 ACCEL 2000 VELOC 2000 Y PMOVE 8000 INC SCURVE 2845257 Figure 7 2 Sample S Curve Motion Types of Programmed Move Commands Positioning Move PMOVE A PMOVE must always come to a complete stop The st
221. er 2002 GFK 1464C Section 3 I O Wiring and Connections I O Circuit Types Each of the module s four connectors Connector A B C and D provide the following types of I O circuits Three differential single ended 5v inputs IN1 IN3 5 VDC Encoder Power P5V One single ended 5v input IN4 Four single ended 5v input output circuits 105 108 Three 24v inputs IN9 IN11 One 24v 125 ma solid state relay output Two differential 5v line driver outputs OUT2 OUT3 One 24v 30 ma solid state relay output OUT4 Two differential 10v Analog Inputs AIN1 AIN2 One single ended 10v Analog Output AOUTI Not all of these I O circuits are available for user connections Some of the circuits are used to control the GE Fanuc digital servo amplifier Refer to Tables 3 11 through 3 14 for additional information Terminal Boards Axis Terminal Board Catalog No IC693ACC335 Used in Digital mode only It connects DSM connector A or B to a GE Fanuc or Digital Servo amplifier It also provides screw terminal connections for I O devices This terminal board contains two 36 pin connectors One connects to the DSM via cable IC693CBL324 325 and the other connects to the GE Fanuc Digital Servo amplifier via the servo command cables IC800CBL001 002 See Figures 3 10 3 16 3 17 and 3 18 Note For Digital Servo applications that do not require use of the DSM s A or B connector I O signals the DSM connector can be cab
222. er tables for each of the FANUC motors supported A particular motor for the indicated axis is selected in the Logicmaster 90 30 configuration fields Motor Type or Motor2 A motor type of 0 for a particular axis disables digital servo control by the DSM302 for the digital servo axis Motor type must be set to zero when digital servo is attached if any Q bit commands or AQ data commands will be sent to the axis Supported FANUC Motor types are listed in the tables below The Motor Type must be 0 for ANALOG Mode or if no motor is attached to the axis Default 0 FANUC Motor part numbers are used to determine the proper FANUC Motor type code and are in the form A06B xxxx yyyy where xxxx represents the motor specification field For example When reading a motor number from a motor label of 06 0032 078 the motor specification digits 0032 indicate the motor model of 82 3000 The Series table references the Motor Type Code 36 needed for the configuration field Supported FANUC Motor types are listed in the tables below The list of supported motors may be expanded in future releases Series FANUC Servo Motor Motor Type Code Motor Model Motor Specification 1 3000 2 2000 2 3000 3 3000 6 2000 o 6 3000 12 2000 12 3000 0 22 1500 0 22 2000 0 22 3000 30 1200 30 2000 30 3000 40 2000 40 FAN Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1
223. er with four 36 pin I O connectors labeled A B C and D The connectors are assigned as follows Table 3 2 Axis I O Connector Assignments Axis Connector Number Axis Type I O Usage Closed Loop Digital or Analog Servo Control 2 Servo Axis Closed Loop Digital or Analog Servo Control Position Feedback and auxiliary analog digital I O D 4 Au Axis Auxiliary analog digital Both the A and B connectors provide the same analog and digital I O circuits Connectors A and B are both used for either analog or digital servo control Note that if the DSM302 is used to GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 3 control two axes they both must be analog or they both must be digital they cannot be one of each The module s C and D connectors are used for auxiliary functions such as Follower Master axis position feedback and additional analog digital I O Any of these four connectors used in a system typically is cabled to an appropriate Terminal Board with cable IC693CBL324 1 meter or IC693CBL325 3 meters There are three different types of terminal boards that provide screw terminals for connecting to external devices described later in the Terminal Board section of this chapter Shield Ground Connection 3 4 The DSM302 faceplate shield must be connected to frame ground This connection from the DSM302 to frame ground can be made using the green ground wire part number 444735970 001
224. eration Mode is used to change velocity to the new velocity All future move velocities will be affected by the feedrate change Note that when a feedrate of 0 is applied no motion will be generated until a new feedrate is commanded Also note the Moving I bit stays ON when the feedrate 15 0 Rate Override has no effect on non programmed motion such as Jog Find Home or Move at Velocity GFK 1464C Chapter 7 Programmed Motion 7 23 Example 17 Feedrate Override During execution of this program feedrate changes of or 10 are commanded Dotted lines indicate 10 dashed lines indicate 10 ACCEL 1000 V 2452702 VELOC 6000 PMOVE 110000 INC LINEAR 10 10 10 t 10 10 Figure 7 20 Feedrate Override Example Multiaxis Programming Sync Blocks can be used in a multiaxis program to synchronize the axis motion commands at positions where timing is critical Example 18 Multiaxis Programming This example assumes that axis 1 controls vertical motion and axis 2 controls horizontal motion The objective is to move a piece of material from point A to point E as quickly as possible while avoiding the obstacle that prevents a direct move between those points A simple way would be to move straight up from point A to point C and then from point C to point E This sequence however wastes time A better way would begin the horizontal movement before reaching point C It has been determined that after axis 1 has moved to a positi
225. erenced to Ov of the DSM module and PLC This signal should be connected to the differential velocity command input of the servo amplifier 2 The DSM302 provides a low current 30 ma solid state relay output on pin 15 of theAuxiliary Terminal Board for connection to a servo amplifier enable input 3 In analog mode the DSM302 requires a Servo Ready input IN 4 on wiring diagrams on pin 5 of the Auxiliary Terminal Board This signal must be switched to 0v when the amplifier is ready to control the servo If the servo amplifier does not provide a suitable output the IN 4 input to the DSM302 must be connected to Ov 4 Quadrature encoder feedback in used in analog mode Encoder wiring connections are detailed in figures 3 19 and 3 20 5 Figures 3 19 and 3 20 are generic analog wiring diagrams for the DSM 6 For details about the GE Fanuc SL Servo products refer to the manual SL Series Servo User s Manual GFK 1581 GFK 1464C Chapter 2 Getting Started 2 19 Grounding the Motion Mate DSM302 Motion System The DSM302 System must be properly grounded Many problems occur simply because this practice is not followed To properly ground your Motion Mate DSM302 system you should follow these guidelines The grounding resistance of the system ground should be 100 ohms or less class 3 grounding The DSM302 faceplate shield ground wire shipped with the module must be connected from the inch blade terminal at the bottom of the module
226. ervo Axis Aux Axis 4 Signal Name Faceplate Auxiliary Servo Identifier 1 2 Circuit Function 1 2 and Aux Axis 3 Circuit Function Axis 1 listed Pin Terminal Terminal Circuit Function Board Board AOUTI Analog Servo Faceplate Analog Out Faceplate Analog AOUT_A Velocity Command t Ou ACOM Analog Out Com Analog Out Com Analog Out Com ACOM A MN GFK 1464C I O Type Circuit Type Load Impedance Single Ended Analog Output Op Amp Voltage Follower Output 2K ohms minimum Output Current 5 ma max Resolution 13 bits Linearity 13 bits Output Offset Voltage 500 uv max Force D A Gain Factor 10 0v 32000 counts Gain Accuracy Force Analog Output Update Rate Notes 1 0 1 PLC sweep rate when used by Force Analog Output command 2 250 microseconds when used as Digital Servo tuning output Since this is a single ended output it should normally drive a user device with a differential input to prevent common mode noise problems The positive differential input should be connected to AOUT and the negative differential input to ACOM The Select Analog Output Mode AQ command can be used to select the source for the analog output Refer to Chapter 5 for more information OP AMP AOUT ACOM PTC DEVICE ov Chapter 3 Installing and Wiring the DSM302 3 45 5v Power Circuit Servo Axis 1 2 Aux Axis 3 Aux Axis 4 Signal Name Faceplate Auxilia
227. ervos Digital Mode The GE Fanuc Digital B pronounced Beta Series Servo features include m World leading reliability m Low maintenance no component drift no commutator brushes m All parameters digitally set no retuning required m Absolute encoder eliminates rehoming m Optional brake m High resolution 32K count per revolution encoder The GE Fanuc f Series Servos offer the highest reliability and performance The latest technologies such as high speed serial encoders and high efficiency Integrated Power Modules further enhance the performance of the servo system Designed with the motion control market in mind the B Series Servo Drives is ideally suited for the packaging material handling converting and metal fabrication industries The GE Fanuc servo system is unique in that all the control loops current velocity and position are closed in the motion controller This approach reduces setup time and delivers significant throughput advantages even in the most challenging applications The servo drives are less costly to integrate and maintain Control circuits are unaffected by temperature changes There are no personality modules The servos have a broad application range including a wide load inertia range flexible acceleration deceleration and position feedback configurations Extensive software customization features are available to optimize performance and overcome machine limitations Series Digital Amplifiers
228. f 1 32 require Logicmaster 9 01 or later Also Version 1 0 of the GE Fanuc VersaPro graphical PLC programming software supports the DSM302 Rack Slot Configuration Logicmaster 90 30 is used to define the type and location of all modules present in the PLC racks This is done by first completing setup screens that represent the modules in a baseplate then saving the information to a configuration file which is then downloaded to the PLC CPU Refer to Chapter 2 Section 4 for the details of selecting a DSM302 baseplate and slot location in the PLC rack After the Rack Slot Configuration is defined proceed to the second part of the configuration process Module Configuration where you will configure the DSM302 for your specific application requirements GFK 1464C 4 1 4 2 Module Configuration Setting the Configuration Parameters As with I O Rack Configuration module configuration is done by completing screens in the Logicmaster 90 30 configuration software DSM302 configuration data consists of four types W Module Configuration Data W Serial Communications Programmer Port Configuration Data W Axis Configuration Data W Program Zero For additional details concerning the operation of DSM302 Configuration or Programming software packages please consult the appropriate User Manuals for those particular software products See Related Publications in the Preface of this Manual Module Configuration Data During each C
229. ference for Servo Axis 2 may be encoder 3 internal master or the analog input Default ENC3 INT Vlim Master Velocity Limit counts ms The maximum positive master velocity command in counts per millisecond allowed for the master axis input to the follower If the master velocity command exceeds the Vlim value the master velocity command will be clamped at the active Vlim value an error F2h will be reported and the Follower Velocity Limit I Status Bit will be set The Master Velocity Limit value is used for an additional function if Follower Ramp Acceleration Control is active The Follower Ramp Acceleration Control function has the capability to create a unique motion profile automatically that will be combined with the master command velocity The calculated velocity used for this automatic profile generation will not exceed 8096 of the Master Velocity Limit The 80 limitation allows the remaining 20 of the Vlim value to be used to respond to changes in the master source velocity See the description for Follower Make Up Time and Chapter 8 Follower Motion for more information Superimposed motion programmed motion executed while the follower is active i e Move Immediate Jog executing a motion program is not affected by the Vlim value It is possible when using superimposed moves with the follower axis enabled to exceed the velocity limit imposed on the follower motion The Vlim status errors are returned only if the master comman
230. for safety and to suppress external and internal noises In a frame ground system the frames cases of the units panels and shields for the interface cables between the units are connected This completes the steps required to assemble the Motion Mate DSM302 system You will have more work to do when interfacing to your machine but for now you can move on to the next step Turning on the Motion Mate DSM302 System GFK 1464C Chapter 2 Getting Started 2 21 2 22 Section 3 Turning on the Motion Mate DSM302 Before turning on the power you should Confirm that the supplied cables are properly attached to the appropriate connectors Confirm that all wiring to the power sources is correct Make sure that the motors are properly secured Check that all components are properly grounded including the DSM302 faceplate shield If you are using more than one motor confirm that the servo amplifier connections and the feedback cables are not crossed between motors There is a specific sequence for turning on power to the DSM302 Control System In the order listed perform these steps I Turn on the 220V AC power to the Digital servos Verify that the charged LED indicator on the amplifier 1s on For B Series Digital amplifiers turn on the 24V DC source Verify that the amplifier Power indicator is on Switch on the power to the Series 90 30 PLC and check that the PWR LED on the Series 90 3
231. form jump testing If the CTL bit is ON the jump is immediately performed If the CTL bit is OFF the DSM302 watches the CTL bit and keeps track of the JUMP destination This monitoring of the CTL bit is called jump testing If during jump testing the CTL bit turns ON before a BLOCK command another JUMP command or a CALL command is encountered the jump is performed These commands will end jump testing Example 7 Jump Testing Consider the following two program section examples In Example 1 the move to position 2000 is completed before jump testing begins The BLOCK command occurring immediately after the JUMP command ends jump testing Thus the duration for which the CTL bit is monitored is very short However in Example 2 the JUMP command is encountered before the move command This starts the jump testing before motion begins and jump testing continues as long as the move lasts If the CTL bit turns ON while the move is being performed the jump will be performed After the move completes the BLOCK command ends jump testing and program execution Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C continues normally Jump testing would continue during subsequent moves encountered before the BLOCK command Example 1 Example 2 ACCEL 5000 ACCEL 5000 VELOC 1000 VELOC 1000 BLOCK 1 BLOCK 1 CMOVE 2000 ABS LINEAR JUMP CTLO1 3 JUMP CTLO1 3 CMOVE 2000 ABS LINEAR BLOCK 2 BLOCK 2 Normal Stop Before JU
232. fy your motion system connections and functionality To identify supporting documentation providing detailed information on this subject This chapter serves as an introduction for the new user to the Motion Mate DSM302 motion system Following through the steps outlined here you should be able to operate or Jog your motion controller and servo in a short time A minimum level of familiarity with the Logicmaster 90 Series 90 30 software is assumed You should have progressed through Appendix A Configuration Lesson and Appendix B Programming Lesson in the Logicmaster 90 Series 90 30 20 Micro Programming Software User s Manual GFK 0466 Do not couple the motor shaft to mechanical devices for this exercise Additionally it is important that the servomotor be fastened securely to a stationary surface A typical DSM302 motion system includes the DSM302 motion controller a Series 90 30 Programmable Logic Controller PLC motor s servo amplifier s I O and the Human Machine Interface HMI The DSM302 control system consists of two parts the servo control and the machine control The servo control translates motion commands into signals that are sent to the servo amplifier The servo amplifier receives the control signals from the servo control and amplifies them to the required power level of the motor The DSM302 provides the servo control The machine control Series 90 30 PLC houses the DSM302 module and I O modules an
233. g Q bit to clear the associated Position Strobe n 1 bit Strobe 1 2 Position will be maintained and will not be overwritten by additional Strobe Inputs until the Position Strobe 1 2 1 bit has been cleared If the Reset Strobe Flag Q bit is left in the ON state thus holding Position Strobe 1 2 input flags in the cleared state then each Strobe Input that occurs will cause the axis position to be captured in Strobe 1 2 Position Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 2 07 2 08 2 09 2 10 2 11 2 12 The Strobe 1 2 Position actual position values are also placed in data parameter registers for use with motion programs commands The data parameter register assignments are as follows Servo Axis 1 Servo Axis 2 Aux Axis 3 Strobe 1 Position Strobe 2 Position This feature allows the strobe input to trigger a Conditional JUMP in a program block using the Strobe 1 Position or Strobe 2 Position as the destination of a CMOVE or PMOVE command See Chapter 1 Product Overview DSM302 Position Strobes for information on strobe latency and processing times Position Error Position Error user units is the difference between Commanded Position and Actual Position In the servo control loop Position Error 1s multiplied by a gain constant to provide the servo velocity command Commanded Velocity Commanded Velocity user units sec is a value generated by t
234. g distance is computed using the present commanded velocity and the acceleration parameters that would be in effect when the jump block became active The axis will STOP before jumping if a Conditional Jump trigger occurs under any of the following conditions E When a PMOVE is active When a CMOVE is active and the Jump destination block contains a CMOVE or PMOVE representing motion in the opposite direction When a CMOVE is active and the Jump destination block contains a CMOVE or PMOVE representing motion in the same direction with insufficient distance for the axis to stop When a CMOVE is active and the Jump destination block contains a DWELL WAIT or END program command If the axis does STOP before a Conditional Jump the Jog Acceleration and Jog Acceleration Mode will be used Unconditional Jumps do not force the axis to stop before jumping to a new program block For example a CMOVE followed by a JUMP Unconditional to another CMOVE will behave just as if the two CMOVEs occurred without an intervening Unconditional JUMP If Conditional Jump testing is active when the DSM302 command processor encounters a CALL SUBROUTINE command the axis will stop and terminate jump testing before the CALL is executed If Conditional Jump testing is active when the DSM302 command processor encounters an END SUBROUTINE command the axis will stop and terminate jump testing before the END SUBROUTINE is executed Conditional jumps per
235. gram Commands Command Definition Logicmaster Range Logicmaster Name Default NULL Donothins 000000 CMOVE AL P Continuous move Absolute Linear Use 1 255 1 data in Parameter CMOVE AS Continuous move Absolute S curve 8 388 608 8 388 607 CMOVE AS P Continuous move Absolute S curve Use 1 255 1 data in Parameter CMOVE IL Continuous move Incremental Linear 8 388 608 8 388 607 CMOVE IL P Continuous move Incremental Linear 1 255 1 Use data in Parameter CMOVE IS Continuous move Incremental S curve 8 388 608 8 388 607 CMOVE IS P Continuous move Incremental S curve 1 255 1 Use data in Parameter PMOVE AL Positioning move Absolute Linear 8 388 608 8 388 607 PMOVE AL P Positioning move Absolute Linear Use 1 255 1 data in Parameter PMOVE AS Positioning move Absolute S curve 8 388 608 8 388 607 PMOVE AS P Positioning move Absolute S curve 1 255 1 Use data in Parameter PMOVE IL Positioning move Incremental Linear 8 388 608 8 388 607 PMOVE IL P Positioning move Incremental Linear Use 1 255 1 data in Parameter PMOVE IS Positioning move Incremental S curve 8 388 608 8 388 607 Use data in Parameter WAIT Wait for CTL XX bit to go high before moving LOAD P01 Load DSM302 Parameter register number LOAD P20 the Parameter Continue program execution at given block JUMP CTLO1 When the given CTL bit goes high during J the current block execution
236. he DSM302 axis command generator Commanded Velocity indicates the instantaneous velocity command that is producing axis motion At the beginning of a move it will increase at the acceleration rate and once the programmed velocity has been reached it will stabilize at the programmed velocity value In Follower mode Commanded Velocity only represents the output of the axis command generator The Follower Master Axis input or the Follower Acceleration Ramp controller does not affect Commanded Velocity Actual Velocity Actual Velocity user units sec represents the axis velocity derived from the Feedback device and is updated by the DSM302 once every 250 milliseconds User Selected Data The information reported in User Selected Data is determined by the Select Return Data command Refer to Section 4 AQ Immediate Commands for additional information User Selected Data has these defaults Servo Axis 1 Data Servo Axis 1 Commanded Torque always 0 in Analog mode Servo Axis 2 Data Servo Axis 2 Commanded Torque always 0 in Analog mode User Selected Analog Input This AI word reports a single analog input value that could be selected from one of the eight analog inputs available in the DSM302 The input data is scaled so that 32000 10 00v The default input is Analog Input 1 of Aux Axis 3 The ability to select any other analog input is not currently available Connector A D Analog Inputs 1 2 When the
237. he APM Motion Programmer Status Screen with the DS5M302 E 1 Standard Mode Status Screen E 2 Follower Mode Status Screen ececcesceseceseeseeeceseeseeseceaecaeeenecaaeeeeesecaesaeeeeceaecaeeeneeaeenaees E 3 Updating Firmware in the 05 302 To Install the New Firmware Perform the Following Steps sese F 1 Restarting an Interrupted Firmware Upgrade sese F2 Answers to Frequently Asked 8 0 4 G L and B Series Motors and Amplifiers sssssessseseseeeeeneeennnenn G 1 Motion Mate Controls dto te en Tp HD INCURRERE G 7 DSM302 Revision HISEOEV rre rator ou one oete 1 Firmware Release 1 40 ccccccsccssossssscccccsscsccnsescocccesscsccnsescccccesccnconscenecscccoonsee H I Features Introduced in Firmware Release 1 40 H 1 DSM Analog Mode onion eene e ei ee dee e H 1 Enhanced Follower Accuracy ene H 1 Problems Resolved by Firmware Release 1 40 sse H 1 EN3 EN4 LEDs Flash when Performing Slow Jog Function H 1 Firmware Release 1 30 eee tnter eerte Eee e fede eis tisk o reir H 2 Features Introduced in Firmware Release 1 30 sss H 2 Enhanced and 94I Processing esses H 2 Enhanced Followe
238. he STAT and CFG LEDs both flash together at a constant rate the DSM302 module is in boot mode waiting for a new firmware download If the STAT and CFG LEDs both flash alternately at a constant rate the DSM302 firmware has detected a software watchdog timeout due to a hardware or software malfunction Irregular Rate CFG LED OFF If this occurs immediately at power up then a hardware or software malfunction has been detected The module will blink the STAT LED to display two error numbers separated by a brief delay The numbers are determined by counting the blinks in both sequences Record the numbers and contact GE Fanuc for information on correcting the problem The OK LED indicates the current status of the DSM302 module When the LED is steady ON the DSM302 is functioning properly Normally this LED should always be ON When the LED is OFF the DSM302 is not functioning This is the result of a hardware or software malfunction which will not allow the module to power up This LED is ON when a valid module configuration has been received from the PLC Flashes s ow four times second during the Motion Program Store function Flashes fast eight times second during the Write User RAM to EEPROM operation When this LED is ON the servo drive for Servo Axis is enabled When this LED is ON the servo drive for Servo Axis 2 is enabled When this LED is ON the Force Analog Output command for Aux Axis 3 is active When this LED i
239. he e Ere eee EE ENT Ud 2 3 Unpacking the Digital Servo Amplifier 2 3 Unpacking FANUC Motor sess enne 2 3 Section 2 Assembling the Motion Mate DSM302 2 5 Motion Mate D8M302 Connections 2 eere nennen 2 5 Connecting the Series SVU Digital Servo Amplifier 2 6 SVU Amplifier Channel Switches esee 2 7 Connecting the D Series SVU Digital Servo Amplifier sse 2 13 Contents vi Chapter 3 Installing and Wiring the DSM302 for Analog Mode esses 2 2 Grounding the Motion Mate DSM302 Motion System sse 2 22 Section 3 Turning on the Motion Mate DSM302 2 24 Section 4 Configuring the Motion Mate 08 302 40 2 2 2 25 Using Logicmaster 90 LM90 Program Folders sene 2 25 Module Configuration Data isses 2 26 Motor Type Digital Mode 2 28 Store the Configuration to the PLC sess nnne 2 32 Section 5 Testing Your Systeii ccssssosesssscssssvsssseessssonssstevesecunssdevanstevnceticese 2 33 Generating Motion s s Te err EE hee 2 33 Enabling Run Mode on the PLC 4 02002411 05000000000000000000000000000000000003 2 33 Jogging With the Motion Mate 302 2 34 Section 6 Trouble
240. he makeup time Mkup Time is a long enough interval so that the resultant velocity remains less than 80 of the Vlim This is the preferred operation no errors are reported and the over speed move of the ramp function occurs within the specified makeup time The follower axis velocity will not exceed 80 of the Vlim unless the master source velocity increases 6 10 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Case 2 The master source velocity is below 80 of the configured Vlim but the makeup time interval is too short to allow operation as in case 1 A status only error ECh will be returned when the follower velocity matches the master command velocity The makeup move will accelerate using the active Jog acceleration to 80 of the velocity limit Vlim The makeup move will occur and all accumulated counts stored during initial acceleration will be used The makeup move will be a multiple of 8msec longer in duration than the active makeup time Case 3 The master source velocity is greater than 80 of the configured velocity limit Vlim when the follower velocity matches the master command velocity A status only error EAh is returned and no makeup correction move is attempted Case 4 At the time when the follower velocity matches the master command velocity and the makeup move is to occur and conditions are the same as in Case or Case 2 and the makeup move has initiated the master source incr
241. inal board assembly and shows a side view of the board configured for DIN rail mounting Table 3 5 Axis Terminal Board Assembly Components Plastic Component Mounting Styles Part Number Description Quantity Used With UMK BE 45 DIN Panel UMK SE 11 25 1 Side Element DIN Panel UMK FE UMK BF Parts shipped with axis terminal board for optional panel mounting 1 3 03 77 0 77 45 0 0 31 REF 9 cu UMK BE 45 1 UMK BF ag 1 02 25 9 d Swed B Figure 3 5 Digital Servo Axis Terminal Board Assembly Drawings 0 72 18 3 3 12 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Figure 3 6 Digital Servo Axis Terminal Board Assembly Side View The following procedure should be used to convert the Digital Servo axis terminal board to its panel mounting form Remember to save all removed parts for possible later conversion back to DIN rail mounting 1 Carefully remove one UMK SE 11 25 1 side element from the UMK BE 45 base element Ifa screwdriver or other device is used exercise extreme caution to avoid damaging either the plastic parts or the circuit board 2 Slide the UMK FE foot element off the base element Save this part for possible future use in converting the terminal board back to its DIN rail mounting configuration 3 Snap the side element removed in step 1 above back into the base element 4
242. ind Home cycle was in progress For 1 halt the Move at Velocity operation Moving I bit off prior to executing the Find Home command For 2 verify that axis is In Zone and not Moving before executing a Find Home command ta tal tal tal Find Home While Follower Enabled Axis ta is tal tal tal 1S Find Home while Abort bit set error AX S S Move at Velocity Errors Move at Velocity while Drive Not Enabled error S 5 Move at Velocity while Program Selected error Move at Velocity while Home Cycle active error Status Only Move at Velocity while Jog error b eps Status Only Move at Velocity while Abort All Moves bit is set error 20 21 22 23 24 25 26 27 28 29 2C 30 31 32 33 34 35 36 39 3A 3B 3D Axis Axis Axis Axis Axis Appendix A Error Reporting A 3 Table A 1 Continued DSM302 Error Codes Error Number Response Description Error Type Hexadecimal Jog Errors tus Only Axis tus Only Axis Status Only Axis Force Digital Servo Velocity Errors Only Axis Only Axis igi is Axis ES n ES 43 47 tus Only Force Digital Servo Velocity while Program Selected error AX tus Only Force Digital Servo Velocity while Follower Enabled error Set Position Errors 2 a lg ls s oa lo n tus Only Set Position while Program Selected error ul n 4 tus Only Set Position Data overrange e
243. ing one of the software packages described below but a single short program Program Zero can be created within the Logicmaster 90 30 configuration software Refer to Chapter 4 Configuring the DSM302 for more information on Program 0 Note The DSM302 has a configurable serial port to communicate with the Motion Programmer A special serial cable IC693CBL316 is required to connect the DSM302 module to a PC for use with any of the supported motion programming software packages APM Motion Programming Software MS DOS The APM Motion Programmer operates much like the Logicmaster software package It provides the capability of writing English language motion programs storing the programs on disks and downloading the programs to the DSM302 as desired A Status Screen supports servo system monitoring For detailed information on the Motion Programmer refer to GFK 0664 Series 90 PLC Axis Positioning Module APM Programmer s Manual Note The APM Motion Programmer software was originally developed to program the APM300 products Even though the APM Motion Programmer documentation does not reference the DSM302 it can still be used to program the DSM302 Version 1 51 or higher should be used to avoid problems with installations to large hard disks It must be installed in a DOS environment Refer to Appendix E Using the APM Motion Programmer With The DSM302 for specifics on using the APM Motion Programmer software to program and mo
244. ing to decelerate See the s curve jump examples for more details The Jog Acceleration is used because a jump stop may indicate something is wrong The current Jog Acceleration which can be changed with an immediate command provides more versatility than the programmed acceleration There are two ways of generating a jump stop each described below A conditional JUMP triggered during a PMOVE will always generate a jump stop Because a PMOVE always stops before continuing to a subsequent motion a jump stop always occurs when a jump takes place during a PMOVE When a conditional jump trigger occurs during a CMOVE however a jump stop will not occur if the motion programmed at the jump destination is a PMOVE or CMOVE representing sufficient distance in the same direction A jump stop will occur if the PMOVE or CMOVE at the jump destination does not represent sufficient distance or represents motion in the opposite direction In an s curve move a jump stop will do one of two things If the jump takes place after the midpoint of the acceleration or deceleration the acceleration or deceleration is completed before the jump stop is initiated If the jump occurs before the midpoint of the acceleration or Motion Mate M DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C deceleration the profile will immediately begin leveling off Once acceleration or deceleration is zero the jump stop begins See the s curve jump e
245. ins the same as with the non HRV motion control The HRV function is standard on all PowerMotion controllers What percentage of the move profile can you spend in the intermittent range of the speed vs torque curve The overload duty characteristic curves are determined based on the motor design temperature restrictions for the heat loss and thermal efficiency of a single motor unit such as protection based on a thermal protector The curves are determined by assuming that the motor temperature increases gradually under certain overload conditions and must dissipate waste heat to the ambient temperature Therefore the normal speed torque curves do not apply to the rapid temperature rise occurring for example when a servo accelerates and decelerates frequently However these duty cycle calculations have limited value in most servo applications Typically a RMS torque calculation is required to properly determine if a motor can handle the application requirements A thermal software function is provided to prevent an abrupt temperature rise in the motor by monitoring for abnormal current in the motor This function may put a thermal limit to the operation of the motor when it is frequently accelerated and decelerated Driving units such as amplifiers contain their own overheating protection devices Therefore note that control may be imposed according to how the equipment is being used The overload duty curves for the Series servos can be fo
246. ion and velocity control 1s by default a single interpolated axis e Motion synchronized to external events such as registration input These external events may trigger a change in speed the start or end of a move or a position correction e Coordinated multi axis control involves the synchronization of multiple axes Examples of these types of moves would be interpolation and master slave Multi axes interpolation is the trajectory of motion between one point and another using a group of points existing along a specified path straight line or arc In multi axes interpolated moves all axes will start and stop at the same time and the velocity vector along the path is controlled Different types of multi axes interpolation include linear circular and polar e Following motion involves non program motion of one axis as a linear function of the measured motion master source Master sources are typically a quadrature encoder or another axis of motion e Complex move profiles such as electronic camming where motion is performed electronically instead of using mechanical components Camming is similar to following except the gearing ratio between the master and slave varies non linear GFK 1464C Appendix G Answers to Frequently Asked Questions G 7 G 8 What is the servo update rate of the Motion Mate DSM302 control When controlling a GE Fanuc digital AC servo the DSM302 uses these loop update times Motor Current Torque Loop 250 microse
247. ion software There are two ways to provide acceleration control when following a master source External means such as ramping the velocity of the master input can be used to limit acceleration 2 Select Follower Mode RAMP in the configuration software to make the Follower axis ramp up at the Jog Acceleration rate Master Sources A DSM302 Servo Axis can follow one of several master input sources The external Aux Axis 3 encoder input The internal master velocity generator The Aux Axis 3 analog input 1 Servo Axis 1 can select the Servo Axis 2 encoder to be its master input source GFK 1464C 8 1 If ENC3 INT is selected in the configuration software for an axis the Select Internal Master Q bit is used to choose between the external Aux Axis 3 encoder input and the internal master generator Note that follower motion is summed with Jog Move at Velocity or Motion Programs If an axis is following the internal master at velocity V1 and a Jog is commanded at velocity V2 the axis will move at velocity V1 V2 Aux Axis 3 ENC 3 Master Input 6 2 When ENC3 INT is configured as the Master Source and the Select Internal Master Q bit 15 OFF the Aux Axis 3 encoder will be the master input source The DSM302 always tracks and reports the position of the encoder in Actual Position Aux Axis 3 AI data The DSM302 also computes and reports the encoder velocity in Actual Velocity Aux Axis 3 data The Aux A
248. is 4 Inputs are reported to the PLC but are not available for Wait Jump Control or Follower Enable Trigger Table 5 2 Faceplate Input l Status Bits Faceplate Digital Wait Follower Bit Signal Input Connector Servo Jump Enable Name Name Signal Use Type Pin TB Pin Control Trigger el Erud Er c i i e iie CTLIS IN9 C AuxAxis3Spare24vinpt 24v Ci6 6 No Ye o o p 5 rp aux Anise Spare ps NO We Tf the Digital Servo Terminal Board IC693ACC335 is used for DSM Connector C or D the IN5 signal is not available If the Auxiliary Terminal Board IC693ACC336 is used the terminal numbers are the same as the DSM faceplate connector pin numbers Axis Enabled The Axis Enabled status bit is ON when the DSM302 is ready to receive commands and control a servo An error condition that stops the servo will turn Axis Enabled OFF When Axis Enabled is OFF no commands other than the Clear Error Q bit will be accepted by the axis Position Valid The Position Valid status bit indicates that a Set Position command or successful completion of a Find Home cycle has initialized the home reference value in the Actual Position AI status word Position Valid must be ON in order to execute a motion program If the DSM302 is configured to use an absolute feedback digital encoder GE Fanuc o or Series servo with optional encoder bat
249. it should be ODD or EVEN Stop Bits All serial communications devices use at least one 1 stop bit For slower devices set this parameter to two 2 stop bits Data Bits Specifies whether seven 7 or eight 8 data bits are to be used to represent a single piece of data Typically seven data bits are used for ASCII only data and eight where binary data Is to be transmitted Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Modem TT When utilizing a modem a Modem Turnaround Time must be specified This is the time required for the modem to start data transmission after receiving the transmit request If no modem is used 0 should be specified If a modem is used a value greater than 0 must be specified Idle Time Specifies the time in seconds that the DSM302 will wait for a new message to be received from the master device for example Motion Programmer or HMI before assuming that communications have been lost or terminated In such a case the DSM302 will reinitialize to wait for the start of anew SNP connection sequence SNP ID An identifier consisting of from 0 to 6 characters consisting of A F and 0 9 The first character specified must be in the set A F An SNP ID need not be specified if the programmer is directly connected to a single module The identifier must be utilized for a multi drop network The DSM302 will support multi drop connections only if the RS232 connection is converted t
250. it Command provides a method of limiting the torque produced by the GE Fanuc servomotor The DSM302 will set the torque limit TRLMT at the default 100 whenever a power cycle or reset occurs The PLC application logic must set any other value for desired TRLMT The valid range for TRLMT is 0 to 100 of peak torque at commanded velocity in units of 1 TRLMT can be changed during axis motion and takes effect immediately Refer to the appropriate servo motor manual for the motor torque curve to determine the actual value of torque output available at a given velocity A simple example would be the use of Torque Limit to prevent over tightening on a machine Internal Master Velocity Counts sec This command loads the FOLLOWER mode Internal Master velocity generator that may be used as an alternate source for the follower Master input The Mstr Source axis configuration must be set to ENC3 INT and the Select Follower Int Master Q bit must be set ON to make use of the Internal Master velocity generator The maximum allowed velocity is 1 000 000 counts sec There is only one Internal Master velocity generator for use by all axes Set Aux Axis 3 Position Counts This command sets the actual position value for the encoder on Aux Axis 3 without using a Find Home operation The Position Valid 1 bit for Aux Axis 3 will be set when the command is received Force Digital Servo Velocity RPM Digital Mode only This command bypasses the position l
251. it is ON the internal master will be used as the master input source The velocity generated is initially zeroed The nternal Master Velocity AQ command can be used to set the generated velocity There is no acceleration control of the internal velocity generator One method of preventing the instantaneous acceleration attempt when Enable Follower is turned ON is to incrementally step up the internal velocity using the Internal Master Velocity command Example 2 Following the Internal Master When following the internal master the following axis simply moves at the current internal velocity In this example dotted lines indicate the times when a master velocity change takes place using the nternal Master Velocity AQ command The DSM302 is configured with Master Source ENC3 INT and the Select Internal Master Q bit is ON The A B ratio is 1 1 The velocities commanded are the following initially 0 then 11 thousand 15 thousand 4 thousand 7 thousand and finally 0 again The velocity of the following axis is identical to the internal master velocity Vel x 1000 245328 time Figure 8 2 Following the Internal Master GFK 1464C Chapter 8 Follower Motion 6 3 8 4 Analog Input Master When ANALOG is configured as the Master Source the faceplate Aux Axis 3 Analog Input 1 is the master input source The DSM302 converts the Analog Input into a velocity command The Analog Maximum Velocity configuration parameter sets
252. ition was not registered correctly in firmware version 1 00 when the encoder marker pulse was sensed This was corrected in firmware version 1 10 Note that this problem only pertained to Follower mode operation Module Sometimes Halted Responding to COMMREQ Commands When the DSM module was receiving a high rate of COMMREQ commands from the PLC CPU and was simultaneously executing a series of short move commands the module would sometimes halt execution and flash a 6 count 7 count error code on its STAT LED see Appendix B of GFK 1464 DSM302 for IC693 PLCs User s Manual for details This timing problem was corrected in firmware version 1 10 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Index Jog Minus 15 13 vA Jog Plus 15 13 0 Reset Strobe Lp ngs 5 13 Master 5 14 AI Status Words 9 So mare Actual Position 5 8 E Actual Velocity 5 9 5 Volt Output Axis L DFollower Master Error Code 5 8 5 Commanded Position Commanded Velocit Module Status Code User Selected Analog Input 5 9 A User Selected Data 5 9 ASB Rati AQ Immediate Commands B Ratio 6 Force D A Output 5 20 5 24 6 6 Absolute Encoder In Position Zone 5 20 First Time Use C 1 Jog Acceleration 5 22 Use After Loss of Encoder Battery Power C 1 Command Block Number 5 Volt Output Q Output Bit Strobe 1 2 Position Follower Ramp Distance Make up Time 5 25 Abort All Moves Q Discrete Command
253. its to Counts ratio the ratio 1s fixed at 1 1 in Follower mode In addition a Master Axis position input can be enabled Each Follower axis tracks the Master Axis input at a programmable A B ratio Motion caused by Jog Move at Velocity and Execute Motion Program commands can be combined with follower motion generated by the master axis Follower options include e Selection of internal or external Master Axis sources e Acceleration Ramp to smoothly accelerate a slave axis until its position and velocity lock to the slave master A B ratio e Winder mode traverse or spool winder for coil winding and material handling applications 1 8 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Standard Mode Operation Figure 1 2 is a simplified diagram of the Standard mode Position Loop An internal motion Command Generator provides Commanded Position and Commanded Velocity to the Position Loop The Position Loop subtracts Actual Position Position Feedback from Commanded Position to produce a Position Error The Position Error value is multiplied by a Position Loop Gain constant to produce the Servo Velocity Command To reduce Position Error while the servo is moving Commanded Velocity from the Command Generator is summed as a Velocity Feedforward term into the Servo Velocity Command output The following items discussed above are included in the data reported by the DSM302 to the PLC Commanded Velocity
254. l automatically switch to a high impedance state until the load 1s removed The load should not be re applied for 60 seconds This is a dc output and it will appear to be always ON if connections to it are reversed SOLID STATE RELAY OUT y x OUT 3 42 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Optically Isolated Enable Relay Output Circuit Servo Axis 1 2 Aux Axis 3 Aux Axis 4 Signal Name Faceplate Auxiliary Servo Identifier Circuit Function Circuit Function Circuit Function Axis 1 listed Pin Terminal Terminal Board Board ENBL Servo MCON Not Used Not Used ENBLI 15 15 N C Servo MCON 0v Not Used Not Used ENBI2 A 33 33 N C I O Type Optically Isolated Enable Relay Output Circuit Type Isolated AC Solid State Relay SSR Output Current 30 ma continuous 50 ma for 10 ms Output Voltage Drop 1 0 v max at 10 ma Notes This is a low current SSR output The output is ON when the associated faceplate Axis Enabled LED is illuminated This occurs when e servo is enabled for Axis 1 or 2 e A Force Digital Servo Velocity AQ Cmd is used on Axis 1 or 2 A Force Analog Output AQ is used on Axis 3 or 4 SOLID STATE EN GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 43 AIN2 IS Phase Current Faceplate Analog In Faceplate Analog In AIN2P A IS Phase Current Facep
255. larm or Over Current 01 B7 Regenerative Circuit Failure Alarm DCOH Regenerative Circuit Discharge Alarm axes N amp L axes or L amp M amp N axes IPM Over Current High Temp or Low Volt L axis M axis N axis L amp M axes amp N L axis M axis N axis L amp M axes M amp N axes N amp L axes or L amp M amp N axes The two segment display on the SVM power supply module PSM indicates power supply alarms Troubleshooting Digital Servo Alarms The guidelines below are intended to assist in isolating problems associated with various servo alarms Ifthe items below do not fit the case or resolve the alarm replace the servo amplifier or call GE Fanuc Hotline for support The appropriate amplifier and motor Maintenance Manual or Description Manual will include more detailed trouble shooting procedures HV High voltage Alarm This alarm occurs if the high voltage DC level DC LINK is abnormally high 1 The AC voltage supplied to the amplifier may be higher than the rated input voltage The Series amplifier three phase supply voltage should be between 200 VAC to 240 VAC GFK 1464C Appendix A Error Reporting A 7 2 The external regeneration resistor may be wired incorrectly Carefully check the connections of the regeneration resistor to the amplifier Check that the resistance of the regeneration resistor is within 20 of the rated value Replace the regeneration unit if the resistance is
256. late Analog In Faceplate Analog In AIN2M A 3 44 Circuit Identifier Digital Servo Axis 1 2 Circuit Function Differential 10v Analog Inputs I O Type Circuit Type Input Impedance Maximum Input Voltage Resolution Linearity Input Offset Gain Factor Gain Accuracy Update Rate Notes Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 Analog Servo Axis 1 2 and Aux Axis 3 Circuit Function Pin AIN1 IR Phase Current Faceplate Analog In Faceplate Analog In AINIP A 7 IR Phase Current Faceplate Analog In Faceplate Analog In AINIM A 25 8 26 Aux Axis 4 Circuit Function Servo Terminal Board Signal Name Faceplate Auxiliary Axis 1 Terminal listed Board 7 N C 25 N C 8 N C 26 N C Differential 10v Analog Inputs Differential Input 102K ohms common mode with respect to faceplate connector Ov 204K ohms differential 15 v common mode with respect to faceplate connector Ov 20 v differential 15 bits 13 bits 1000 uv 10 0v 32 000 counts 0 5 1 10 milliseconds PLC sweep time when data is reported to PLC AI table 2 2 milliseconds when used as Analog Master Input in Follower mode Use faceplate Ov pins for common mode reference TO A D MULTIPLEXER ov GFK 1464C Single Ended 10v Analog Output Circuit Analog Servo Axis Digital S
257. ld review the information provided in all the manuals see Related Publications in the Preface of this manual Additionally GE Fanuc offers applicable training courses If your application requires a custom machine interface you should also attend a GE Fanuc programming course For information about training call 1 800 GE FANUC or contact your GE Fanuc Sales representative The installation and wiring chapter of this manual will be your guide to completing the DSM hardware installation The configuration chapter will provide details needed to configure the DSM module for your application You should begin by reviewing the Configuration Parameters section in chapter 4 Two final recommendations Save the paperwork that came with your system The Important Product Information sheet will contain the latest information on this product some of which may not be included in this manual W Back up your ladder logic folder Important Do this frequently while developing your application Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter 3 Section 1 Installing and Wiring the DSM302 Hardware Description This section identifies the module s major hardware features The module s faceplate provides seven status LEDs one communications port RJ 11 connector and four user I O connectors 36 pin A grounding tab on the bottom of the module provides a convenient way to
258. le HMI Human Machine Interface 2 2 1 VO Hass of 2 2 Motors 2 36 Servo Amplifiers 2 1 Turning Power On 2 24 Motion Program Commands Program Zero 4 27 Motion Program Conditions Which Stop 7 4 Motor IP ratings G 1 Motor direction startup validation D 1 Motor Power Cable Prefabricated Part Numbers to a Series 2 8 2 15 Move AQ Immediate Command 5 22 Move At Velocity AQ Immediate Command 5 19 Move at Velocity Command 6 5 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 N Neg MM Software End of Travel 4 22 New Configuration Received 1 Status Bit 5 3 Normal Stop Before J UMP 7 15 Null 7 2 Null AQ Immediate Command 5 19 0 OK LED 3 2 A 11 for Follower Winder 8 15 Operation Steps for Foll ower Winder 8 14 Operation Unidirectional Other Considerations 6 7 Other Programmed Motion Considerations 7 21 Out of Sync 4 16 Overload curves duty c cles 6 4 6 4 Override Feedrate 7 23 17 23 Overtravel inputs startup validation D 1 Overtravel Limit Switch parameter Parameters in the Motion Mate DSM302 7 26 PMOVEL7 6 PMOVE Command Program Zero 4 28 Pos EOT Positive Software End of Travel 4 22 Pos Err Lim Position Error Limit 4 15 Pos Loop TC Position Loop Time Constant 4 16 Position Error Limit I Status Bit 5 6 Posi
259. le will repeat indefinitely The follower axis will always stay within the zone for both directions of master commands During the winding motion the PLC can send zone adjustments to accommodate winder reel taper on either or both sides of the reel Configuration Follower Winder Mode Enable Use the configuration software to select Follower Mode WINDER with the desired taper mode If desired use the Select Return Data AQ command to select the Zone Position Register to be reported in the User Selected Data 1 location Note Taper is only applied when the PLC sends a different winder zone length Winder Zone Length Use the configuration software or Follower Winder Zone Length AQ command to establish the initial move zone length for the winder motion The Follower Winder Zone Length AQ command may be sent later during the winding operation to alter the zone length to produce the desired taper Note In WINDER Mode only the following formula applies to determine a valid combination of the follower B A ratio and the winder zone length Follower B A Ratio Winder Zone Length lt 1 073 741 823 counts Operation Steps 1 With the Enable Follower Q bit OFF set the Winder Zone Length to the count value representing the width of the spool or the distance to be traversed in one direction for the winding operation Note The following formula applies when issuing a Winder Set Position command Follower B A Ratio Winder Set Position Value
260. le identifies all circuits and pin assignments for Analog Servo Axis 1 and Analog Servo Axis 2 The shaded areas indicate signals which are unused and not available for user connections Table 3 12 Circuit and Pin Assignments for Analog Servo Axis 1 and Analog Servo Axis 2 Circuit Circuit Type Servo Axis 1 2 Faceplate Aux Term Identifier Circuit Function Pin Board Terminal IN Encoder Chan A A INIP B 1 Encoder Chan INIM A INIM B 19 Single ended Encoder Chan IN2P A IN2P B 2 IN2 differential X Encoder Chan IN2M A IN2M B 20 3 21 2 5v inputs 2 Encoder Marker IN3M_A IN3M B 2 EV ov Single ended svin Seno Ready Input NLA INQ B55 osa ios po _ osa h isolated inputs mus 7 24v opticall 16 dead Overtravel A 4 INCOM 24v Input Common 24v Input Common INCOM A INCOM B 13 16 34 17 DC SSR output PLC 24 Output OUTIM A OU 36 13 31 14 3 3 3 3 3 U 2 Not Used UT2P A UT2P _ OUT2 Differential Not Used UT2M A OUT2M B 0 0 3 5 OUT 5v outputs PLC 5v Output OUT3P A OU 14 PLC 5v Output OUT3M A OU E 32 ENBL 24v 30 ma Servo Enable ENBLI ENBLI B 15 SSR output Servo Enable 2 ENBI2B 33 3 PLC Analog In AINIP_A AINIP B 7 7 AINI Differential 110 PLC Analog In AINIM AINIM B 25 2 10v
261. le length G 1 Cables for D5M302 Call Subroutine Catalog Numbers Motor Encoder Cables for B Series Motor Power Cables a CFG LED 3 2 A 11 Changing A B Ratio Follower Winder 8 15 Clamping Velocity 8 7 Clear Error Q Discrete Command CMOVE CMOVE Command Program Zero 4 28 COMM REQ error detection and handling 4 Command Block B 10 compared to Load Param Immediate B 1 example FT fault output B 7 memory code table Status Word codes Status Word monitoring verifying 4 verifying example B 20 Command Block Number AI Status Word 5 8 Program Zero 4 26 Command Name Field Commanded Velocity AI Status Word Commands Position Increment 6 7 Commands Program Zero Motion Program 4 27 COMMREQ Command Block B 1 B 10_ COMMREQ Ladder Instruction B 1 B 7 Communications Request See COMM REO Communications aD uest COMMREQ B 1 Commanded Position AI Status 7 Conditional Jumps 7 12 Conditions Which Stop a Motion Program 7 4 Configuration 8 14 DSM302 module 4 1 Software 1 5 Configuration Parameters 4 2 Configuring the Motion Mate DSM302 4 2 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Configuring the Rack Slot 4 1 Connecting Motor to Servo Amplifier Terminal Strip Series 2 9 2 1 Connections User 330 Connector 151812 6 2 13 2 19
262. lections presented Press the Enter key to make your choice and enter the configuration screens Escape ESC can be used to save and exit when completed Refer to the Logicmaster Programming Software User s Manual GFK 0466 for additional information GFK 1464C Chapter 2 Getting Started 2 23 Module Configuration Data Using the Logicmaster 90 30 configuration package with the rack configuration displayed 1 Position the cursor on the DSM302 module and select the Zoom function key Note that page up and page down select other screens of configuration data The cursor keys move from field to field on the screen The tab key toggles between alternate selections available in most non numeric fields 2 For now select or enter the values from the following tables for the type of servo system digital or analog that you will be using Later sections of this document provide additional detail for each configuration parameter which will allow you to customize settings for your specific application requirements Table 2 7 Module Digital Mode Configuration Data Screen 1 Configuration Configure Configure Logicmaster Parameter Description for Digital for Analog Default Mode Mode Settings Ref Adr Start address for I ref type 100001 100001 Next highest 64 bits available 1 reference Ref Adr Start address for Q ref type 000001 000001 Next highest 64 bits available Q reference Ref Adr Start address for AI ref 100001 1
263. led directly to the Digital servo amplifier Refer to Section 3 I O Wiring and Connections later in this Chapter for additional information Auxiliary Terminal Board Catalog No 69 36 This terminal board contains single 36 pin connector which connects to the DSM302 module This board has two basic applications see Figures 3 10 and 3 11 GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 7 1 In Analog mode it connects to DSM Connector A or B to provide screw terminals for wiring to a third party Analog servo amplifier and I O devices See Figures 3 19 and 3 20 2 Ineither Analog or Digital mode it connects to DSM Connector C or D to provide screw terminals for wiring to external devices such as Strobe sensors Home switches and Overtravel Limit switches See Figures 3 21 3 22 and 3 23 e SL Series Servo to APM DSM Terminal Board Catalog IC800SLT001 Used to connect DSM connector A or B to a GE Fanuc SL Series analog servo amplifier as well as provide screw terminals for wiring to I O devices It contains two connectors One connects to the DSM module and the other to the SL Series Servo amplifier For additional information please see the SL Series Servo User s Manual GFK 1581 DSM Terminal Board Quick Selection Table DSM Terminal Board Connect to or B Series digital servo 1C693ACC335 and I O Connect directly to 0 or B Series AorB Digital None digital
264. les of this SYSID Examples Rack Slot Hex Word Value 0 4 0004h 3 4 0304h 2 9 0209h TASK The number 0 should always be entered here for a DSM module FT Output The function s FT fault output can provide an output to optional logic that can verify successful completion of the Communications Request The FT output can have these states B 6 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C Table B 2 COMM_REQ Instruction FT Output Truth Table FT Output Enable Input Does an Error Active No Low Active Yes High Not active No execution Low The FT output will be set High if e specified target address is not present for example specifying Rack 1 when the system only uses Rack 0 specified task number is not valid for the device the TASK number should always be 0 for the DSM e Data length is set to 0 DSM COMM_REQ Programming Requirements and Recommendations It is recommended that DSM instructions be enabled with a contact from a transition coil If using more than one DSM COMM_REQ in a ladder program verify that a previous COMM REQ executed successfully before executing another one This can be done by checking the Status Word and the FT Fault output explained earlier in this appendix under the heading Monitoring the Status Word As seen in the table above the FT output will be held False if the Enable Input is not ac
265. load is complete the PC loader will instruct you to power cycle your module At this time power cycle the rack containing the module If the module is installed in a remote or expansion rack it is also necessary to power cycle the main rack 13 Label the unit using the supplied labels Restarting an Interrupted Firmware Upgrade Connect all cables as described in step 4 of the procedure above B Power cycle the rack containing the module Ifa partial or erroneous download was performed the module will power up with the STAT and CFG LED s on the module flashing in unison C Ifyou are still running the PC Loader program on your PC skip to step D otherwise follow steps 5 and 6 above D Follow steps 7 and 8 above Note that you will automatically be placed in BOOT MODE Follow steps 10 through 13 above MS MS DOS Windows and Windows NT are registered trademarks of Microsoft Corporation Pentium is a trademark of Intel Corporation IBM AT and IBM PC are registered trademarks of International Business Machines Corporation Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Appendix Answers to Frequently Asked Questions G and Series Motors and Amplifiers GFK 1464C What is the meaning of the IP ratings associated with the motors The degree of motor protection is indicated by a symbol consisting of the two code letters IP International Protection and two reference
266. lso change the required rest period Does logic have to be put in controller for activation of brake or is the brake controlled automatically from the amplifier The Series and Series amplifiers do not control the brake function An external brake relay and appropriately rated 90 volt DC power supply is required A circuit diagram is provided in the servo manual to illustrate a simple full wave rectifier and transformer to supply the required 90 volts DC Can GE Fanuc servo motors be controlled with a controller from another manufacturer No both the Series and Series servos are operated via a digital command signal from a GE Fanuc Motion Mate or Power Mate or CNC motion controller Do GE Fanuc servos interface with Pulse and Direction command signals from stepper controllers No both the a Series and B Series servos require a PWM command signal from the controller What is dynamic braking and how is it different from regenerative braking Regenerative Braking The purpose of a regenerative braking circuit is to dissipate the stored kinetic energy in a rotating controlled motor when a speed reduction is called for If regenerative braking were not used a motor would coast down to a slower speed at a rate based largely upon the momentum of the applied load This coasting type of slowdown would not be acceptable for applications where a fast controlled response is desired Regenerative braking in contrast helps reduce motor spe
267. mance Versatile VO 1 2 Feed Hold Off Transition Q Discrete Command 5 12 Feed Hold On Transition Q Discrete Command 5 12 Feedback Devices Types of Incremental Quadrature Encoder C 5 Feedrate Override Field Wiring Connections 3 30 Find Home Q Discrete Command 5 13 Find Home Cycle C 3 Find Home routine Find Home Vel Find Home Velocity 4 22 Firmware histor Release 1 10 Release 1 20 Release 1 30 H2 Release 1 40 Firmware Upgrades F 1 First Time Use Absolute Encoder C 1 Flash Memory F 1 Fnl Home Vel Final Home Velocity 4 22 Follower Axis Acceleration Ramp Control 8 10 Ramp Distance Make up Time AQ Immediate Command Follower Enabled 1 Status Bit 5 6 Follower Mode Follower Motion Combined with Motion Programs 9 2 Follower Ramp distance make up time 8 10 Follower Velocity Limit I Status Bit 5 6 Follower Winder Changing A B 8 19 Configuration Operation Description Feedhold with the E a Mate DSM302 7 22 Ratio Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 Operation Steps 8 14 FollwrEnInp Follower Enable Input 4 23 Force D A Command Force D A Output AQ Immediate Command 520152466 Frequently asked questions FAQ G 1 Functional Block Diagrams for the 2 Axis DSM302 Axis 1 Master Source Analog Input 8 18 Axis 1 Master Source Encoder 3 Internal Master 1 10 8 19 Axis 2 aster Source Analog
268. mand Block The Command Block contains the details of a Communications Request The first address of the Command Block is specified by the IN input of the COMM REQ Ladder Instruction This address can be in any word oriented area of memory or AQ The Command Block structure can be placed in the designated memory area using an appropriate programming instruction the BLOCK MOVE instruction is recommended The DSM Command Block has the following structure Table B 3 DSM COMM REQ Command Block COMM REQ Command Block for DSM Module Address Offset Word No and Value Data Block Header Length Address 0 Word 1 always set to 4 WAIT NOWAIT Flag Address 1 Word 2 always set to 0 Status Pointer Memory Type see Word 3 chosen by user see Memory Type Codes table below Memory Type Codes table below Word 4 chosen by user Idle Timeout Value Maximum Communication Time Command Code Parameter Data Size in bytes Address 7 Word 8 Size depends on the value in Word 12 Parameter Data Memory Type Address 8 Word 9 chosen by user see Memory Type Codes table below 9 Parameter Data Offset Word 10 chosen by user Starting parameter number 0 Word 11 chosen by user 11 Number of parameters to load Ist parameter data 2nd parameter data 16th parameter data 4 bytes Use of these words depends on the value in Word 12 Data Block Length Word 1 The length of the Data Block header portion of the Comman
269. mand yields the following home cycle Unless otherwise specified acceleration is at the current Jog Acceleration and configured Jog Acceleration Mode Find Home Routine for Home Switch If initiated from a position on the positive side of the home switch in which case the home switch must be OPEN Logic 0 the Find Home routine starts with step 1 below All of the first several steps of the following routine are necessary to allow for a variety of possible home switch designs and starting positions If the Find Home routine is initiated from a position on the negative side of the home switch in which case the home switch must be CLOSED Logic 1 the routine starts with step 3 below The axis is moved in the negative direction at the configured Find Home Velocity until the Home Switch input closes 2 The axis decelerates and is stopped 3 The axis is accelerated in the positive direction and moved at the configured Find Home Velocity until the Home Switch input opens 4 The axis decelerates and is stopped 5 axis is accelerated in the negative direction and moved at the configured Final Home Velocity until the Home Switch input closes 6 The axis continues negative motion at the configured Final Home Velocity until a marker pulse is sensed The marker establishes the home reference position 7 axis decelerates and is stopped 8 The axis is moved at the current Jog Velocity the number of user units specifi
270. mber 2002 GFK 1464C GFK 1464C Table 4 1 Continued Module Configuration Data Configuration Description Values Logicmaster Defaults Units Reference Parameter Section Fdback Type Feedback Type ENCODER ENCODER N A 1 02 LINEAR RESOLVR CUSTOM 1 CUSTOM 2 DIGITAL Control Loop Type STANDARD STANDARD N A 1 03 FOLLOWER ccri CCL2 Servo Cmd Servo Interface Type ANALOG ANALOG N A 1 04 DIGITAL DUAL Motorl Type Motor2 Type GE Fanuc Motor Type 0 127 0 no motor digital N A 1 05 0 or valid analog mode FANUC Motor types ONLY Motor Dir Motor direction for POS POS N A 1 06 Motor2 Dir positive velocity command NEG 1 01 1 02 1 03 1 04 Reserved for future use not implemented at this time For special purpose applications only AI AQ Len Sets the number of AI and references assigned to the DSM302 The possible combinations of AI and AQ references are 40 6 50 9 and 64 12 40 6 is typically selected for Standard mode applications Follower mode applications typically use the 50 9 selection The 64 12 selection is normally reserved for applications requiring additional analog I O 1 to gain access to the analog I O on module connectors and D Default 40 6 Fdback Type ENCODER selects incremental quadrature encoder A quad B x4 input mode LINEAR selects linear transducer absolute feedback input mode for special purpose use with CCL2 RESOLVR selects resolver absolute feedb
271. meter Download Using the COMM_REQ Instruction 11 MSWD TWM SEND ENABLE 0001 T0001 COMM REQ FAULT Command Block pointer 0295 Fault output ame cae R196 IN Ecke 5 00000 TASK Always 0 for DSM 1 1 I 1 1 1 0007 Rack 0 Slot 7 Power Supply Slot No Series 90 30 PLC Rack 0 CPU 1 2 3 4 5 6 7 8 9 Command Block for DBM COMM REQ Memory Address R196 Value 4 Description Length in words of Data Block header always 4 197 0 WAIT NOWAIT Flag Always 0 for DSM 8 8 Register memory R for Status Word 195 Statu address Word Register R201 0 Specifies register 195 for Status Word address R200 0 Always 0 for DSM Always 0 for DSM Start of Data Block section of Command Block E501 Always E501 for DSM 68 Parameter Data size in bytes Data Block R204 8 Register memory R for Data Block Header Parameter Data 4 words R205 Specifies register 206 for start of Parameter Data Start of Parameter Data section of Data Block R206 1 Starting Parameter Number Data Block R207 16 Number of Parameters to send bus i be ta 208 Parameter data for 16 contiguous double word 68 b R239 parameters ytes Figure B 4 Overview of the DSM COMM_REQ Example Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C KK
272. mmed motion executed while the follower is active i e Move Immediate Jog executing a motion program is not affected by the Vlim value It is possible when using superimposed moves with the follower axis enabled to exceed the velocity limit imposed on the follower motion The Vlim status errors are returned only if the master command velocity exceed the active Vlim Configuring the Master Velocity Limit to zero disables error reporting for the negative direction and provides unidirectional follower operation in the positive direction Default 1000 Refer to Chapter 8 Follower Motion for additional information FollwrEnInp Follower Enable Input Selects the control bit CTLO1 CTL16 to be used as the Follower Enable input The follower axis is enabled only when the selected input is ON and the Enable Follower Q bit is also ON When the Enable Follower is ON then the CTL bit chosen acts as a rising edge trigger to enable follower mode After Follower is enabled only the PLC Enable Follower bit controls the active state of the following function A value of 0 means the follower axis is enabled only by the Enable Follower Q bit CTLO1 CTL08 and CTL13 CTL16 are faceplate inputs CTL09 CTL12 are Q bits from the PLC Default 0 Follwr Mode Follower Mode Specifies the follower operating mode NORMAL means the follower is enabled and disabled immediately without any ramp acceleration control by the Enable Follower Q bit ANDed with
273. motor speed the braking torque decreases exponentially as the motor decelerates to a stop If this 1s required use the optional holding brake GE Fanuc servo amplifiers use dynamic braking in the following speed reduction situations e When the amplifier power is removed e When the amplifier E stop is asserted e When the motion control disables the amplifier Can I use the brake in the servomotor to stop my load No the brake is designed to hold the machine when the servo motor control is turned off a parking brake It is possible to brake the machine by turning off the brake power at emergency stop such as at the stroke end but it is not designed to reduce the stop distance Servo motor brakes have thin friction linings and will be damaged or their service life greatly reduced 1f used to stop moving loads What is B Series Servo with I O link I O Link is a device network for high speed serial communications between PLC and CNC PowerMotion products The Series Servo with I O Link is a slave I O link device for advanced single axis motion control Axis control resides in the amplifier Commands are sent from the host control over the I O link to the amplifier which can store up to 32 blocks of motion program A total of 8 axes can be connected to an I O link master device PLC s may support multiple I O Link master modules The Series Servo with I O LINK is a dependable and inexpensive option for CNCs requiring additional serv
274. move away from an open hardware overtravel limit switch Execute Motion Program 0 10 These commands are used to select stored programs for immediate execution Each command uses a one shot action thus a command bit must transition from OFF to ON each time a program is to be executed Programs may be temporarily interrupted by a Feed Hold command When a program begins execution Rate Override is always set to 100 A Rate Override AQ command can be sent on the same sweep as the Execute Motion Program n bit and will be effective as the program starts Only one Motion Program can be executed at a time per axis The Program Active Vol status bit must be OFF or Motion Program execution will not be allowed to start A multi axis Motion Program uses both axis 1 and axis 2 so both Program Active bits must be OFF to start a multi axis Motion Program CTLO9 CTL12 Control Bits These command bits may be tested by the DSM302 during execution of Wait or Conditional Jump commands Abort All Moves This command causes any motion in progress to halt at the current Jog Acceleration rate Any pending programmed or immediate command is canceled and therefore not allowed to become effective The abort condition is in effect as long as this command is on If motion was in progress when the command was received the Moving status bit will remain set and the Jn Zone status bit will remain cleared until the commanded velocity reaches zero and the Jn Zone condi
275. munications Request e Section2 The COMM REQ Ladder Instruction e Section 3 The COMM REQ Command Block e Section 4 Example ofa DSM COMM REQ Section 1 The Communications Request The Communications Request uses the parameters of the COMM REQ Ladder Instruction and an associated Command Block to define the characteristics of the request An associated Status Word reports the progress and results of each request Structure of the Communications Request The Communications Request is made up of three main parts The COMM REQ Ladder Instruction e The Command Block which is a block of PLC memory usually R memory that contains instructions and data for the COMM REQ GFK 1464C B 1 e Status Word which is one word of memory that status error codes are written to The figure below illustrates the relationship of these parts COMREQ 244916 INSTRUCTION INPUTS COMMAND AND BLOCK OUTPUTS FOR COMREQ INSTRUCTION COMMAND DETAILS BLOCK OF THE POINTER REQUEST STATUS WORD STATUS WORD POINTER Figure B 1 Structure of the COMM REQ The COMM REQ Ladder Instruction The COMM REQ Ladder Instruction is the main structure used to enter specific information about a communications request This information includes the rack and slot location of the DSM module associated with the request and a parameter that points to the starting address of the Command Block Note that in programming this instruction the command block da
276. n j o DSM Digital Servo Alarms 0 GE Fanuc and servo systems have built in detection and safety shut down circuitry for many potentially dangerous conditions The table below reflects that three different models of servo amplifiers may be used with the DSM the B Series the Series SVU and the a Series SVM The following table indicates alarms supported by a particular servo amplifier and the corresponding DSM error code Table entries that are blank in the amplifier columns indicate amplifier alarms not supported by the particular amplifier series To clear a servo alarm amplifier power cycle reset is required Additionally a Clear Error Q discrete command is required to clear the DSM Error Code Amplifier alarms not cleared by power cycle of the amplifier will continue to be reported to the DSM module A brief trouble shooting section for servo alarms appears at the end of the error alarm tables A 6 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Table A 2 DSM Digital Servo Alarms Amplifier Alarm Display Error Number Description SVM SVU B Hexadecimal 7SEG 7 SEG ALM LED lOve VolagDCLINK 1 ON jLlowVolagConolPowr 06 2 B2 DBRLY Dynamic Brake Circuit Failure T ENLUL 7 tance on Amplifier OverHeat ot ON FAL CoolingFan Failure ow SVM PSM IPM A
277. n a double layered box Remove the top layer of packing material to uncover the amplifier Next carefully remove the inner box from the outer layer Then lift the amplifier out of the inner box Retain any loose parts or gasket materials packed with the amplifier Visually inspect the amplifier for damage during shipment Note Do not attempt to change any pre configured jumpers or switches on the amplifier at this time Unpacking the FANUC Motor FANUC motors are packed two different ways depending on their size The largest motors are shipped on wooden pallets and are covered with cardboard Most motors however are packed in cardboard boxes 1 Unpacking Instructions e For those FANUC motors packed in boxes open the box from the top The motors are packed in two pieces of form fitted material Carefully lift the top piece from the box This should allow sufficient clearance for removing the motor e Ifthe motor is attached to a pallet remove the cardboard covering This will allow access to the bolts holding the motor to the pallet Remove the bolts to free the motor from the pallet 2 Inspect the motor for damage 3 Confirm that the motor shaft turns by hand NOTE If the motor was ordered with the optional holding brake the shaft will not turn until the brake is energized Let s start Assembling the Motion Mate DSM302 System GFK 1464C Chapter 2 Getting Started 2 3 2 4 Section 2 Assembling the Motion Mate DS
278. n control functions are enabled and servo motion can be commanded A signal will be sent MCON to the digital servo enabling the drive Enable Drive must be maintained ON to allow normal servo motion except when using Jog commands Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C 3 07 Find Home Servo Axis 1 2 This command causes DSM302 to establish the Home Position A Home Limit Switch Input from the I O connector roughly indicates the reference position for Home and the next encoder marker encountered indicates the exact home position When the Home Mode axis configuration is set to MOVE or MOVE the Home Limit Switch input will be ignored The configured Home Offset defines the location of Home Position as the offset distance from the Home Marker The Position Valid l bit indication is set at the conclusion of the Home Cycle See Chapter 6 for more information regarding the Home Cycle See Appendix C for considerations when using an absolute encoder 3 08 Find Home Aux Axis 3 This command does not cause any motion instead it initializes the Aux Axis 3 Encoder logic to wait for a marker pulse transition when the Aux Axis 3 Home Switch input is ON When the Home Switch Marker condition is satisfied the Aux Axis 3 Actual Position will be set to the configured Home Position and the Aux Axis 3 Position Valid Vol bit will be set The Home Switch input may be disabled by the Home Mode axis config
279. n controller and servo The startup guide is intended for the new user but will help all users to get their system up and running in a short time Chapter 3 Installing and Wiring the DSM302 This chapter provides the installation and wiring information required for your Motion Mate DSM302 motion control system Chapter 4 Configuring the DSM302 This chapter explains how to configure the Motion Mate DSM302 using the Logicmaster 90 30 programming software configuration function Note that the later releases of the graphical Control configuration software also support the DSM302 Chapter 5 Motion Mate DSM302 to PLC Interface This chapter describes the 1 V6 AI Q and AQ data that is transferred between the Motion Mate DSM302 and the Series 90 30 PLC CPU Chapter 6 Non Programmed Motion This chapter describes the six different ways that non programmed motion is generated Chapter 7 Programmed Motion This chapter describes how the DSM302 executes program motion commands sequentially in a block by block fashion in a selected program Chapter 8 Follower Motion This chapter describes how follower motion is executed by the DSM302 Chapter 9 Combined Follower and Commanded Motion This chapter describes combined motion which consists of follower motion commanded from a master axis combined with specific internally commanded motions Appendix A Error Reporting This appendix describes the errors reported by the AI module status cod
280. n is lower than the velocity of the first CMOVE the DSM302 slows the acceleration to zero Constant velocity zero acceleration occurs at the second dashed line There the DSM302 begins decelerating to the new velocity using the acceleration at the jump destination Finally the second CMOVE finishes ACCEL 1000 VELOC 50000 M Mis BLOCK 1 JUMP CTLO1 3 CMOVE 50000 INC SCURVE BLOCK 3 VELOC 5000 ACCEL 10000 CTLO1 ON CMOVE 15000 INC SCURVE C2 Begins Figure 7 16 Jumping before the Midpoint of Acceleration or Deceleration GFK 1464C Chapter 7 Programmed Motion 7 19 S CURVE Jumps to a higher Acceleration while Accelerating or a lower Deceleration while Decelerating The second case involves jumping to a higher velocity while accelerating or a lower velocity while decelerating When this occurs the DSM302 continues to the first move s acceleration or deceleration This acceleration or deceleration is maintained similar to be a linear acceleration until the axis approaches the new velocity Then the normal S curve is used to reduce acceleration or deceleration to zero Example 14 S CURVE Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating In this example a JUMP command is triggered during the initial phase of acceleration at the first dashed line and the velocity at the jump destination is higher than that of the current move The first dashed line indicates the maximum acc
281. n the same amount of time Equations Velocity y 2 Vpk k X 5X P a 2V nn LL Acceleration a a X Kes Figure 7 24 S Curve Acceleration 7 30 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter Follower Motion Configuring the DSM302 for Control Loop FOLLOWER allows each Servo Axis slave to respond to a Master Axis input using a programmable slave master ratio The DSM302 defines the slave master ratio as the ratio of two integer numbers A and B The basic formula for computing Follower motion is Follower Servo Axis motion slave axis Master Axis motion x A B or slave master ratio A B ratio If a Jog Move at Velocity or Execute Motion Program command is also initiated the axis motion will represent the combination of the Master Axis motion and the internally commanded motion This Chapter provides details of servo motion related to the Master Axis input Refer to Chapter 9 for additional information about combined Follower and commanded motion When the Enable Follower Q bit is turned ON an axis will immediately begin following the selected Master Source unless an external Enable Trigger input has been selected If an external Enable Trigger input has been selected then the Enable Follower Q bit must be ON and an OFF to ON transition of the trigger input must occur The external trigger input CTLO1 CTL016 is selected in the configurat
282. naccurate Encoder Position Resolution Data The description for the Enhanced Position Loop Resolution function description was not clear The description was improved in the IPI for release 1 30 Turn off CONFIG LED when Flashing Error Code A fatal error did not turn off the CONFIG LED when a fatal error code occurs Firmware version 1 30 was updated to turn off the CONFIG LED when a fatal error code is issued Jog Vel User Units Counts Configuration Value Causes Module to Crash Configuring the module for User Units to Counts ratio of greater than 1 3 and Jog Vel 8 388 607 caused a fatal error NMI generated watchdog timeout Firmware version 1 30 was enhanced to internally limit the Jog Velocity to 1 000 000 count sec If the module is configured to a number greater than 1 000 000 counts sec the module uses the maximum jog velocity of 1 000 000 count sec Follower Deceleration Ramp Reentry after Drive off on In follower mode if follower is disabled and then the drive is disabled motion will stop However the module continues to calculate the deceleration ramp while the follower is disabled If the deceleration ramp has not reached zero prior to the drive being re enabled the module will issue a velocity command corresponding to the current deceleration ramp value and complete the deceleration ramp This was corrected in firmware version 1 30 such that the deceleration ramp is not re entered GFK 1464C
283. nalog Input Axis 1 Master Source Encoder 3 Internal Master 8 18 Figure 8 20 Axis Follower Control Loop Block 8 19 Figure 9 1 Combined Motion Follower Jog sssseseseeeeen nennen 9 Figure 1 Status Code Organization sssssssssesseeeeeeee ener ener enne trennen nennen nennen nnns A 2 Figure B 1 Structure of the COMM REQ sse B 2 Figure B 2 Operation of the DSM Communications Request sese B 6 Figure B 3 DSM COMM REQ Ladder Instruction essent nete B 7 Figure B 4 Overview of the DSM COMM REQ Example B 14 Figure D 1 Control Loops Block Diagram ssssssseeseeeeeeee enne D 4 Figure D 2 Velocity Loop Step Response Velocity vs Time VLGN 0 sese D 7 Figure D 3 Velocity Loop Step Response Torque Command vs Time VLGN Q sees D 7 Figure D 4 Velocity Loop Step Response Velocity vs Time VLGN 24 sse D 8 Figure D 5 Velocity Loop Step Response Torque Command vs Time VLGN 24 D 8 Figure D 6 Velocity Loop Step Response Velocity vs Time VLGN 48 sse D 9 Figure D 7 Velocity Loop Step Response Torque Command vs Time VLGN 48 D 9 Figure
284. nce the value may need to be adjusted To tune the Velocity Loop Gain the following procedure can be used 1 Choose the method to introduce velocity command to the velocity loop Method 1 and Method 2 above are examples of methods to perform this task Appendix D Tuning GE Fanuc Digital and Analog Servo Systems D 5 2 Connect an oscilloscope to the analog outputs for Motor Velocity feedback and Torque Command See Section 4 25 of Chapter 5 for analog output configuration instructions 3 Set the Velocity Loop Gain to zero This is a conservative approach If the application is known to not have resonant frequencies from zero to approximately 250 Hz you can start with a higher value but do not exceed the value calculated in equation 1 at this point 4 Generate a velocity command step change At this point the step change should be relatively small compared to the full speed of the machine Ten to 20 of the rated machine speed is a good start 5 Observe the Motor Velocity and Torque Command on the oscilloscope The objective is to obtain a critically damped velocity loop response Pay particular attention to any oscillations that are occurring in the velocity feedback signal 6 Increase the Velocity Loop Gain in small steps and repeat 4 and 5 until instability in the Motor Velocity feedback signal is observed Once this point is reached decrease the Velocity Loop Gain by at least 15 Asa general rule the lower the Velocity Loop G
285. nce is provided in the negative direction between the home position and the negative overtravel position This is to allow some working room for adjustment Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C 5 and setup of these positions and for the find home routine which requires that its final move be in the negative direction Distance is also provided between the overtravel limit position and the positive stop Enough distance should be allowed here to prevent the machine slide from hitting the positive stop The correct distance needs to be greater than the worst case stopping distance required by the machine slide after it reaches the overtravel limit position In this example the machine slide s working range is on the positive side of the home switch If the DSM s Home Position parameter was set to 0 this would simplify programming absolute positioning commands since only positive numbers would be used Often the home position needs to be set to an exact distance from a reference point on the machine To facilitate this adjustment the home switch cam could be made with slotted mounting holes that would allow a coarse adjustment of the cam to bring the calibration to within one turn of the encoder Then the small remaining distance would be accurately measured and the value obtained would be entered into the DSM s Home Offset parameter 4 44 Direction Positive
286. nd Home Switch checking for correct motor rotation direction and tuning the velocity and position loops This must be done by experienced personnel For detailed start up instructions refer to Appendix D Start Up and Tuning a GE Fanuc Digital or Analog Servo System Enabling Run Mode on the PLC The next step in the operation of the DSM302 system is to place the PLC in the RUN mode 1 From the top level Logicmaster 90 Software menu select F1 Logicmaster Programmer Package From the Programmer Package main menu select F3 Control and Status Select F3 again for PLC Fault Table Use the Alt M hot key to place the control in the ONLINE mode Status line at the bottom of the screen Review the fault tables for any problems and then use the function key F9 Clear to delete any PLC faults present Select the F4 I O Fault Table and clear I O faults as well Use the Alt R hot key to place the PLC in RUN Mode Make sure that your motor is properly fastened down If not the motor could be damaged and or cause injury to personnel Visually check that the PLC LED s PWR OK and RUN are all on Visually check that the DSM302 module LEDs STAT and CFG are on For Series Digital amplifiers visually check that the amplifier status readout is showing a minus sign which indicates Standby Mode For Series Digital amplifiers check that the Power LED is and ALM LED s are off For SL Series amplifiers check the f
287. nd of Travel limit User Units If the DSM302 is programmed to go to a position less than the Negative EOT an error will result and the DSM302 will not allow axis motion In Follower mode the DSM302 internally sets Neg EOT to the LO Limit position rollover value See Note under Axis Mode The Neg EOT limit applies only when the Axis Mode configuration is set to LINEAR Default 8 388 608 If Pos Neg EOT limits are both set to zero the DSM302 uses 8 388 607 8 388 608 instead Ratio A and B Values The A over B ratio sets the follower slave master gear ratio A Master Reference Counts B Follower Axis Motion counts The range for A is 32 768 to 32 767 and B is 1 to 432 767 When A is negative the slave axis will move in the opposite direction from the master For DSM firmware revision 1 20 and later the A B slave master follower ratio has been expanded from the original range of 32 1 to 1 32 now supporting 32 1 to 1 10 000 Starting with Logicmaster release 8 02 the AQ Immediate Command 2Dh can also be used to specify this expanded range at runtime However specifying the expanded range ratio greater than 1 32 in the module configuration requires Logicmaster 90 30 release 9 0 or later Default 1 1 Mstr Source Master Axis Source ENC3 INT ENC2 or ANALOG The master reference for Servo Axis can be selected as encoder 3 internal master ENC3 INT encoder 2 ENC2 or the analog input ANALOG The master re
288. nerator esses eene 8 3 Example 2 Following the Internal 0100 8 3 Analog Input Master eret ie E eie een 8 4 Example 3 Following the Analog Input eeseeeeeeneeneenen 8 4 Encoder Servo Axis 2 8 4 Example 4 Following Servo Axis 2 Encoder eee 8 5 A B Ratios etse eU berto ridet fees tes teen er euet 8 5 Example 5 Sample A B 8 6 Example 6 Changing the A B eene ene 8 7 Example 7 Ratio Stepping eene enne 8 7 Velocity Clamplng eter e eT eo eb me e rece ete pus 8 7 Example 8 Velocity 1 8 8 Unidirectional Operation teet ete reete ltr late Chane tr e lative 8 8 Example 9 Unidirectional Operation essen 8 8 Synchronizing Aux Axis 3 Velocity and the Internal Master sees 8 9 Example 10 Aux Axis 3 Velocity and Internal Master Synchronization 8 9 Enabling the Follower with External Input essere 8 9 Follower Axis Acceleration Ramp Control 1 4 20020044000 000000100000000000000000000000004 8 10 Poll wer Winder eere eret e tere m e 8 14 Intro dictiOne coectetuer em 8 1
289. nertia mismatches e All Digital Servo Command Signals A PWM command between the amplifier and motor improves efficiency by varying the on time of the transistor switches to control motor voltage and current The GE Fanuc system also provides the benefits of the PWM command from the controller to the drive The PWM command used in Digital Mode is more immune to noise allowing for increased distances between the controller and the amplifier e High Performance Serial Encoders Standard serial encoders built into the motors provide 32K Series or 64K a Series counts per revolution feedback Serial messages support higher resolutions at high motor velocities than common quadrature encoders and are more immune to noise An optional battery connection provides absolute position feedback eliminating the need to re home the system after a power shutdown e Reduced Tuning and Setup There is no need for potentiometer tuning or personality modules little tuning is required for properly sized drives drive parameters are stored in the controller in a standard motor database Configuration settings are not stored in the drive so it can be replaced with little set up time Stored drive and machine parameters are quickly transferred to repeat production machines What diagnostic information can be gathered on the B Series Servo amplifier The a Series Servo Amplifier can detect many error conditions and provide alarm information The LED s
290. ng the correction the velocity is not allowed to exceed the maximum Appropriate warning error codes notify the user about abnormal operation see error table below Hexadecimal Type EC Status Only Programmed makeup time is not long enough for trapezoidal correction of Axis the makeup distance Status Only Velocity limit violation during ramp Status Only Time limit violation during acceleration sector of the distance correction The figure below shows the velocity profile during the follower ramp cycle Note The enhanced follower make up may affect existing applications that use the old follower make up feature max Vel 0 8 Vlim Follower Disabled Make up distance 4 4 correction 1 Velocity i Time Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Problems Resolved by Firmware Release 1 30 AQ Command 30h Causes Module to Crash Issuing an AQ command of 30h Set Internal Master Velocity in Follower to a value larger that 32 767 999 generated a fatal error NMI generated watchdog timeout This was fixed in firmware version 1 30 Error checking was added to generate a warning when values outside the valid range 1 000 000 1 000 000 counts sec are entered If values outside the valid range are entered the command is ignored and error code01E9 for Axis 1 or 02E9 for Axis 2 is reported IPI for Release 1 20 Contained I
291. nitor the DSM302 module Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Operator Interfaces Operator interfaces provide a way for the operator to control and monitor the servo system through a control panel or CRT display These interfaces communicate with the PLC through discrete I O modules or an intelligent serial communications or network communications module Operator data is automatically transferred between the PLC and the DSM302 through 9 I AIT Q and AQ references which are specified when the module is configured This automatic transfer of data provides a flexible and simple interface to a variety of operator interfaces that can interface to the Series 90 30 PLC Servo Drive and Machine Interfaces GFK 1464C The servo drive and machine interface is made through a 36 pin connector for each axis This interface carries the signals that control axis position such as the Digital Pulse Width Modulated PWM signals to the amplifier Digital Serial Encoder Feedback signals or Analog Servo Command and Quadrature Encoder Feedback Also provided are Home Switch and Axis Overtravel inputs as well as general purpose PLC inputs and outputs Standard cables which connect directly to custom DIN rail or Panel mounted terminal blocks simplify user wiring and are available from GE Fanuc The terminal blocks provide screw terminal connection points for field wiring to the DSM302 module Refer to chapte
292. numbers indicating the degree of protection The first number represents the level of protection against physical intrusion The second number represents the protection against liquid intrusion This standard does not specify a degree of protection of electrical against mechanical damage against the risk of explosion or against conditions such as moisture i e condensation corrosive vapors fungus or vermin __ First IP Number Physical Protection Second IP Number Liquid Protection 0 No special protection 7 0 No special protection Dripping water 4 Solid objects greater than 1 mm 4 Splashed water any direction 5 Harmful dust deposits no contact 5 Water projected from a nozzle 6 Dust tight no contact 6 Heavyseas O 1 1 Pp E oF immersion D EXAMPLE IP 55 An enclosure with this designation is physically protected against harmful dust deposits with complete protection against contact The liquid protection is from water projected from a specified type of nozzle What is the max cable length and recommended cable length from the controller to the amp and from the amp to the motor There are limitations to how far apart the motion control servo amplifier and motor can be and still have reliable operation These are determined by such factors as signal attenuation and resistance losses in the power lines The DC power to the serial encoder must provide
293. o RS422 485 GFK 1464C Chapter 4 Configuring the DSM302 4 7 Axis Configuration Data The DSM302 configuration parameters define such things as control mode motor type feedback type as well as tuning settings that match the servo system to the physical equipment being driven Therefore most configuration parameters values do not change and so they can not be accessed in the motion program However a relatively small number of configuration parameters may require changing to accommodate changes in the user s application Examples of these parameters are In Pos Zone Jog Vel and Jog Acc Changes to these parameters are supported by PLC AQ Immediate Commands Refer to Chapter 5 Section 4 for more information The configuration parameters for each control loop mode are defined and briefly described here The numbers in the Ref column refer to item numbers in this chapter Table 4 3 Axis Configuration Data ue Lac Parameter Description Values Defaults Units Modes Standard Mode Only Standard Mode Only Enable Disable DISABLED Follower See Note 1 Follower Follower Constant See Note 1 Follower 4 8 Vel at 10 V Vel FF Intgr TC Intgr Mode Rev Comp DisDly Vel Lp Gain Digital Mode only Fdback Mode Digital Mode only Jog Vel Jog Acc Jog Acc Mod See Note 1 Follower PE Follower Follower m Integrator Mode OFF N CONT IN ZONE m N N S A Drive Disable Delay 0 65 535 S
294. o for example to specify R memory you would put either the decimal code number 8 or the hexadecimal code number 08h in this word Note that if you select a discrete memory type I or Q a group of 32 consecutive bits will be required for each parameter and a group of 16 consecutive bits each will be required for Words 11 and 12 Parameter Data Start Pointer Offset Word 10 This word contains the offset within the memory type selected in the Parameter Data Memory Type parameter Note The Parameter Data Pointer Offset is a zero based number In practical terms this means that you should subtract one from the address number that you wish to specify For example to select R0001 as the Parameter Data Start location enter zero 1 1 0 Or to select 0100 enter 99 100 1 99 Note that the memory type R in this example is specified in the previous word Appendix DSM Parameter Download Using the COMM REQ Instruction B 9 Starting Parameter Number Word 11 Specifies the number of the first parameter to be loaded Valid values are 0 255 However this number must take into account the value in Word 12 For example if Word 12 specifies that 10 parameters are to be loaded the Starting Parameter Number must be less than 247 otherwise the number of the last parameter to be loaded would be out of range would be greater than 255 Number of Parameters to Send Word 12 Specifies how many parameters will be loaded
295. o sets 1 User Unit equal to 0 001 inch Default is 1 1 For FOLLOWER mode this ratio is fixed at one to one 1 1 and cannot be changed The default User Unit is one encoder count For STANDARD mode the User Units to Counts ratio sets the number of position programming units for each feedback count It is a requirement to set this value correctly for the mechanical systems coupled to the axis otherwise movement to unsafe and inaccurate positions may occur It is important to set this relationship at the beginning of the configuration session most other configuration fields are specified in user units For example Velocity will be specified in user units per second and Acceleration will be specified in user units per second per second The DSM300 Series module has a very powerful scaling feature A User Unit to Counts ratio can be configured to allow programming in other than default counts In a simplified example suppose an encoder feedback application has an encoder that produces 1 000 counts per revolution 250 lines and is geared to a machine that produces one inch per revolution The default unit would be one thousandth of an inch per count However you may want to write programs and use the DSM300 Series module with metric units A ratio of 2540 User Units to 1000 Counts can be configured to allow this With this ratio one user unit would represent 01 millimeters 2540 user units would represent 25 40 millimeters one inch of travel
296. o the next command Jumps may be conditional or unconditional An unconditional jump always redirects execution to a specified Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C program location A conditional jump is assigned a CTL bit to check If the CTL bit is ON the jump redirects execution to a specified program location If the CTL bit is OFF the jump is ignored Type 2 commands also do not affect position The Block command provides an identification or label for the Type 3 command that follows If a program block does not contain a Block the previous Block is used The Block SYNC is a two axis synchronization command this may or may not delay motion on one axis The Load Parameter command allows the user to load a value into a parameter register The Velocity and Acceleration commands specify velocity and acceleration rates for the Type 3 MOVE command or commands that follow Velocity and Acceleration commands remain in effect until changed Type 3 commands start or stop motion and thus affect positioning control Positioning PMOVE and Continuous CMOVE moves command motion the Dwell Wait and End of Program commands stop motion Program Blocks and Motion Command Processing A program block consists of and is defined as one and only one Type 3 command with any number and combination of preceding Type 1 and 2 commands The Block command has two primary uses 1 it provides a J
297. oard Assembly Drawings essere 3 16 Figure 3 9 Auxiliary Terminal Board Assembly Side View sese 3 17 Figure 3 10 DSM302 Digital Servo Terminal Boards and Connectors esee 3 19 Figure 3 11 DSM302 Terminal Boards and Connectors for Analog Servos see GFK 1581 for SL Servos 3 20 Figure 3 12 Detail of Cable Grounding Clamp A99L 0035 0001 sese 3 22 Figure 3 13 44B295864 001 Grounding Bar Side View 3 22 Figure 3 14 44B295864 001 Grounding Bar Dimensions Rear View Showing Mounting Holes 3 23 Figure 3 15 DSM302 I O Cable Grounding esses eene enne nennen nnne 3 24 Figure 3 16 Digital Servo Axis 1 Connections 0 cceccceceessessceseseecesecseeecesecaceeseeseceaeeeeceaecaeeeneeaecaeeaeenees 3 30 Figure 3 17 Digital Servo Axis 2 Connections ceccceseesseseceseseecesecaeeeeesecaeeeseeseceaeeeceaecaeeeeeeaecnaeeneeaees 3 31 GFK 1464C Contents xiii Contents Figure 3 18 and BSeries Digital Servo Command Cable IC800CBL001 002 Connections 3 32 Figure 3 20 Analog Servo Axis 2 Connections isses ener trennen treten 3 34 Figure 3 21 Aux Axis 3 Follower Master Axis Connections 0 3 35 Figure 3 22 Aux Axis 3 Follower Master Axis Encoder Connections sss 3 36 Figure 3 23 Aux Axis A Connections ostia ere e NE Ee
298. oders can be operated in either Incremental mode or Absolute mode The mode is configured using the Feedback Mode selection in the configuration software Proper operation of the Absolute mode requires an external battery pack that must be connected to the servo amplifier Refer to the appropriate amplifier manual for selection and installation of the battery pack Limitations on Total Travel for Linear Axis Mode When Axis Mode is set to LINEAR in the configuration software the POS EOT and NEG EOT configuration values set the limits of programmed motion The maximum value that can be used for the is 8 388 607 user units User units are configured as a ratio to the encoder count value and are limited to the range of 8 1 to 1 32 Additionally the position feedback from a digital servo is by default fixed at 8192 counts per revolution A simple formula can be used to determine the maximum number of motor shaft revolutions possible for axis travel when Linear non continuous Axis Mode is used If the position feedback resolution is changed via Tuning Parameter 1 then substitute the new resolution 8 388 608 User Units Position Counts Per Rev Counts Maximum Absolute Revolutions Using the above calculation and the 8192 position counts per revolution default the maximum possible move is realized with the User Units to Counts ratio at the maximum 1 32 resulting in a Motion Mate DSM302 for Series 907 30 PLCs User s Manual
299. odule Hardware Limit Switch Errors Limit Switch error Axis Limit Switch error Axis Hardware Errors Out of Sync error Axis Encoder Loss of Quadrature or Linear Feedback Loss of Signal error i See Table A 2 Encoder Alarms op Fast 11 Fast Servo not ready when MCON command is on may be caused by the amplifier E STOP input Serial Encoder Battery Low Serial Encoder Battery Failed Axis Servo Motor Over Temperature Axis Not used Loss of Encoder Error in encoder pulse detection Encoder counter error Encoder LED is disconnected Encoder CRC checksum failure Axis Unsupported encoder linear or Type A Axis H Q Status Only a Stop Normal Stop Normal N A op Fast Q Fast Fast a i op Fast 9 Q Q t op Fast Unsupported encoder Type C Axis DSP Alarms Over current Detected Loss of Analog Feedback Over Acceleration Detected Axis Over Velocity Detected Axis KpVelFix Too Large Axis IntGainFix Too Large Alpha Calculation Overflow G S IntGainCur Calculation Overflow Axis Fast Fast op Fast op Fast Status Only Status Only Status Only Status Only 3 1464 Appendix Error Reporting A 5 ops Status Only KpCur Calculation Overflow pa Stop Fast_ FPGA Eror Detected Axis Table
300. odule Module Module Module Status Only Empty or Invalid Program requested Module Status Only AQ Move Command Position Out of Range Axis Status Only Status Only Status Only Status Only Too many programs requested in same PLC sweep Request Program 0 10 with multi axis program active Request two programs on same sweep with program active Request two programs for same axis lower number program executed Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Table A 1 Continued DSM302 Error Codes Error Number Response Description Error Type Hexadecimal Axis Move at Velocity Data greater than 8 388 607 user units sec Move at Velocity Data greater than 1 million cts sec error Program Execution Conditions Errors Execute Program while Home Cycle active Execute Program while Jog ta ta ta ta S S Execute Program while Move at Velocity Axis Execute Program while Force Digital Servo Velocity Axis Execute Program while Program Selected Execute Program while Abort All Moves bit set Execute Program while Position Valid not set Execute Program while Drive Enabled not set ta Status Only Execute Program with active Error Stop Axis Enabled off Program Synchronous Block Errors Status Only Sync Block Error during CMOVE Status Only Sync Block Error during Jump EEPROM Errors Status Only Flash EEPROM memory programming failure a M
301. of Acceleration or Deceleration In the following example a jump occurs during the final phase of deceleration at the dashed line The deceleration continues until constant velocity is reached and then the acceleration to the higher velocity begins Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C ACCEL 50000 VELOC 100000 BLOCK 1 JUMP CTLO1 3 CMOVE 500000 ABS SCURVE BLOCK 2 VELOC 60000 CMOVE 500000 INC SCURVE BLOCK 3 VELOC 85000 Pa t ACCEL 100000 econ CMOVE 250000 INC SCURVE V a45265a Figure 7 15 Jumping After the Midpoint of Acceleration or Deceleration S CURVE Jumps before the Midpoint of Acceleration or Deceleration If a jump takes place before the midpoint of acceleration or deceleration the result depends on whether the velocity at the jump destination is higher or lower than the velocity before the jump took place In the first case when accelerating but the new velocity is lower or decelerating and the new velocity is greater the DSM302 will immediately begin reducing the acceleration or deceleration to zero Once at zero velocity the DSM302 will use the jump destination acceleration and velocity and change to the new velocity Example 13 S CURVE Jumping Before the Midpoint of Acceleration or Deceleration In the following example during the acceleration of the first CMOVE a jump takes place at the first dashed line Because the velocity at the jump destinatio
302. ol Power Alarm The control voltage used to operate the low voltage circuitry in the amplifier is too low 1 a Series SVU type amplifiers will be shipped with default jumpers to use a single phase of the 220 VAC power to the amplifier Optionally the user may remove the jumpers and connect 220 VAC control power separately Check that a minimum 200VAC is available on terminals L1C and L2C for default installation or on connector CX3 Y Key for separate control power 2 Check the amplifier fuse If the fuse is open replace with a new fuse after checking control power voltage If the second fuse blows open replace the amplifier DBRLY Dynamic Brake Relay Failure This alarm indicates that the contacts of the braking relay are welded together Replace amplifier immediately IPML IPMM etc IPM Alarm The Intelligent Power Module IPM is the high current switching device in the amplifier The IPM can detect over current over heat or low voltage conditions in the power switching circuitry The suffix L M N etc indicates which axis is in alarm 1 Motor power wiring U V W may be shorted to ground or connected with improper phase connections Check the wiring and connections Check the servomotor for shorts to motor frame Replace the motor if shorted 2 Improper motor type code may be configured or excessive values for tuning parameters Confirm that the proper motor is configured and lower gain values 3 The amplifier mainten
303. ome Switch MUST transition at least 10 milliseconds before Motion Mate DSM302 for Series 901M 30 PLCs User s Manual December 2002 GFK 1464C 11 12 n the encoder reference point is encountered The physical location of Home Position can be adjusted by changing the Home Offset value with the configuration software Monitor servo performance and use the Jog Plus and Jog Minus Q bits to move the servomotor in each direction Placing the correct command code in the AQ table can temporarily modify the Position Loop Time Constant For most systems the Position Loop Time Constant can be reduced until some servo instability is noted then increased to a value approximately 50 higher Once the correct time constant is determined the DSM302 configuration should be updated using the configuration software Velocity Feedforward can also be set to a non zero value typically 90 100 for optimum servo response Refer to Tuning a GE Fanuc Digital Servo for information on setting the digital servo Velocity Loop Gain If Follower mode is used with an Incremental Quadrature Encoder confirm that Actual Position Aux Axis 3 represents the encoder position Make sure the desired Follower axis slave master ratio has been programmed as the A B ratio using the configuration software Digital Servo System Startup Troubleshooting Hints GFK 1464C The DSM302 requires PLC firmware release 6 50 or greater and Logicmaster 90 30 20 Micro softwa
304. on 2 11 2 18 Example Follower Combined with Jog 9 1 Example Follower Motion Changing the A B Ratio 8 7 Encoder and Internal Master Synchronization Following Encoder Axis 218 5 Following lude Inp 8 2 Following the Analog Input 8 4 Following the Internal Master Ratio Stepping 8 7 Sample A B Ratios Unidirectional Operation 8 8 Velocity Clamping Example Follower Motion Combined with Motion Program 9 5 Example Standard mode Changing the Acceleration Mode During a Profile 7 9 Combining PMOVEs and CMOVEs 7 8 Dwell Feedhold Feedrate Override 7 24 Hanging the Motion Mate DSM302 When the Distance Runs Out 7 9 Jump Followed b PMOVE 7 18 Jump Stop Jump Testing JUMP Without Stopping 7 Maximum Acceleration Time 7 Multiaxis Programming 7 24 _ Normal Stop before JUMP n Not Enough Distance to Reach Programmed Velocity 7 9 S Curve Jumping After the Midpoint of Acceleration or Deceleration 7 18 Index 3 Index Index 4 S Curve Jumping Before the Midpoint of Acceleration or Deceleration 7 19 S Curve Jumping to a Higher Velocity While Accelerating or Jumping to a Lower Velocity While Decelerating 17 20 Unconditional Jump Execute Motion Program 0 10 Q Discrete Command 5 12 External Input for Enabling the Follower 8 9 F FAX Back System 2 35 Fdback Mode Feedback Mod 4 19 Features of the DSM302 1 1 Easy to Use 1 2 High Perfor
305. on Parameters 4 2 Shield Ground Clamp 3 23 Shield Ground Connection 3 4 Signal Names Single phase Beta amplific Software Configuration Sources Master Specifications I Startup analog servo bs m D 14 14 troubleshoo s g LER 3 Status LED 3 2 Status Word T table of codes Stop Befor gt JUMP Normal Strobe 1 m osition AI Status Word 5 8 Subroutines Sync Out of 4 16 Synchronizin ig c NM the Internal 3 Master 8 9 System Troubleshooting Hints Terminal Board and Cable Connections Illustration of 3 19 Terminal Board Assemblies PEC ATA From DIN Rail to Panel Mounting Board Assemblies Servo Auxiliary Terminal Board 3 15 Terminal Board Pin Assignments Terminal Board Auxiliar Terminal Board Axis Terminal Boards 3 8 Terminal Strip Servo Amplifier Series 2 9 2 17 Terminology Definitions of Actual Position Actual Velocity 1 9 Commanded 221 Commanded Velo ity 1 9 Position Error 1 9 Testing Jump 7 14 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 Torque Limit I Status Bit 5 6 Trapezoidal velocity profile calculations 7 2 Triangular Velocity Profile Equations 7 30 Troubleshooting Hints System Tuning analog servo D 1 digital servo D LID response curves E Fanuc Digital Servo System D 1 Be 4 Tuning Dat Tuning Parameter 1 Data Tuning Dat2 Tuning Parameter 2 4 Tuning
306. on each connector The signal names associated with circuit OUT2 are Table 3 9 Signal Names Associated with OUT2 Connector TBC Output Signal OUT2P_A OUT2P B OUT2P C OUT2P D Output Signal OUT2M OUT2M OUT2M C OUT2M D I O Circuit Function and Pin Assignments The next three tables list the I O circuit functional assignments as well as the connector and terminal board pin assignments for each axis connector Although each connector has the same I O circuits the functional assignment of the I O circuits is axis dependent Table 3 10 Connector Axis Assignment and Function Axis Connector Number Axis Type Usage Closed Loop Servo Control and user I O B 2 Servo Axis Closed Loop Servo Control and user I O C 3 Aux Axis Master Position Feedback and auxiliary analog and digital I O 4 Aux Axis Auxiliary analog and digital GFK 1464C Chapter 3 Installing and Wiring the DSM302 3 23 Digital Servo Axis 1 2 Circuit and Pin Assignments This table identifies all circuits and pin assignments for Digital Servo Axis and Digital Servo Axis 2 The shaded areas indicate signals which are cabled to the servo amplifier and are not available for user connections Table 3 11 Circuit and Pin Assignments for Digital Servo Axis 1 and Digital Servo Axis 2 Circuit Identifier Circuit Type Single ended differential 5v inputs Single ended 5v in Single ended 5v inputs o
307. on of 30 000 user units to point B axis 2 could then start and still clear the obstacle The program segment could be programmed as follows BLOCK 10 CMOVE 30000 INC AXIS 1 BLOCK 20 SYNC PMOVE 50000 INC AXIS 1 PMOVE 120000 INC AXIS 2 When BLOCK 10 is executed axis 1 begins its 30 000 unit move while axis 2 pauses When the axis 1 move completes two things occur axis 1 begins the 50 000 unit PMOVE commanded in BLOCK 20 SYNC without stopping because the first move was a CMOVE and axis 2 begins its 120 000 unit move In the figure below the axis 1 first move transfers the part from point A to point B At point B axis 1 continues moving performing its second move and axis 2 begins its move bringing the part to point D Axis 1 completes its second move at point D and stops however axis 2 continues and moves the part to point E Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C a45271 0 AXIS 2 120 000 30 00 000 B OBSTACLE Move 1 AXIS1 ol A Figure 7 21 Multiaxis Programming Example If this program segment is not at the beginning of a program and for some reason axis 2 has not yet reached Block 20 when axis 1 has moved 30 000 counts an error would occur Axis 1 would continue to 80 000 counts and the DSM302 would report a Block Sync Error during a CMOVE in the Status Code If it is imperative that the axes synchronize at Block 20 changing Block 10 to a PMOVE woul
308. on the front of the amplifier provide a visual cue to the status of the system by indicating for example when the motor and amplifier are ready to function The ALM LED is turned ON when an alarm condition is detected When an alarm is detected power is dropped and the motor is stopped by dynamic braking action Alarm information is generated in the B Series Servo Amplifier and sent to the attached motion controller The following alarm conditions are generated in the B Series Servo Amplifier e Overvoltage DC link voltage is too high a larger regeneration resistor needed or AC main voltage too high e Undervoltage DC link voltage is too low or loss of AC supply Appendix G Answers to Frequently Asked Questions G 3 e Regen Resistor Overheat Average regenerative discharge energy is excessive reduce load cycle rate or acceleration speed e Over Heat Amplifier temperature is too high reduce load cycle rate or ambient temperature e Fan Failure Internal fan failed or jammed e Overcurrent DC link current is excessive reduce load or accel decel rates Which B motors can you run faster than rated speed and how much faster The High Response Vector Function HRV allows improved torque at higher speeds in the intermittent operating area For servos less than 9 Nm continuous the intermittent torque operating velocity range can be extended approximately 1000 RPM The continuous operating torque and velocity specification curve rema
309. oop and forces a velocity command to the digital servo for tuning purposes Acceleration control is not used and changes in velocity take effect immediately A Force Digital Servo Velocity command value of 4095 will produce a motor velocity of 4 095 RPM and 4095 will produce a motor velocity of 4 095 RPM depending on individual motor maximum velocities The digital servo control loops may limit actual motor speed to a lower value Care should be taken not to operate a servomotor past the rated duty cycle The Enable Drive Q bit must be active with no other motion commanded for the Force Digital Servo Velocity command to operate The command must remain continuously in the AQ data for proper operation When a Force Digital Servo Velocity command is active for a given axis any other AQ immediate command for that axis will remove the Force Digital Servo Velocity data and halt the servo Chapter 6 Non Programmed Motion also contains information on Force Digital Servo Velocity Select Return Data This command allows alternate data to be reported in the User Selected Data 1 location for each axis The alternate data includes information such as Parameter memory contents and the DSM302 Firmware Revision The Select Return Data command uses a mode selection and an offset selection The mode selection byte offset 1 of the six byte command determines the Return Data type The offset selection byte offsets 2 3 of six byte command sel
310. op must long enough to allow the Jn Zone lI bit to turn ON before the next move begin A PMOVE uses the most recently programmed velocity and acceleration If a VELOC command has not been encountered in the motion program the Jog Velocity is used as default If an ACCEL command has not been encountered in the motion program the Jog Acceleration is used as default Continuous Move CMOVE A CMOVE does not stop when completed unless it is followed by a DWELL or a WAIT the next programmed velocity is zero or it is the last program command It does not wait for Jn Zone 1 bit to turn ON before going to the next move A normal CMOVE is a command that reaches its programmed position at the same time that it reaches the velocity of the following Move command A CMOVE uses the most recently programmed velocity and acceleration If a VELOC command has not been encountered in the motion program the Jog Velocity is used as default If an ACCEL command has not been encountered in the motion program the Jog Acceleration is used as default A special form of the CMOVE command can be used to force the DSM302 to reach the programmed CMOVE position before starting the velocity change associated with the next move command that is execute the entire CMOVE command at a constant velocity Programming an incremental CMOVE command with an operand of 0 CMOVE INC 0 will force a delay in the servo velocity change for the next move command in sequence
311. oper operation When a Force Analog Output command is active for a given axis any other AQ immediate command for that axis will remove the Force Analog command and turn off the associated analog output Position Increment With Position Update User units This command is similar to the Position Increment Without Position Update command 21h except that Actual Position and Commanded Position returned in AI data are both updated by the increment value If the servo is enabled the DSM302 will immediately move the axis by the increment value Position Increments can be used to make minor machine position corrections to compensate for changing actual conditions See Chapter 6 Non Programmed Motion for more information on Position Increment Commands with the DSM302 In Position Zone This command can be used to set the active In Position Zone to a value different than the configured value The DSM302 compares In Position Zone to the Position Error in order to control the Jn Zone 1 bit When the Moving l bit is OFF and Position Error is In Position Zone the In Zone l bit is ON If the DSM302 is power cycled or the PLC CPU is reset for any reason the value set by this command will be lost and the Jn Position zone value set by configuration software will be reinstated Chapter 5 Motion Mate DSM302 to PLC Interface 5 19 4 09 4 10 Move Command This command will produce a single move profile that will move the axis to the po
312. os 10volt Velocity Command analog output Home and overtravel switch inputs for each Servo Axis Two Position Capture Strobe Inputs for each Position Feedback Input 5v 24v and analog I O for use by PLC Incremental Quadrature Encoder input on each axis for Encoder Analog mode Incremental Quadrature Encoder input for Follower Master axis 13 bit Analog Output can be controlled by PLC or used as Digital Servo Tuning monitor Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 1 Motion System Overview The DSM302 is an intelligent fully programmable motion control option module for the Series 90 30 Programmable Logic Controller PLC The DSM302 allows a PLC user to combine high performance motion control with PLC logic solving functions in one integrated system The figure below illustrates the hardware and software used to set up and operate a servo system This section will discuss briefly each system element to provide an overall understanding of system operation OPERATOR o INTERFACES gt O Th MACHINE 1 PS C D JDRIVE 1 o P S U M eS L Im ENCODER 1 MACHINE 2 IDRIVE 2 Bs RENE Ley Iu LOGICMAST
313. os that are unable to support these additional axes For Series 90 30 applications it may not be cost effective on low axis count applications especially with the advent of the less expensive Motion Mate DSM Below a five axis application the Motion Mate DSM with Series servos is a more cost effective solution When using the B Servo with I O LINK with a Series 90 30 PLC the amount of available I O in the PLC must be considered 128 discrete inputs 1 and 128 discrete outputs 0 are required for each amplifier The Discrete Command Interface protocol must be used to configure and the load the configuration parameters to the amplifier The Series 90 30 PLC I O LINK Master Module can only be configured with 1 Q discrete inputs and outputs or AI AQ analog inputs and outputs word format When sufficient I and Q data types are not available on the PLC using AQ to download some of the bit formatted discrete configuration parameters or commands can be difficult Accessing individual BMI control and status bits in a word can also be a ladder programmers nightmare Staying with discrete I O points may require a more powerful CPU eliminating any price benefit over the DSM B servo option Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Coupled with a CNC and the Power Motion Manager software package is where the D Series Servo with I O LINK is most effective It may be used as a tool changer or
314. other simple auxiliary axis requiring simple positioning There already exists parameter settings and information for tool turret configuration What is a serial encoder A serial encoder transmits positional information from the encoder to the motion control every 250 microseconds It provides velocity position and commutation feedback All digital GE Fanuc motion controllers have a built in serial interface for decoding this positional information Some benefits of the serial encoder are Higher data rates than quadrature encoder e Serial messages are not affected by capacitance degradation in the cable which may distort an signals e Supports high resolution at high speed and is not limited by the upper data rate limitations of quadrature encoders Higher resolution than a resolver Serial encoders provide a fixed message count per time period Battery backed absolute positioning option available Increased distance from signal source to the encoder Motion Mate Controls What is the difference between coordinated and non coordinated moves What is interpolation Motion types can be classified into various categories e Simple control of position or velocity of a single axis or non synchronized multiple axes There may be multiple moves taking place however there is no point to point positional relation between any of the axes These independent moves constitute the simplest of motion requirements Any axis that uses accelerat
315. ounts per second Although the Logicmaster 90 default is 0 when the DSM302 detects the default of zero it internally sets the value to be equal to 32 000 Default 0 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Program Zero For additional details concerning the operation of DSM302 Configuration or Programming software packages please consult the appropriate User Manuals for those particular software products See Related Publications in the Preface of this Manual Program Zero is a short default motion program 20 commands maximum in Standard mode 9 commands maximum in Follower mode which is defined in the Logicmaster 90 30 configuration software and downloaded to the DSM302 whenever the module is initialized by the PLC Program Zero is programmed by entering motion commands in an English language text format similar to that of the MS DOS based APM Motion Programmer software used for Programs 1 10 One main difference is that sub routines are not allowed in Program Zero The DSM302 determines whether Program Zero is an axis 1 axis 2 or multi axis program according to which axis or axes are used in the program For example if all Program Zero commands contain Axis number 1 Program Zero will be classified as a single axis program for Axis 1 Therefore Program Zero will be allowed to execute concurrently with another single axis program 1 10 for Axis 2 A multi axis program 0 requires that both axes
316. out of tolerance 3 The regeneration resistor may not be capable of dissipating excess generated voltage Review the calculations for selecting the regenerative discharge unit and replace with a resistor of higher wattage rating as needed Reducing acceleration values and position loop gains larger value Position Loop Time Constant will additionally reduce regenerated voltage levels LVDC Low Voltage DC Link This alarm occurs if the high voltage DC level DC LINK voltage is abnormally low 1 The AC voltage supplied to the amplifier may be missing or lower in value than the rated input voltage The B Series amplifier three phase supply voltage should be between 200 VAC to 240 VAC Verify that the proper level of AC voltage is supplied to the line input L1 L2 and L3 connections of the amplifier DCOH or DCSW Regeneration Alarm The DCOH alarm occurs if the temperature of the regeneration resistors is too high The DCSW alarm indicates problems in the switching portion of the regeneration circuitry 1 Ifthe external regeneration resistor is not used check that the temperature sensor input to the amplifier is shorted or jumped The Series amplifier jumper T604 should be installed on connector CX11 6 2 The external regeneration resistor may be wired incorrectly Carefully check the connections of the regeneration resistor to the amplifier Check that the resistance of the regeneration resistor temperature sensor is near zero ohms at
317. ove commands Actual Position and Actual Velocity AI return data reflect the combination of the master input and the move commands In other words counts coming from the master source affect only the Actual Position and Actual Velocity If there are no internally generated move commands the Commanded Velocity will be 0 and the Program Command Position will not change Table 9 1 Command Input Effect on Position Registers COMMAND Follower Input Enabled 7 Registers Affected by input Enabled Follower Registers Affected by input Master Commands None affected from selected Master source Actual Position AI status word is updated Commanded Position AI status word is updated Actual Position Position Error Program Command Position is Not affected Actual Velocity AI status word is updated Commanded Velocity status word is Not affected Program Commands Actual Position AI status word is updated Commanded Position AI status word is updated Actual Position Position Error Program Command Position is updated Actual Velocity AI status word is updated Commanded Velocity AI status word is updated by Program commanded velocity only Actual Position AI status word is updated by Program command Master command Commanded Position AI status word is updated Actual Position Position Error Program Command Position is updated by Program command only Actual Velocity AI status word is updated b
318. pproach to tuning the control loops is to tune the inner control loops first In this example the inner control loop that requires tuning is the velocity loop As shown in the figure below the position loop is the outer loop and sends velocity commands to the velocity loop Position Velocity Torque Command Command Command M Torque Path Position Velocity Flux Servo Mot Planning Control Control Amp id Controller A A 1 ES Position to Encoder Velocity Interface Figure D 1 Control Loops Block Diagram Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C n Tuning the Velocity Loop The proper method to tune the velocity loop is to separate the velocity loop from the position loop To achieve this separation a method must be used to directly send velocity commands without using the position loop control The DSM module has several modes that will allow the user to send a velocity command directly to the velocity loop Two methods are as follows Method 1 The Force Digital Servo Velocity AQ immediate command 34h will send a velocity command directly to the velocity loop This command is different from the Move at Velocity Command which uses the position loop to generate the command This is important since we do not want the position loop interacting with th
319. pter 3 for 04h Connector D Terminal Board connections Signal Codes The following table lists the Signal Codes Note that some signals have a default output while others do not The Select Analog Output Mode command lets you 1 re route two of the signals that have a default output the AQ Force Analog Output data signal cannot be re routed 2 gain access to signals lacking a default output and 3 restore signals to their default outputs Signal Code Signal Description Default Output to 00 decimal AQ Force Analog Output data Connector C or D 10 decimal Servo Axis Torque Command None 15 decimal Servo Axis Actual Velocity Connector A 20 decimal Servo Axis 2 Torque Command None 25 decimal Servo Axis 2 Actual Velocity Connector B Cannot be re routed This signal code can only be used to restore this signal back to its default output Example To select Servo Axis 1 Torque Command as the Analog Output on Connector D place the following data in the AQ immediate command words Word 2 Word 1 Word 0 Byte 5 and Byte 4 Byte3 and Byte2 Byte 1 and Byte 0 00000 00010 0447h Lote Signal Code 10 Target Connector Select Analog Output Mode Code 04h Command Code 47h GFK 1464C Chapter 5 Motion Mate DSM302 to PLC Interface 5 25 4 26 4 27 Clear New Configuration Received This command clears the New Configuration Received I bit Once cleared the Configuration Complete bit is only set
320. pter 8 Follower Motion 8 17 Follower Control Loop Block Diagram CTLO1 CTL16 Q ENABLE FOLLOWER Extra Master input for Axis 1 only FOLLOWER ENABLED Y 1 AXIS FOLLOWER CONTROL LOOP ENABLE IN VEL Axis 1 loop is shown o RCT PORN Axis 2 loop is identical eee wl T 4 L VELOCITY POSITION VEL POSN LOOP LOOP GAIN FF P EGAN TIME CONSTANT ve SERVO VELOCITY CMD SELECTED BY CFG 4 O O 4 O RAMP TIMEBASE ENE EN ei Mak Ed CTL ANALOG INPUT SCALING MASTER ACT POSN REGISTER O O Q SELECT TRACKI A x INT MASTER RATIO l ACCUMULATOR B AB INTERNAL MASTER VELOCITY GENERATOR xB COMMEND Ps GENERATOR 1 per DSM302 MOVE POSN ERROR 1 per Servo Axis VEL FB COUNTS GE Master Axis functions inside this outline SoS SSeS See eS Se a See tr MOTION PROGRAMS PGM CMD y ACT POSN __FB COUNTS SAMPLE POSITION veLocmv REGISTER v POSN ERROR NOTE POSITION FB COUNTS IN FOLLOWER MODE SERVO AXIS 1 MOTION ERROR MASTER CTS x A B CMD GENERATOR CTS IN ZONE DETECTION IN ZONE i SERVO AMPLIFIER Figure 8 20 Axis Follower Control Loop Block Diagram 8 18 Motion Mate DSM302 for Serie
321. ptically Isolated eene 3 44 Optically Isolated Enable Relay 1 121 412 420000000 000000000 000000000054 3 45 Single Ended 10v Analog Output esssssseeeeeeeenenenen enn 3 47 o P CORR ND TE E OE C rie EC ERU TERR 3 48 Configuring th 5 02 9 f L Rack Slot Configuration 4 1 Mod le Conti guration rc 4 2 Setting the Configuration 204100120240404060000000000000000000000000000004 4 2 Module Configuration Data eant e eR 4 2 Serial Communications Port Configuration Data sss 4 7 Axis Configuration Data ate e Ee RENE I TRIN PAESE 4 9 Tuning Parameters ore co ee RR suse tev HIS PEERS AE PEEL EVER e ols 4 20 Progra ZrO ees M 4 25 Logicmaster Program Zero Programmer Instruction Format suus 4 26 Program Zero Motion Command Descriptions 2 0 240 11000000000000005003 4 28 Motion Mate DSM302 to PLC 1 1 1 9 1 Section 1 I Status Bits eee eese eee eee eese sensns nee eeeeeeeessssss sese eeeees 9
322. r 3 Installing and Wiring the Motion Mate DSM302 for more information concerning the cables and terminal blocks used with the DSM302 module Chapter 1 Product Overview 1 7 Section 2 Overview of Product Operations The DSM302 module may be operated in one of two modes Standard Mode In Digital Standard mode the module provides closed loop position and velocity control for one or two servomotors In Analog Standard mode the module provides closed loop position control only for one or two servomotors Note that when used with analog servos velocity control is performed in the analog servo amplifier not in the DSM module For both digital and analog applications user programming units can be adjusted by configuring the ratio of User Units and Feedback Counts configuration parameters Jog Move at Velocity and Execute Motion Program commands allow Standard mode to be used in a wide variety of positioning applications Follower Mode In Digital Follower mode the module provides closed loop position and velocity control for one or two servomotors In Analog Follower mode the module provides only closed loop position control for one or two servomotors Note that when the DSM is used with analog servos velocity control is performed in the analog servo amplifier not in the DSM module In both digital and analog applications the module provides most of the same features as Standard mode with the exception of a configurable User Un
323. r Axis Ramp Control sss H 2 Problems Resolved by Firmware Release 1 30 sene H 3 AQ Command 30h Causes Module to H 3 IPI for Release 1 20 Contained Inaccurate Encoder Position Resolution Data H 3 Turn off CONFIG LED when Flashing Error 2 2 2 2 2222 H 3 Jog Vel User Units Counts Configuration Value Causes Module to Crash H 3 Follower Deceleration Ramp Reentry after Drive H 3 Contents xi Contents Birmware Release 1 20 45 cde nete t eee the H 4 Features Introduced in Release 1 20 4 4 12 02020000040060 000 000000000004 H 4 Expanded Follower H 4 Enhanced Position Loop Resolution sess H 4 Problems Resolved by Firmware Release 1 20 H 5 Input INA C Does Not Function As H 5 Firmware Reports D6 Error Sporadically during Normal Operation H 5 Documentation Issues in D M302 for IC693 PLCs User s Manual Resolved by Revision A Release eee iiie H 5 Firmware Release 1 10 iue eS de d ridge ege eed H 6 Features Introduced in Firmware Release 1 10 sse H 6 ELVOMOLOESu eie et tds 6 Set Aux Axis 3 Position Command
324. r Units per revolution of spur gear Thus the User Units to Counts ratio is 45 038 160 000 0 2815 or about 1 3 6 which is within the valid ratio range So a 45 038 160 000 ratio would be used except that 160 000 is larger than the maximum 65 535 range value Dividing both numbers by 10 solves this to make the ratio 4 504 16 000 Note that in the above example we simply reduced the fraction and ignored the slight rounding error One method of avoiding rounding is to express the numeric ratio as a fraction From the previous example any number set that produced a 0 2815 ratio could be used An example is 2815 10000 Another approach is to rationalize the fraction reduce it to its lowest terms This is done by evenly dividing both the numerator and denominator by successively smaller prime numbers beginning with the largest prime that will evenly divide into both the numerator and the denominator until no more division without remainders is possible Always maintain an exact integer fraction a decimal ratio expressed as a fraction or a rationalized fraction when configuring the User Units to Counts ratio for the best accuracy The user must determine if the rounding error if present is of significance A rotary mode application that always operates in one direction will accumulate rounding errors over time and drift A linear application will only accumulate error for the length of travel then rewind as the axis re
325. r Velocity Configuration Data in Counts per Revolution Revolutions per Minute Default Setting Some motors are restricted to a lower maximum rpm rating Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Problems Resolved by Firmware Release 1 20 Input IN4_C Does Not Function As Described The on off state of the INA C input see GFK 1464 DSM302 for C693 PLCs User s Manual chapter 5 DSM302 to PLC Interface for details was inverted from what was documented This was corrected in firmware version 1 20 such that the on off state of the input matches the documentation Firmware Reports D6 Error Sporadically during Normal Operation Previous firmware contains an error that causes a D6 error to be reported incorrectly during normal operation The nature of the firmware error also causes errors D3 D9 to be reported incorrectly These firmware errors were fixed in version 1 20 Documentation Issues in DSM302 for IC693 PLCs User s Manual Resolved by Revision A Release The following table outlines the previously identified documentation issues that have been resolved by the revision A release of GFK 1464 DSM302 for IC693 PLCs User s Manual Issues Resolved by Revision A of GFK 1464 Documentation Issue Description Resolution PCR Connectors Chapter 2 Two different connector pin configurations for the emergency stop JX5 Mislabeled in Pin connector on the Series servo amplifier wer
326. r Zone length Counts Specifies the initial movement zone length for the follower winder motion Refer to Chapter 8 for additional details of Winder operation Default 10000 Enc3 Hi Lim ENC3 Aux Axis 3 High Count Limit Counts The maximum position which the Aux Axis 3 encoder will reach before the Actual Position AI register rolls over to the value set in the Low Limit parameter Default 8 388 607 Enc3 Lo Lim ENC3 Aux Axis 3 Low Count Limit Counts The minimum position which the Aux Axis 3 encoder will reach before the Actual Position AI register rolls over to the value in the High Limit parameter Default 8 388608 Master Home Position Aux Axis 3 Home Position Counts The position to which Aux Axis 3 Actual Position 1s set at the completion of an Aux Axis 3 Find Home Cycle Default 0 Master Home Switch Aux Axis 3 Home Switch Enable Determines whether the Aux Axis 3 Home Switch is monitored during the Aux Axis 3 Find Home Cycle ENABLED means the Home Switch input must be on for the Home Cycle to recognize the encoder marker pulse DISABLED means the Home Switch input is ignored and the Aux Axis 3 Home Cycle will set Actual Position equal to Home Position when the first marker pulse occurs after the Find Home Q bit command Default ENABLED Anlg Max Vel Analog Input Maximum Velocity Counts second The follower master velocity that will be produced by 10 00V on the Analog Input 0V always produces a velocity of 0 C
327. ration parameters in the DSM302 These values are used whenever a Jog Plus or Jog Minus Q bit is turned ON Note that if both bits are ON simultaneously no motion is generated The Jog Acceleration and Jog Acceleration Mode are also used during a Find Home cycle and when a Move at Velocity immediate command is performed Programmed motions use the Jog Velocity and Jog Acceleration as defaults A Jog Plus Minus Q command can be performed when no other motion is commanded or while programmed motion is temporarily halted due to a Feed Hold Q command The Enable Drive Q bit does not need to be ON to jog but it can be ON Turning on a Jog Plus Minus bit will automatically close the Enable Relay and turn on the Drive Enabled 1 bit When an overtravel limit switch is OFF Jog Plus Minus and Clear Error Q bits may be turned on simultaneously to move away from the open limit switch Thus a Jog Plus Q command will not work while the positive end of travel switch is open and Jog Minus will not work while the negative end of travel switch is open Move at Velocity Command GFK 1464C A Move at Velocity command is generated by placing the value 22h in the first word of data assigned to an axis The second and third words together represent a signed 32 bit velocity Note that the third word is the most significant word of the velocity Once the command is given the AQ data can be cleared by sending a NULL command or changed as
328. ration up to the speed insuring the minimum possible distance correction time The velocity profile for such case is shown on the figure 8 12 Follower Make up Disabled distance make up time l s Velocity Time Figure 8 12 Follower Ramp Up Ramp Down Cycle Case 2 with make up time too small During the ramp phase of the distance correction the velocity limit is controlled If calculated velocity is too high then the velocity is clamped and warning error code is set in the point C of the trajectory Figure 8 13 shows the velocity profile during the follower ramp cycle for this case Constant velocity max 0 8 Follower Disabled Velocity make up time i Time Figure 8 13 Follower Ramp Up Ramp Down Cycle case with active velocity limit If the acceleration time sector BC of the trajectory in figure 8 13 exceeds 128 seconds then another warning error will be reported In this case the distance also will be corrected accurately 8 12 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Follower Winder Introduction The Follower Winder feature is a Traverse or Spool Winder and can be thought of as an electronic fishing reel With this feature selected the slave axis will follow within a specified distance zone and then at the end of the zone reverse direction and traverse the distance in reverse This cyc
329. rd for each axis Text has been corrected Wrong Graphic Used for Chapter 7 Figure showed an expected velocity profile for a program example Velocity Profile Figure 7 6 describing hanging the DSM302 when distance runs out The incorrect graphic that was included has been replaced with the correct one Error Code 35 Not Appendix Axis status error code 35 was not documented This error is now correctly Documented B described as a find home while follower enabled error Wire Size Screw Torque Appendix The wire size screw torque and MOV descriptions for terminal block and MOVs for Terminal assemblies IC693ACC335 and IC693ACC336 were not specified These Blocks Not Specified descriptions have been added GFK 1464C Appendix H DSM302 Revision History H 5 Firmware Release 1 10 Features Introduced in Firmware Release 1 10 HV Motors Support for the following three HV motors was added in firmware release 1 10 Motor Model Motor Type Code 12 3000 3 022HV 3000 3000 5 Set Aux Axis 3 Position Command Enhancement The Set Aux Axis 3 Position command was enhanced to execute regardless of the axis current velocity In firmware version 1 00 the command would be ignored and a 0X52 axis status error reported if the axis velocity exceeded 128 counts per second Problems Resolved by Firmware Release 1 10 Encoder 3 Home Position During a Find Home cycle on the Aux 3 axis the Encoder 3 home pos
330. re essere 1 6 Motion Programming Software sess 1 6 APM Motion Programming Software 5 5 1 6 Operator Interfaces eee eter 1 7 Servo Drive and Machine Interfaces 1 1 4 1 00 02220 000 1 7 Section 2 Overview of Product 8 0 2 1 8 Standard Mode ui i abeo Ee Ese Pi deb dee nea ees 1 8 Follower Mode td Ra TE fee eres 1 8 Standard Mode 1 9 Follower Mode Operation sss ener enne nnns 1 10 Section 3 a Series Servos Digital Mode 1 11 Series Integrated Digital Amplifier 5 1 4 122412122 0 00400000 0000 000000004 1 11 Series FANUC Servo Motors ccccccesccesscescesseeeseeeseecacecseecssensecsseeeeeeseeessneneneenaes 1 12 Section 4 Series Servos Digital 1 13 B Series Digital uis e et ete be esie de ec re i dein 1 13 B Series FANUC Servo Motors te s ace Lt Siete eden eae t diede Roda 1 14 Section 5 SL Series Servos Analog 0 42 1 15 Getting SCA ted 2 1 Section 1 Unpacking the Systeitt c s 0scessssssssesosssssonssstevenssuvesderenssensncesecsseos 2 3 Unpacking the DSMS302 eee
331. re are also two high speed 250 us strobe inputs which capture the current axis position into separate registers These can be used to support feed to registration mark applications for measuring distance between events The general purpose outputs CTL9 CTL10 CTL11 and CTL12 are also available for each axis The new DSM hardware platform has the flexibility to increase the per axis I O in future releases Are the I O tables for the DSM302 consistent with the APM300 and MCS300 Series The following table compares the I O table sizes of the three modules Data Type DSM300 APM301 MCS301 APM302 MCS302 64 32 32 l bits Q bits 64 words 40 50 64 AQ words 6 9 12 The AI lengths can be set during configuration to one of three sizes The 40 6 default length contains all data for a two axis STANDARD mode configuration The next 10 AI words contain additional information useful for FOLLOWER mode The last 14 AI words enable access to additional module analog inputs and outputs Since the Logicmaster software tends to Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C concatenate memory space for devices during the PLC system configuration it is unlikely that most applications will be able to accommodate the larger tables without some changing of I O references Because of this a decision was made to alter the order within each table to provide a logical grouping of I O on
332. re release 8 02 or greater The default DSM302 configuration for the Overtravel Limit Switch inputs is ENABLED Therefore 24 vdc must be applied to the Overtravel inputs or the DSM302 will not operate If Overtravel inputs are not used the DSM302 configuration should be set to Overtravel Limit Switch inputs DISABLED If the Axis Enabled 1 bit is OFF the axis will not respond to any bits or AQ commands When a servomotor is not used with a Servo Axis the Motor Type must be set to 0 or Axis Enabled will stay OFF A Motor Type of 0 disables the axis servo loop processing and sets Axis Enabled ON allowing the axis to accept commands such as Load Parameter Immediate and Set Analog Output Mode The Enable Drive Q control bit must be set continuously to ON or no motion other than Jogs will be allowed If no STOP errors have occurred the Drive Enabled 9 I status bit will mirror the state of the Enable Drive Q bit A STOP error will turn off Drive Enabled even though Enable Drive is still ON The error condition must be corrected and the Clear Error Q control bit turned ON for one PLC sweep to re enable the drive If the Module Error Present 1 status bit is ON and the Axis Enabled and Drive Enabled status bits are OFF then a STOP error has occurred Status LED flashing fast In this state the Servo Axis will not respond to any bits or commands other than the Clear Error Q bit The Clear Error Q control bit uses one sho
333. reated edited with version 1 50 or higher of the Motion Mate APM300 Series DOS Motion Programmer software Program 0 does not support subroutines the APM Motion Programming Software supports up to 40 subroutines What units do we program for velocity accel distance etc Both the Motion Mate APM300 and DSM300 Series allow for user scaling of programming units user units Both controls operate with user units position units user units sec velocity units user units sec sec acceleration units Logicmaster configuration software allows each of the controls to be configured with user define units for position velocity and acceleration The relationship between user units and encoder feedback counts is set by the User Units and Counts configuration values The range of User Units and Counts is 1 65535 The RATIO of User Units Counts must be from 8 1 to 1 32 The default scaling is 1 User Unit 1 Count What is the maximum number DSM axes per 90 30 CPU 1 The Standard Mode of the DSM302 requires 40 AI references per 2 axes The Follower Mode of the DSM302 requires 50 AI references per 2 axes 64 Q and 64 94I references per module The power supply requirement for DSM302 is 800 ma 5 Vdc The DSM302 installs in 1 I O slot location The DSM302 requires Logicmaster 8 02 or later for configuration The DSM will be supported in future releases of CIMPLICITY Control 7 DSM302 functions with all Series 90 30 CPU models releas
334. refer to Sections 2 10 and 4 21 of Chapter 5 for more information on the User Selected Data word and the Select Return Data command respectively Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Operation of the Communications Request The figure below illustrates the flow of information from the PLC CPU to the DSM module DSM PLC CPU MODULE 44917 BACKPLANE LADDER PROGRAM e COMREQ FIRMWARE INSTRUCTIONS MEMORY MEMORY e DATA e STATUS WORD Figure B 2 Operation of the DSM Communications Request A Communications Request is initiated when a COMM ladder instruction is activated during the PLC scan At this time details of the Communications Request consisting of command and parameter data are sent from the PLC CPU to the DSM module The command data notifies the DSM that parameter data is to be sent and directs the DSM to place the data into specified parameter memory locations The order in which these instructions are sent is critical so the Command Block should be programmed exactly as instructed later in this chapter In the figure above the DSM module is shown in the CPU rack and communications occur over the PLC backplane If the DSM module is located in an expansion or remote rack the commands and data are sent over the CPU rack s backplane through the expansion or remote cable to the rack containing the DSM module and across that rack s backplane to the DSM
335. rmance BANDWIDTH is a figure of merit used to compare control system or mechanical performance As the frequency of command increases the system response will begin to lag The bandwidth is defined as the frequency range over which system response gain is at least 70 3 decibels of the desired command High Bandwidth e Allows the servo to more accurately reproduce the desired motion e Allows accurate following of sharp corners in motion paths and high machine cycle rates e Rejects torque disturbances from mechanics or outside influences improving system accuracy Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C n e expose machine resonance which occur at frequencies near or below the bandwidth The response of a proportional only system which is what we set up by setting ntegrator Mode to OFF is an exponential rise A time constant for an exponential curve represents 68 of the remaining rise For instance starting at zero velocity the response of the position loop to a change in command will require one time constant to reach 68 of the commanded velocity The second time constant will reduce 68 of the remaining command Subsequent time constants will reduce 68 of remaining command For example 100 68 one time constant 32 32 68 21 8 68 first time constant 21 8 second time constant 89 8 We see that two time constants eliminate 89 8 of the command
336. rocessor is in the different Motion Mate controllers The Motion Mate APM300 Series uses the NEC 25 8 448 MHz while the Motion Mate DSM302 uses the Intel 386EX 25 MHz and an Analog Devices DSP Can the Motion Mate controls interface to motors from another manufacturer The Motion Mate APM300 Series position controller provides a standard 10V analog velocity command interface to servos and drives of the customer s choice while the Motion Mate D5M302 Releases through 1 30 deliver a single vendor solution to the GE Fanuc digital servos Release 1 40 of the DSM302 also provides a standard 10V analog velocity command interface to servos and drives of the customer s choice Will the MCS300 Former Power Mate J Series become obsolete Yes The Motion Mate DSM302 supports all of the features presently included in the MCS300 Series at a lower price and power consumption When do I need to buy the APM Motion Programmer Software and when can I use program 0 Program 0 is a short default motion program 20 commands maximum in Standard mode 9 commands maximum in Follower mode which is defined in the Logicmaster 90 30 configuration software version 8 02 or higher and downloaded to the DSM302 when the module is initialized by the PLC Program 0 is created by entering motion commands in an English language text format Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Motion programs 1 10 must be c
337. rogram execution jumps to the destination BLOCK if the bit is OFF the program continues executing the command after the JUMP Note that the Type 3 command after the conditional jump and at the jump destination will affect jump behavior Conditional JUMP commands should not be used with multiaxis programs containing sync blocks unless the Jump is triggered while both axes are testing the same JUMP command Failure to follow this recommendation can result in unpredictable operation Conditional Jump testing starts when the next PMOVE CMOVE DWELL WAIT or END Program command following a Conditional JUMP becomes active When Conditional Jump testing 1s active the designated CTL bit 1s tested once every 2 milliseconds Conditional Jump testing ends when the designated CTL bit turns ON Jump Trigger occurs or when a new Block Number becomes active If more than one Conditional JUMP is programmed without an intervening PMOVE CMOVE DWELL WAIT or END Program command only the last Conditional JUMP will be recognized In summary a Conditional JUMP transfers control to a new program block on the basis of one of the external CTL input bits turning ON Tests for CTL bit status can be carried out once or continuously during the following Type 3 command if it is in the same program block Multiple conditional jumps are not supported within the same program block Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 14
338. ront panel display on each amplifier for any errors If an amplifier indicates a fault it may be necessary to completely remove power from the amplifiers and the PLC and repeat the power on sequence described in Section 3 Assuming no errors are present you should be able to jog the attached axes For the startup configuration previously described to clear any error indicated by the DSM302 s STAT LED blinking toggle on then off the Clear Error Q bit Q0001 in the PLC data table Conditions that continue to cause an error must be corrected in order to clear the status indicator Refer to Appendix A Error Codes for Error Status information Chapter 2 Getting Started 2 29 Jogging With the Motion Mate DSM302 Section 6 Alarms The Jog Velocity Jog Acceleration and Jog Acceleration Mode are configurable in the DSM302 module These values are used whenever a Jog Plus or Jog Minus Q bit is turned ON Note that if both Jog bits are ON no motion is generated Default jog values were set during configuration A Jog can be performed when no other motion is commanded The Enable Drive Q bit does not need to be ON to Jog Turning on a Jog Q bit will automatically turn on or enable the servo You should hear the amplifier enable and the motor will have torque on the shaft Conversely the drive will automatically disable when the jog bit is released and completed To jog the axis in the positive direction toggle ON 00021 for axi
339. room temperature Replace the regeneration resistor 1f the temperature sensor indicates an open condition 3 The regeneration resistor may not be capable of dissipating excess generated voltage Review the calculations for selecting the regenerative discharge unit and replace with a resistor of higher wattage rating as needed Reducing acceleration values and position loop gains larger value Position Loop Time Constant will additionally reduce regenerated voltage levels OH Over heat Alarm The temperature of the amplifier heat sink is too high or motor temperature is excessive 1 Ambient temperature may be too high consider a cooling fan for the servomotor GE Fanuc supplies fan kits for most FANUC motors 2 The motor may be operating in violation of duty cycle restrictions Calculate the amount of cooling time needed based on the duty cycle curves published for the particular motor 3 The motor may be over loaded Check for excessive friction or binding in the machine For all the above problems allow ten minutes cooling of the amplifier with minimum or no motor loading then cycle amplifier power to reset FAL Fan Alarm The cooling fan has failed 1 Check the fan for obstructions or debris With amplifier power removed attempt to manually rotate the fan 2 ForSVM type amplifier systems the power supply module PSM and the servo amplifier module each include a cooling fan The alarm code will indicate which unit failed
340. rrect switch Refer to Chapter 5 for I bit definitions Turn on the Enable Drive Q bit and confirm that the servo amplifier is enabled Ifa brake is used on the servomotor it should be released at this time Send the AQ command code for Force Digital Servo Velocity 100 Confirm that the motor moves in the desired POSITIVE direction and the Actual Velocity reported in the AI table is POSITIVE If the motor moves in the wrong direction use the Motor Dir parameter in the configuration software to swap the positive and negative axis directions Remove the Force Digital Servo Velocity command from the AQ table Use a low speed Jog velocity and Jog acceleration in the configuration values may be increased later Turn on the Jog Plus Q bit Confirm that the servo moves in the proper direction and that the Actual Velocity reported by the DSM302 in the AI table matches the configured Jog Velocity Use a low speed value for Find Home velocity and Final Home velocity in the module configuration values may be increased later Check for proper operation of the Find Home cycle by momentarily turning the Find Home Q bit the Drive Enabled Q bit must also be maintained on The axis should move towards the Home Switch at the configured Find Home Velocity then seek the Encoder Reference point at the configured Final Home Velocity If necessary adjust the configured velocities and the location of the Home Switch for consistent operation The final H
341. rrection velocity exceeds 80 of the velocity limit then the automatically calculated move velocity will be clamped at 80 of the configured velocity limit Clamping the makeup move velocity at 80 of the velocity limit allows the system some reserve velocity capacity for continued tracking of the master source velocity In both cases a warning message is reported and the real distance make up time is longer than programmed but the distance is still corrected properly Setting a Follower Ramp Distance Make Up Time of 0 allows the Ramp feature to accelerate the axis without making up any of the accumulated counts In this instance velocity will not exceed the master velocity For applications where lost counts do not matter set the distance make up time 0 By default the superimposed motion profile that is automatically generated by the follower ramp function with non zero makeup time is trapezoidal using the active jog acceleration and a distance derived from the active Acceleration Ramp Makeup Time If trapezoidal correction is performed the effective make up time increments by 8ms and can have a minimum value of 40 ms The value of the Master Velocity Limit Vlim or Vlim may affect functionality differently depending on the relationships of the master source Enc3 Internal Master Analog Master velocity The following case examples illustrate these points Case 1 The master source velocity is less than 80 of the configured Vlim and t
342. rror tus Only Servo Axis 1 2 Set Position while not In Zone error Aux Axis 3 Set Position while ENC3 Velocity gt 128 error tus Only Attempt to initialize position before digital encoder passes reference point n 2 n gt n n tus Only Digital encoder position invalid must use Find Home or Set Position ul w Nje n End of Travel and Count Limit Errors tus Only Commanded Position gt Positive End of Travel or High Count Limit ul 2 tus Only tus Only Absolute Position Position offset gt Positive End of Travel or High Count Limit Commanded Position lt Negative End of Travel or Low Count Limit i n 2 n tus Only Absolute Position Position offset lt Negative End of travel or Low Count Limit 1 Drive Disable Errors Stop Normal Drive Disabled while Moving ul Stop Normal Drive Disabled while Program Active Software Errors Software Error Call GE Fanuc Field Service Program and Subroutine Errors Status Only 1 Status Only Absolute Encoder Rotary Position Computation error 2 n Stop Normal Subroutine not in list Stop Normal Call Error subroutine already active w Stop Normal Subroutine End command found in Program Stop Normal Program End command found in Subroutine is Stop Normal Sync subroutine encountered by non sync program Axis Program Execution Errors M
343. rst word of the Immediate Command The low byte value 40h specifies the Select Return Data Immediate Command The high byte value 18h specifies the Mode selection for Parameter Data The MOVE INT instruction moves a decimal value of 1 indicating Parameter 1 into 00002 This commands that the value in DSM Parameter 1 be written to the User Selected Data double word for Axis 1 10021 10022 in this example Note The actual AI addresses used for DSM module are specified when the module is configured Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C The TMR timer instruction produces a 45 millisecond time delay after the Select Return Data Immediate Command is sent This is required because User Selected Data is not available in the ladder until at least 3 sweeps or 20 milliseconds which ever is greater elapses after the Select Return Data Immediate Command is sent Since the sweep time in this example is 14 milliseconds this 45 millisecond delay ensures that the Parameter 1 data will be present in the User Selected Data double word before the Equal instruction in the next rung executes Note that contact 0200 must stay ON long enough for the TMR timer to time out and enable the second rung Second Rung After the 45 millisecond delay in the previous rung elapses contact M0202 closes and enables this rung In this rung a double integer EQUAL instruction compares the value in R0208 R0209
344. rt the Program Command Position by using the Select Return Data AQ command Refer to Chapter 5 for details The following application example illustrates how a stored program can be used to control positioning operations relative to the detected edge of a moving object as it moves at a rate detected by the master axis Aux Axis 3 encoder input Example 2 Follower Motion Combined with Motion Program GFK 1464C Applications that require modifying parts on the fly such as notching marking riveting spot welding spot gluing and so forth would make use of the point to point moves superimposed on follower motion and enable follower at input features A typical configuration and control sequence required for these applications is shown below Follower Home Carriage Part Sensor Edge Sensor 4 Master motion PART Aux Axis Follower Axis Control Sequence 1 With Enable Follower Q bit OFF the PLC commands Follower axis to home position where Actual Position amp Program Command Position are synchronized and set to Home Position value Position Valid l bit indicates when this step is complete 2 The PLC sets the Enable Follower Q bit command Note 01 CTL16 bit to which the part edge sensor is connected would already have been configured in the Follower Enable Input configuration parameter 3 When the Part edge sensor trips the DSM302 ena
345. rvo Alarm Not Used Ov Ov I O Type Circuit Identifier Digital Servo Circuit Type Input Impedance Maximum Input Voltage Logic 0 Input Threshold Logic 1 Input Threshold Input Filtering Output Sink Current On State Output Voltage Strobe Response Notes 3 40 Aux Axis 4 Circuit Function Auxiliary Terminal Signal Name Axis 1 listed 105 A IN5 Single Ended 5 Inputs Outputs Sink 4 7K ohm pull up to internal 5v 4 7K ohms to internal 5v 1 0v 7 0v 0 8 v max 2 4 v min 10 microseconds typical 10 ma max 0 5v at 10 ma Minimum Pulse Width 25 microseconds Position Capture Delay 10 to 280 microseconds Servo Terminal For digital servos these points act as the PWM ENBL outputs and Alarm inputs For Aux Axis 3 these points are input only The listed Ov pins should be normally used for the signal return 5 COMPARATOR 82K M 4700 4700 IN OUT Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C 5v Differential Outputs Circuit Digital Servo Analog Servo Axis Aux Axis 4 Signal Name Faceplate Auxiliary Servo Identifier Axis 1 2 1 2 and Aux Axis 3 Circuit Function Axis 1 listed Pin Terminal Terminal Circuit Function Circuit Function Board Board OUT2 Ser Encoder Req Not Used Not Used OUT2P A 13 13 N C Ser Encoder Req Not Used Not Used OUT2M A 31
346. ry Servo Identifier Circuit Function Circuit Function Circuit Function Axis 1 listed Terminal Terminal Pin I O Type 5V Encoder Power Circuit Type 5V Power with Electronic Short Circuit Protection Output Voltage 4 70 v to 5 20 v at 0 5 amp Output Current 0 5 amp max total for all connectors Notes This output is intended to power external devices such as Incremental Quadrature Encoders requiring less than 0 5 amps total from all 4 axis connectors The output current is provided by the PLC backplane 5v supply and is protected by an electronic short circuit protector in the DSM302 module The listed Ov pin should normally be used as the power return signal 3 46 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter Configuring the DSM302 4 This chapter describes all configuration details necessary to set up the DSM302 for a specific application Refer to Chapter 2 for start up instructions on how to configure the system to send a Jog command to the DSM in order to test that system components are operable The DSM302 module is configured using the Logicmaster 90 30 configuration software Configuration is a two part procedure consisting of W Rack Slot Configuration W Module Configuration Note In order to configure the DSM302 module you must have version 8 02 or later of the Logicmaster 90 30 configuration software Certain functions i e follower mode ratios in excess o
347. s 1 or 00037 for axis 2 Note that the references used here are for Q references starting at Q0001 The starting Q reference is configurable If the motor will not jog skip over this section and go to Section 6 Troubleshooting Your Motion System Troubleshooting Your Motion System The first step in correcting a problem is to determine if any alarms have occurred PLC alarms or errors may be viewed in the PLC fault table Servo and motion subsystem alarms may be viewed in the DSM302 Module Status Code word AI0001 Servo Axis 1 Error Code word 10002 and or Servo Axis 2 Error Code word 10003 Note that the references used here are for AI references starting at AI1 The starting AI reference is configurable For more information on Motion Mate DSM302 alarms please refer Appendix A Error Codes which contains a list of alarm codes and descriptions Check to see if this information can help you For more information on Troubleshooting see Appendix D Start Up and Tuning a GE Fanuc Digital or Analog Servo System Configuration Settings Getting Help If your system powers up with alarms it may be due to an incorrect configuration setting The Series 90 30 PLC configuration must be stored to the PLC CPU and the PLC must be in Run Output Enabled mode If you cannot move an axis or execute a jog check to see that all conditions necessary to perform these operations are met Refer to the appropriate areas in this manu
348. s 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter 9 Example 1 GFK 1464C Combined Follower and Commanded Motion Combined motion consists of Follower motion commanded from a master axis combined with one of these internally commanded motions Jog Plus Minus Q Command E Move at Velocity Command W Move AQ Command W Stored Motion Program Combined motions are additive The slave axis motion 1s equal to the sum of the motion commanded by the master axis and the internally commanded motion Follower Motion Combined with Jog In this example the Enable Follower bit is set causing the slave axis to follow the master input While the slave axis is following the Jog Plus Q bit is set The following axis accelerates from its master s velocity to its master s velocity added to the current Jog Velocity This acceleration will be just as if the axis was not following a master source at the time When the Jog Plus Q bit is cleared the following axis decelerates to its master s velocity In the velocity profiles below the dotted lines indicate when the Jog Plus Q bit is turned ON and then OFF a45337 Master Source t Following Axis t Figure 9 1 Combined Motion Follower Jog 9 Follower Motion Combined with Motion Programs Motion commands from stored programs or the Move AQ command can also be combined with the master command to drive the follower axis These point to point move comm
349. s ON the Force Analog Output command for Aux Axis 4 is active 3 2 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C The DSM COMM Serial Communications Connector The module s front panel contains a single RJ 11 connector for serial communications labeled COMM This port has two main uses e It is used to upload or download motion programs between the DSM302 and a computer running the GE Fanuc APM Motion Programmer software e tis used to download firmware updates to the DSM module from a personal computer running the GE Fanuc PC Loader utility software See Appendix F for details The serial COMM port connects to the personal computer s serial port It uses the GE Fanuc SNP protocol and is RS 232 compatible The baud rate is configurable from 300 to 19 200 baud The COMM port is configured using the Logicmaster 90 30 Configuration Software A l meter cable IC693CBL3 16 is available from GE Fanuc to connect to a personal computer This cable uses a 9 pin female D shell connector for the computer side and an RJ 11 connector for the DSM302 If a longer cable is used the maximum recommended length is 50 feet Table 3 1 DSM302 COMM Port Pin Assignments RJ 11 Pin 9 Pin Signal Description Number female Name Number CTS Clear to Send TXD Pin 1 is at the bottom of the connector when viewed from the front of the module Connectors The DSM302 is a two axis servo controll
350. s Servo Amplifier 2 2 2 12 Figure 2 9 B Series Servo Amplifier Contiections seti ee bo a v bae or idea 2 14 Figure 2 10 Connecting the D Series Digital Servo Amplifier Terminal Strip sss 2 15 Figure 2 11 Connecting the B Series Servo Amplifier to the Line Filter and Power Source 2 17 Figure 2 12 Connecting the E STOP to the B Series Servo Amplifier sss 2 18 Figure 2 13 20 Pin PCR Connector Pin Out sese enne nre nne trennen nest enne 2 19 Figure 2 14 Installing a Jumper When an External Regeneration Resistor is Not Used 2 20 Figure 2 15 Connecting the External Regeneration Resistor essere 2 20 Figure 2 16 Motion Mate DSM302 System Grounding Connections esee 2 22 Figure 34 DSM302 MOod les iet teet ons ita ettet tte tte en toute edet 3 1 Figure 3 2 Connecting the Shield Ground sees esent 3 4 Figure 3 3 Axis and Auxiliary Terminal Board 3 9 Figure 3 4 Digital Axis Terminal Board with Mounting Dimensions eene 3 12 Figure 3 5 Digital Servo Axis Terminal Board Assembly Drawings eese 3 13 Figure 3 6 Digital Servo Axis Terminal Board Assembly Side View sss 3 14 Figure 3 7 Auxiliary Terminal Board with Mounting Dimensions eese 3 15 Figure 3 8 Auxiliary Terminal B
351. s only used by follower mode Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 4 GFK 1464C Immediate Commands The following AQ Immediate Command words are transferred each PLC sweep from the CPU data to the DSM302 The length of the AQ Immediate Command words is configured with the Configuration Software to be a length of 6 9 or 12 The actual addresses of the Immediate Command words depend on the starting address configured for the AQ references See Table 4 1 Module Configuration Data The word numbers listed in the following table are offsets to this starting address The words are assigned as follows Table 5 6 AQ Word Assignments Word Offset Description Axis 00 Immediate Command Word 01 02 Immediate Command Word 04 05 77746 immediate Command Word _ Contigired for 12 Ag wors iS 09 immediate Command Word These words can be used for Force Analog Output commands ONLY Only one AQ Immediate command may be sent to each axis of the DSM302 every PLC sweep The only exception is the Load Parameter Immediate command which is axis independent Thus two Load Parameter Immediate commands can be sent on the same sweep one in the first three AQ words and the other in the second three AQ words Even though the commands are sent each sweep the DSM302 will act on a command ONLY if it changed since
352. s set indicating that the Q discrete commands or AQ immediate commands from the PLC can control the DSM302 PLC Control Active is cleared only when the Status screen in the Motion Programmer is used instead of the PLC to control the DSM302 a capability not yet implemented 1 03 New Configuration Received The New Configuration Received 1 status bit is set whenever the PLC sends a reset command or new configuration to the DSM302 New Configuration Received should be cleared by a PLC program before any AQ Immediate commands such as n Position Zone or Position Loop Time Constant have been sent to the DSM302 The status bit can then be monitored by the PLC If the bit is set then the DSM302 has been reset or reconfigured The PLC should clear the bit and then re send all necessary AQ commands The bit is cleared by AQ Immediate command 49h Refer to section 4 Immediate Commands later in this chapter for more details about the AQ immediate command interfaces GFK 1464C Chapter 5 Motion Mate DSM302 to PLC Interface 5 3 5 4 1 04 1 05 1 06 Faceplate Input l Status Bits These inputs indicate the state of external input devices connected to faceplate signals The CTLO1 CTLO8 inputs as well as CTL09 CTL12 outputs from the PLC Q table may be tested during the execution of Wait and Conditional Jump commands CTLO1 CTL08 CTL13 CTLI16 are all selectable as the Follower Enable Trigger bit in Follower mode The Aux Ax
353. sate for changing actual conditions See Chapter 6 Non Programmed Motion for more information on Position Increment Commands with the DSM302 4 04 Move At Velocity User units sec This command is executed from the PLC to move the axis at a constant velocity The active Jog Acceleration rate 1s used for Move at Velocity commands Axis actual position data will roll over at the configured Hi or Lo Limit when reached during these moves See Chapter 6 Non Programmed Motion for more information on the Move at Velocity Command 5 18 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 4 05 4 06 4 07 4 08 Set Position User units This command changes the axis position register values without moving the axis The Commanded Position and Actual Position values will both be changed so that no motion command will be generated The Actual Position will be set to the value designated and the Commanded Position will be set to the value Position Error Set Position cannot be performed when the Moving 1 bit or the Program Active 1 bit is ON In Follower mode Set Position is not allowed if the Zone 1 bit is OFF In Standard mode Set Position is allowed if the In Zone 91 bit is OFF as long as Actual Velocity is lt 100 cts sec The position value must be within the End of Travel Limits and Count Limits or a status error will be reported The Position Valid oI bit is set after a suc
354. se Parameters sc ce erect tare titre ate de 7 26 Linear Equation Transformations eese eere 7 28 Command Input Effect on Position Registers en eene ens 9 3 Actions Affecting Program Command Position essere 9 4 DSM302 Error Codes ett tao GO PEE E e eder pe Hep eR ep A 3 Continued DSM302 Error Codes sss netten nnne nennen A 7 DSM Digital Servo Al rins tied eerte rg cadre Ero de to eda he te A 8 DSM COMM REQ Status Word Codes sess eee enne enne nnn B 3 COMM REQ Instruction FT Output Truth Table B 8 DSM COMM REQ Command ener eene B 10 COMM REQ Memory Type Codes sees eene B 12 Digital Serial Encoder Resolutions sess nnne nnns C 1 Contents xvii Chapter 1 Product Overview The Motion Mate DSM302 is a high performance easy to use 2 axis motion control module which is highly integrated with the Series 90 30 PLC logic solving and communications functions The DSM302 operates in two primary control loop configurations W Standard Mode W Follower Mode Servo Types Supported Features of the Motion Mate DSM302 High Performance GFK 1464C W Digital All firmware releases of the DSM302 support the GE Fanuc digital servo amplifiers and motors W Analog Starting
355. ser s Manual December 2002 GFK 1464C 0 Velocity Loop Step Response Velocity vs Time VLGN Time Sec 0 Figure D 2 Velocity Loop Step Response Velocity vs Time VLGN op Step Response Torque Command vs Time YLGN Velocity La sdiug PUBLULUOS enbuo Time Sec 0 Note that in Figures D 2 and D 3 the system does not have enough damping In this case the Figure D 3 Velocity Loop Step Response Torque Command vs Time VLGN controller does not have the required bandwidth and the Velocity Loop Gain must be increased D 7 Appendix D Tuning GE Fanuc Digital and Analog Servo Systems GFK 1464C 24 Velocity Loop Step Response Velocity vs Time VL GN Eee 1 1 1 1 1 1 1 ua 1 1 1 1 1 1 1 T 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0r 1 1 1 1 1 1 2 Alda AjiSojeA 100 0 2 0 3 04 0 5 0 1 0 2 Time Sec 24 Figure D 4 Velocity Loop Step Response Velocity vs Time VLGN 24 Torque Command vs Time VLGN Velocity Loop Step Response sdiug PUBLULUOS enbuo 0 3 04 05 02 0 1 Time Sec 24 Figure D 5 Velocity Loop Step Response Torque Command vs Time VLGN Note that in Figures D 4 and D 5 the system is beginning to look acceptable
356. servo No I O connections needed Connect to third party analog servo and I O EOS Connect to SL Series analog servo and I O 1 00517001 Connect to Auxiliary Axis I O on DSM Cor D Analog or Digital IC693ACC336 connector C or D 0140 BLOG G 4026 BORG ROB G Bo NO 9 Bo do 8 o 5 9 gt Jo zo BO do 4049 r A o ao LO LO JOD So Jo PL2 En E co NO DSM dolo Ho O Je le 0 3 NO ono fol Oy 32 oO 70 DSM SERVO E vo e Orz T6 IC693ACC335 1C693ACC336 Servo AxisTerminal Board Auxiliary Terminal Board Figure 3 3 Axis and Auxiliary Terminal Board Assemblies Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Note Each Terminal Board is shipped with DIN Rail mounting feet Instructions for converting a terminal board to panel mount are included in this Chapter Digital Servo Axis Terminal Board IC693ACC335 Description The IC693ACC335 Digital Servo Axis Terminal Board is used to connect the DSM302 to GE Fanuc Digital Servo Amplifiers The board contains two 36 pin connectors labeled DSM and SERVO A cable IC693CBL
357. shipped with each amplifier package P Amplifier Figure 2 14 Installing a Jumper When an External Regeneration Resistor is Not Used GFK 1464C Chapter 2 Getting Started 2 17 2 18 With External Regeneration Resistor If you have an external regeneration resistor observe that it has 4 wires The two smaller wires K8 connect to the resistor s internal normally closed over temperature switch This switch will open and shut down the amplifier if the resistor get too hot The two larger wires K7 connect to the resistor All connectors needed to connect this resistor unit to the amplifier are provided in the amplifier package Connect the two over temperature switch wires K8 to CX11 6 terminals TH and 2 These connections are not polarity sensitive Connect the two resistor wires K7 to CX11 2 terminals DCP and DCC These connections are not polarity sensitive B Amplifier External Regeneration Resistor 30 ohm 100 watt NC Over Temperature Switch CX11 2 DCC CX11 6 TH1 External Regeneration CX11 6 TH2 Resistor CX11 2 Figure 2 15 Connecting the External Regeneration Resistor Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Installing and Wiring the DSM302 for Analog Mode Important Analog Servo Considerations 1 The Analog Servo Velocity Command output is a single ended signal on pin 6 of the Auxiliary Terminal Board This signal is ref
358. shooting Your Motion System eeeeeeeeeee 2 34 ANTA ii tr rob nn e br IE ial og 2 34 Configuration Settings eerie eee 2 34 Getting Help ea eiie ete ede or cele cen ee meet eet 2 34 Telephone Numbers ccrte etse tee rtt one d kde aee OE fe sce e Ee Rd d 2 35 GE RE eoe Hu Re mdr ro ORE PE eee 2 35 Fax Emk Systenm x eet ee atr ner det etie decine es e 2 35 Section 7 Next Steps to 2 36 Installing and Wiring 05 302 4 4 0 ceres eee eene rennen een nettes seen nao 3 1 Section 1 Hardware Description 4 crees eee ee esee esee eren seen 3 1 LEED Indicatots 25s EU EHE es 3 2 The DSM COMM Serial Communications Connector esses 3 3 Connectors ciarn 3 3 Shield Ground Connection 3 4 Section 2 Installing the DSM302 3 5 Section 3 Wiring and Connections ccscccscssccsscccsscecscsssescssssseeeees 3 8 Circuit Types ERE 3 8 Terminal Boards RUE De re 3 8 Digital Servo Axis Terminal Board 693 335 000 3 10 D SCFIDIOD teri ee P eee re eri ts e ded 3 10 Mounting Dimensions
359. sing the same acceleration value with Linear acceleration In order to maintain equal machine cycle times an S Curve motion profile requires an acceleration value and peak motor torque twice as large as the equivalent Linear acceleration motion profile Therefore a tradeoff between motor cost and machine cycle time may be necessary Default LINEAR Axis Mode Axis Mode CONTINU LINEAR ROTARY1 ROTARY2 Sets the axis operation mode CONTINU means that the end of travel EOT EOT limits not used and continuous programmed motion can be achieved using a series of incremental move commands In this mode Actual Position will roll over at the configured HI LO limits LINEAR means that the EOT EOT limits are used to restrict axis motion for both jogs and programmed moves In LINEAR mode the EOT EOT limits must be less than or equal to the HI LO rollover limits If an EOT Limit is outside a HI LO Limit the DSM will internally set it equal to the HI LO Limit The ROTARY1 and ROTARY operation modes are reserved for the future Default CONTINU Chapter 4 Configuring the DSM302 4 17 2 18 2 19 2 20 2 21 4 18 Note When Follower mode is selected the DSM302 internally assigns Pos EOT to the HI Limit rollover value and Neg EOT to the Lo Limit rollover value The LINEAR Axis Mode selection can only be used in Follower mode when the axis Actual Position does not reach the Hi Lo limit rollover boundaries Therefore at present
360. sition commanded each time it is sent The current Jog Acceleration and Jog Velocity which can also be changed by AQ commands will be used for the move The data field for this command may contain the move position or distance in bytes 2 5 with the command type in hexadecimal format as defined below Move Type byte 1 00h Abs Pmove Linear 01h Abs Cmove Linear 10h Abs Pmove Scurve 11h Abs Cmove Scurve 40h Inc Pmove Linear 41h Inc Cmove Linear 50h Inc Pmove Scurve 51h Inc Cmove Scurve The data field for this command may contain a parameter number in byte 2 bytes 3 5 unused with the command type as defined below Move Type byte 1 80h Abs Pmove Linear 81h Abs Cmove Linear 90h Abs Pmove Scurve 91h Abs Cmove Scurve COh Inc Pmove Linear Clh Inc Cmove Linear DOh Inc Pmove Scurve D1h Cmove Scurve The Move Command 1s executed as a single move motion program Therefore all the restrictions that apply to motion program execution also apply to the Move Command For example if a program is already active for axis 1 then an attempt to send this command for axis 1 will result in an error condition being reported Jog Velocity User units sec This command sets the velocity used when a Jog Q bit is used to jog in the positive or negative direction A PLC reset or power cycle returns this value to the configured data Additionally the Jog Velocity is used
361. sition to move to 2 The type of positioning reference command modifier to use for the move and 3 The type of acceleration command modifier to use while performing the move Note Motion programs can contain statements that use constants as data associated with commands or variables that are also referred to as parameters PO P255 Parameter 0 is not supported by all configuration and programming software packages Absolute or Incremental Positioning 7 4 Absolute Positioning In an absolute positioning move the first parameter is the position to move to The following is an absolute positioning move example PMOVE 5000 ABS LINEAR Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C In this example the axis will move from its current position whatever it may be to the position 5000 Thus the actual distance moved depends upon the axis current position when the move is encountered If the initial position is 0 the axis will move 5000 user units in the positive direction If the initial position is 8000 the axis will move 3000 user units in the negative direction If the initial position is 5000 the axis will not move Incremental Positioning In an incremental move the first parameter specifies the distance to move from the current position The DSM302 translates incremental move distances into absolute move positions This eliminates error accumulation The following is an increm
362. speed FANUC Motor Specification The configuration data for the motor type field is determined by the motor nameplate data Motor part numbers are in the form A06B xxxx yyyy where xxxx represents the Motor Specification field For example Reading the significant digits 0032 from a motor nameplate of A06B 0032 B078 indicates motor model 82 3000 The table below shows that 36 1s the correct Motor Type Code for a Motor Specification number of 0032 Table 2 8 FANUC Motor Type Code Selection Motor Specification Continued on next page GFK 1464C Chapter 2 Getting Started 2 25 Table 2 8 Continued os s wma 2 26 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Table 2 9 Additional Configuration Screen Information Configuration Configure Configure Logicmaster Parameter Description for Digital for Analog Default Mode g Pos EOT s ui Fdback Mode Feedback Mode Jog Vel Jog Velocity Jog Ace Mod LINEAR Find Hm Vel Home Mode Find Home Mode MOVE MOVE HOMESW Proper settings determined during system startup tuning See page D 14 in Appendix D Note Repeat the above settings for axis 2 configuration if needed We will not use Program 0 at this time so leave the Program 0 screens at their default values GFK 1464C 2 27 2 28 Store the Configuration to the PLC You should complete the configuration of your Series 90 30
363. st also be maintained ON The axis should move towards the Home Switch at the configured Find Home Velocity then seek the Encoder Marker at the configured Home Velocity If necessary adjust the configured velocities and the location of the Home Switch for consistent operation The final Home Switch transition MUST occur at least 10 ms before the Encoder Marker Pulse is encountered The physical location of Home Position can then be adjusted by changing the Home Offset value in the Configuration Software 11 Monitor servo performance and use the Q Jog Plus and Jog Minus bits to move the analog servo motor in each direction The Pos Loop Time Constant can be temporarily modified by placing the correct command code in the 6AQ table For most systems the Position Loop Time Constant can be reduced until some servo instability 1s noted then increased to a value approximately 50 higher Once the correct time constant is determined the DSM302 configuration should be updated using the Configuration Software Velocity Feedforward can also be set to a non zero value typically 90 100 96 for optimum servo response Note For proper servo operation the Configuration entry for Vel at 10v MUST be set to the actual servo velocity in User Units sec caused by a 10 Volt Velocity command to the amplifier GFK 1464C Appendix D Tuning GE Fanuc Digital and Analog Servo Systems D 15 System Troubleshooting Hints Analog Mode 1 The Motion Mate Analog
364. sub directory on your pf M hard drive or floppy disk The PLC configuration and logic Q yr program and the DSM302 configuration will all be stored in the SA LM90 folder eae 2 Connect your personal computer to the PLC using the correct communication cable s The cable type will vary depending upon the communication method used by the Logicmaster 90 30 software serial or Ethernet For more information please refer to GFK 0466 Logicmaster 90 Series 90 30 Programming Software User s Manual and GFK 0356 Series 90 30 Programmable Controller Installation Manual 3 Start up the Logicmaster 90 30 Programming Software then select F2 for the configuration package When prompted select an existing working folder or create a new working folder by using the Folder Functions Shift F8 and then Select Create F1 This working folder will be used to hold a copy of the system configuration and ladder logic program A Select the working folder you have just created Press I O Configuration Shift F1 or F1 from the Configuration Package Main Menu The main rack of the Series 90 30 PLC should now be displayed B Configure the components that make up your PLC system The DSM302 s are chosen to be placed in a particular rack slot location s in the PLC The configuration software must be used to put these modules in the same places as their physical locations Select Other F8 and Motion F5 Then choose the DSM302 with the cursor key from the se
365. system to include the Power Supply Rack CPU and additional modules to match the target system Consult the Logicmaster 90 Series 90 30 Programming Software User s Manual GFK 0466 as needed IMPORTANT The completed configuration must be stored to the PLC The Logicmaster configuration package menu selection F9 UTILITY Load Store will allow you to complete this important step Press Store F2 and follow prompts to transfer the configuration to the PLC If all seems in order that is there are no PLC or IO status errors after Store etc then it must be Motion Time NOTE A PLC status error of System Configuration Mismatch with the same rack slot location as a DSM302 indicates that there is a parameter configured and sent to the DSM302 that has been rejected by the DSM302 Carefully check each parameter of your DSM302 configuration with the configuration settings in this manual for the discrepancy Correct the discrepancy clear the PLC Fault and re Store the configuration Check that the error has been corrected See the next section Enabling Run Mode on the PLC for instructions on viewing and clearing PLC faults Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Section 5 Testing Your System Generating Motion GFK 1464C CAUTION For correct machine operation the recommended start up procedure must be performed This includes validating operation of the Overtravel Limits a
366. t action Each time an error is generated the bit must be set OFF then ON for at least one PLC sweep to clear the error The CFG OK LED must be ON or the DSM302 will not respond to PLC commands If the LED is OFF then a valid DSM302 configuration has not been received from the PLC Appendix D Tuning GE Fanuc Digital and Analog Servo Systems D 3 Tuning a GE Fanuc Digital Servo Drive The following pages provide you with an introduction to the basics required for tuning a GE Fanuc Digital servo drive This introduction shows one method for tuning a servo drive The method will not work in all applications and you should modify the approach based on the application In order to display and measure the necessary signal waveforms the DSM302 analog outputs must be connected to an oscilloscope Without an oscilloscope to measure the signals tuning the servo drive with the following approach will not be possible The Select Analog Output Mode AQ command 47h is used to select the data that is sent to the analog outputs during servo tuning Refer to Chapter 5 for a discussion of this AQ command Tuning Requirements D 4 The module has three main parameters that are adjusted during tuning The parameters are the Position Loop Time Constant Velocity Feed Forward Gain and Velocity Loop Gain The Position Loop Integrator Time Constant gives the position loop an additional degree of freedom but in typical applications is not required The a
367. ta should be initialized in the ladder program before the rung containing the COMM REQ instruction is executed The Command Block The Command Block consists of several words of PLC memory that contain additional information about the communications request This information includes timing parameters a pointer to the Status Word and a Data Block The Data Block specifies the direction of the data transfer via the Command Code and location and type of data to be transferred The Status Word The Status Word is a single location in PLC data memory where the CPU reports the result of the communications request The Status Word address is specified in the Command Block by the user The following table lists the status codes reported in the Status Word Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C Table B 1 DSM COMM_REQ Status Word Codes DSM REQ Status Word Codes Code Name Code Description Possible Corrective Action IOB_SUCCESS 1 All communications proceeded None required normally IOB PARITY ERR 1 A parity error occurred while Retry Check hardware communicating with an expansion cables DSM expansion rack module etc IOB NOT COMPL 2 After the communication was Retry Verify the COMM REQ over the module did not indicate parameters that it was complete MOD ABORT 3 The module aborted the Retry Verify the COMM REQ communication parameters IOB MOD SYNTAX 4
368. ternal master selectable as the master source for axis 1 or axis 2 MASTER ENCODER FEED FORWARD SLAVE O o AXIS 2 FOLLOWER SELECT JOG INTERNAL PROGRAM MOVE MASTER AT VELOCITY 2 ENCODER SLAVE AXIS 2 FEED FORWARD SLAVE RATIO POSITION os rae st S ENABLE AXIS 1 FOLLOWER SELECT INTERNAL INTERNAL MOTION 199 MASTER MASTER PROGRAM VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 8 15 2 Axis Parallel Master Source Encoder 3 Internal Master GFK 1464C Chapter 8 Follower Motion 8 15 6 16 The following diagram illustrates the two axes of the DSM302 connected in cascade with the analog input as the master source for axis 2 and encoder 2 the master source for axis 1 FEED FORWARD 2845322 SLAVE ANALOG INPUT MOTOR ENABLE FOLLOWER 2 MOTION JOG PROGRAM MOVE VELOCITY 2 ENCODER SLAVE AXIS 2 FEED FORWARD SLAVE POSITION LOOP MOTOR MOTION JOG PROGRAM MOVE VELOCITY 1 ENCODER SLAVE AXIS 1 Figure 8 16 2 Axis Cascade Master Source Analog Input ENABLE FOLLOWER 1 The following diagram illustrates the two axes of the DSM302 connected in parallel with the analog input as the master source for both axis and axis 2 FEED FORWARD 245323 SLAVE ANALOG INPUT 07 0 MOTOR ENABLE FOLLOWER MOTION JOG PROGRAM MOVE VELOCITY 2 ENCODER SLAVE AXIS 2 FEED FORWARD SLAVE Oo o MOTOR ENABLE FOLLOWER 1
369. tery Position Valid is automatically set whenever the digital encoder reports a valid absolute position See Appendix C for details of operation when absolute mode digital encoders are used Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 1 07 1 08 1 09 Drive Enabled The Drive Enabled status bit indicates the state of the Enable Drive Q bit and the solid state relay output supplied by the DSM302 The ON state of the Drive Enabled I bit corresponds to the CLOSED state of the relay output and the ON state of the associated faceplate EN LED In Digital mode the solid state relay provides the MCON signal to the GE Fanuc Digital Servo through the servo command cable Drive Enabled is cleared following power up or an error condition that stops the servo Program Active The Program Active status bit for each axis indicates that a Motion Program 0 10 or a Move AQ command 27h is executing on that axis Executing a multi axis program will set both Program Active I bits Moving The Moving status bit is ON when Commanded Velocity is non zero otherwise it is OFF i e the Moving bit will transition to OFF while an axis is steadily following a Master input All Move positioning and continuous Jog Accel and Decel Ramps and Move at Velocity commands will cause the Moving bit to be set to ON The Force Digital Servo Velocity AQ command will not set the Moving bit In FOLLOWER mo
370. that is suitable for driving 5v TTL or CMOS loads The OUT3 A OUT3 B OUT3 C and OUT3 D Output Control Q bits control the state of the associated output For each axis the following connector pins are assigned Faceplate Auxiliary TB Servo TB Connector IC693ACC336 IC693ACC335 Pin Terminal Terminal OUT3 7 terminal 14 14 5 OUT3 terminal 32 32 13 Enable Follower When this bit is set and the Follower Enabled I status bit indicates the Follower is enabled motion commanded by the external or internal master will act as an input to the follower loop An optional Follower Trigger bit may be configured to initiate follower motion When a Follower Trigger is used Enable Follower must be ON for the trigger condition to be tested Clearing Enable Follower disconnects the follower loop from the master source Jog Move at Velocity and Execute Program n commands will be allowed regardless of the state of Enable Follower When the Follower is enabled Jog Move at Velocity or Execute Program n commands will be superimposed on the master velocity or position command Find Home is not allowed unless Enable Follower is cleared Refer to Chapter 8 for additional information This bit is only used by follower mode Select Follower Internal Master This bit switches the master axis source from Encoder 3 to the Internal Master Velocity generator The Internal Master Velocity AQ command can be used to change the velocity of the internal master This bit i
371. the PMOVE s velocity The CTLO bit OFF when the PMOVE begins turns ON at the second dashed line Motion stops after a PMOVE even if a conditional jump goes to another block Thus the CTL01 bit triggers a deceleration to zero before the final CMOVE begins BLOCK 1 ACCEL 2000 VELOC 8000 CMOVE 76000 INC 45311 LINEAR BLOCK 2 ACCEL 1000 VELOC 4000 JUMP 01 3 PMOVE 50000 INC LINEAR BLOCK 3 ACCEL 6000 VELOC 6000 CMOVE 6000 INC LINEAR Figure 7 14 Jump Followed by PMOVE S CURVE Jumps Jumps during linear motion and jumps during s curve motion at constant velocities immediately begin accelerating or decelerating to a new velocity Jumps during a s curve acceleration or deceleration however require different rules in order to maintain a s curve profile What happens when a jump occurs during an s curve move while changing velocity depends on whether the jump occurs before or after the midpoint the point where the acceleration magnitude is greatest and whether the velocity at the jump destination 1s higher or lower than the current velocity S CURVE Jumps after the Midpoint of Acceleration or Deceleration If the jump occurs after the midpoint of the change in velocity the change will continue normally until constant velocity is reached then the velocity will be changed to the new velocity using the acceleration mode of the move at the jump destination Example 12 S CURVE Jumping After the Midpoint
372. the following error due to master axis sampling delay Problems Resolved by Firmware Release 1 40 GFK 1464C EN3 EN4 LEDs Flash when Performing Slow Jog Function When performing a slow jog LEDs EN3 and EN4 incorrectly flashed The problem was caused by an internal Axis 3 Axis 4 AQ processing error The result was that if the DSM configuration used 6 or 9 AQ words the Force D A command for Axis 3 and Axis 4 operated incorrectly This has been corrected in firmware version 1 40 such that the error no longer occurs H 2 Firmware Release 1 30 Features Introduced in Firmware Release 1 30 Enhanced AI and l Processing The internal DSM update rate for I data and AI data except for the Actual Velocity data has been increased from once every 10 milliseconds to once every 2 milliseconds Actual Velocity data is updated every 128 milliseconds Enhanced Follower Axis Ramp Control The Follower Axis Ramp Control Function is enhanced in DSM firmware release 1 30 The enhancement improves motion smoothness Prior to this release when the follower was active and the master in motion the acceleration deceleration control during the make up correction phase was not controlled by a velocity profile This could cause unwanted machine shock The enhanced method uses a trapezoidal velocity profile to address this problem During the entire make up correction phase the acceleration deceleration is limited to the jog acceleration value Also duri
373. the last sweep When any of the 3 words change the DSM302 will accept the data as a new command and respond accordingly The Axis Enabled 1 bit must be ON for an axis to accept a new AQ Immediate Command Under some conditions such as a disconnected encoder or un powered servo amplifier Axis Enabled will be OFF and the AQ command processing for that axis will be disabled If Servo Axis 1 or 2 is not used for motor control the configured Motor Type must be set to 0 or an error will be reported and Axis Enabled will stay OFF The 6 byte format for the Immediate Commands is defined in Table 5 7 The actual addresses of the Immediate Command Words depend on the starting address configured for the AQ references The word numbers listed in the following table are offsets to this starting address The word offsets are shown in reverse order and in hexadecimal to simplify the data entry The following example sends the Set Position command to axis 1 The first word word 0 contains the actual command number For the Set Position command the command number is 0023h The Chapter 5 Motion Mate DSM302 to PLC Interface 5 15 second and third words contain the data for the Set Position command that is a position The second word word 1 is the least significant word of the position and the third word word 2 is the most significant word Example To set a position of 3 400 250 first convert the value to hexadecimal 3 400 250 decimal equals 0033E
374. ther location in the program under certain specified states of the Faceplate control inputs CTL01 CTLO8 and Q control outputs CTL09 CTL12 The jump will occur when the condition tests true logic 1 An unconditional Jump can also be selected The jump may be forward or backward in the program The jump condition will be tested as soon as the move prior to the Jump command has completed A maximum of 220 jumps can exist for all programs and subroutines Once the condition testing is allowed to start the test will occur once every two milliseconds until a Block Number or another Jump command is encountered This will allow continued testing while a move or series of moves takes place if the Jump command is located ahead of the moves in the block If a jump occurs during a move the remainder of the move is aborted and the command at the destination location is immediately effective Jump destinations must be limited to the bounds of the program containing the Jump command Load Parameter LOAD This command initializes or changes a DSM302 data parameter value The new value becomes effective immediately when encountered in the program Program Zero may load parameters to 20 only Pmove PMOVE Positioning Move this command is used when it is necessary for the axis to be within the configured n Position Zone before proceeding to the next command If no previous acceleration or velocity has been specified in a motion program the config
375. tion Feedback Devices C 1 GFK 1464C GFK 1464C Position Increment AO Immediate Commana 5 19 6 20 Position Increment Command 6 7 Position Initialization C 3 Position Loop Time Constant AQ Immediate Command 5 23 Position Strobe 1 2 1 Status Bits 5 5 Position Valid I Status Bit 5 4 Positioning Move 7 2 Positioning Move PMOVE 7 6 Positioning Absolute Positioning Incrementa 17 5 Power On Check List 2 24 Power Sequence Prerequisites for Programmed Motion 7 3 Program Active I Status Bit 5 5 Program Motion Commands Type 1 Call Subroutine 7 2 Jump 7 2 Type Acceleration Block Null 7 2 Velocity Type Load Parameter 7 2 Type Continuous Move 7 2 Dwell 7 2 End of program 7 2 Positioning Move 7 2 Wait 7 2_ Program Zero 4 25 Creation in Logicmaster 90 30 Configuration Software 1 6 Program Zero Commands 4 28 ACCEL 4 28 BLOCK 4 28 CMOVE 4 28 DWELL 4 28 JUMP 4 28 LOAD 4 28 PMOVE 4 28 VELOC 4 28 WAIT 4 29 Program Zero Motion Program Commands 4 27 Program Zero Programmer Instruction Format 14 26 Axis Field 4 26 Command Name Field Data Field 4 26 Programmed Motion Considerations Other 7 21 Index Index Programmed Move Commands 7 6 Programmed Moves 7 8 Programming multiaxis 7 24 R Rack Slot Configuration 4 1 Rate Override AQ Immediate Command 5 19 Ratio A and B Values 4 22 AB
376. tion Program PMOVE and CMOVE commands In Digital mode these strobes are 5V single ended differential inputs IN1 IN2 In Analog mode these strobes are only 5V single ended 105 106 In Analog mode only these strobe inputs are pulled up high as seen in the PLC 1 Strobe status bits if not physically connected to a device Configuration Software Packages GFK 1464C Logicmaster 90 30 The DSM302 is easily configured using the Logicmaster 90 30 Configuration software version 8 02 or later The DSM302 is assigned to a particular slot and rack like any other PLC module In addition other types of configuration data must be entered such as m I O addresses where the CPU to DSM302 data transfers take place m Serial Port Setup for connecting the Motion Programmer software m DSM302 Setup Data m A small optional motion program Program Zero 20 lines in standard mode 9 lines in follower mode All of the DSM302 configuration data is discussed in detail in Chapter 4 Configuring the DSM302 Chapter 1 Product Overview 1 5 Windows Programming Software GE Fanuc Control the Windows based PLC configuration software will support the DSM302 module in Release 2 11 ServicePak 3 or later The VersaPro releases will support the DSM302 also PC Control Programming Software The PC Control configuration software will support the DSM302 in the later releases Motion Programming Software 1 6 Motion programs are normally created us
377. tion is achieved Feed Hold On Transition This command causes any motion programs in progress to stop at the active acceleration rate This Feed Hold command does not stop motion commanded by a master source in Follower Mode Once the motion is stopped the Moving status bit is cleared and the n Zone status bit is set when the In Zone condition is attained Jog commands are allowed when in the Feed hold condition After an ON transition program motion will stop even if the command bit transitions back OFF before motion stops Feed Hold Off Transition This command causes any motion programs interrupted by Feed Hold to resume at the programmed acceleration and velocity rate Additional program moves will then be processed and normal program execution will continue Feed Hold OFF behaves in a similar fashion to an Execute Program command except the path generation software uses only the remaining distance in the program If jogging occurred while Feed Hold was ON the interrupted Move command will resume from where the axis was left after the Jog The Move finishes at the correct programmed velocity and continues to the original programmed position as if no jog displacement occurred Enable Drive MCON Ifthe Module Error Present and Drive Enabled 1 status bits are cleared this command will cause the Drive Enable relay contact to close and the Drive Enabled bit to be set When the Drive Enabled l bit is set the path generation and positio
378. tive This means that if the COMM REQ is enabled by a transitional one shot contact and fault occurs the FT output will only be High for one PLC scan Therefore to capture the fault you can program the fault output as a Set coil which would not be automatically reset at the end of a scan Additional logic would then be needed to reset the fault output coil after the fault is acknowledged Programming a device such as a Set Coil on the FT output of the COMM is optional Note that the Series 90 30 COMM REQ unlike many of the other Series 90 30 PLC instructions does not have an OK output It is necessary to initialize the parameters in the Command Block prior to executing the COMM REQ instruction Since the normal PLC sweep order is from top to bottom initializing the Command Block in an earlier rung or rungs than the rung that contains the COMM REQ will facilitate this requirement See the example at the end of this appendix Recommendation If you use MOVE instructions to load values into Command Block registers use a Word type MOVE to load a hexadecimal number and an Integer type MOVE to load a decimal number You will see this applied in the example at the end of this appendix where the 501 code is loaded via Word type MOVE instruction and the remaining decimal values are loaded via Integer type MOVEs Appendix DSM Parameter Download Using the COMM REQ Instruction B 7 B 8 Section 3 The COMM REQ Com
379. to a panel frame ground If an axis terminal board is used two shield 5 connections are provided and one of these must be connected to a panel frame ground The system ground cable must have sufficient cross sectional area to safely carry the accidental current flow into the system ground when an accident such as a short circuit occurs Typically it must have at minimum the cross sectional area of the AC power cable Figure 2 15 illustrates the grounding systems W The amplifier ground connections power earth PE connections and motor frame ground connections should always be wired to conform to local electrical wiring regulations When installing in conformance to CE Mark directives a grounding bar and clamp s ordered separately is required for the terminal block to amplifier cable Refer to Chapter 3 Installing and Wiring the DSM302 I O Cable Grounding section for more details Machine Motor Power Servo Series 90 30 Magnetics Amplifiers PLC Operator s Unit Rack Panel 7 Magnetics 7 Cabinet L 4 Ue Distribution Board r FrameGround SystemGround Figure 2 16 Motion Mate DSM302 System Grounding Connections Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Table 2 6 Grounding Systems Frame Ground System The frame ground system is used
380. toring encoder battery power The incremental data is lost when motor shaft rotation causes the encoder to pass a reference point similar to a marker signal within one revolution of the motor shaft The diagram below describes this situation as well as the state of the DS internal signal The signal DS is not directly available to the user but serves to illustrate the sequence of events The DS signal indicates that absolute position data is available Ifno battery pack is used DS will be reset on each power cycle Note The asterisk in DS indicates that it is a negated or inverse form of signal DS Therefore if DS is logic 1 DS is logic 0 and if DS is logic 0 DS is logic 1 Sometimes an overline is used instead of an asterisk to indicate this relationship DS DS Absolute Data in One Revolution Incremental Data ae Power ON Reference Point Reference Point Encoder Counts prior to Bntgg det This Point are Lost DS Note The GE Fanuc Digital serial encoder must be rotated up to one full revolution after the absolute mode battery has been reattached to the amplifier Within one revolution the encoder will reference itself and report a referenced status DS 0 to the DSM302 The encoder will set its internal counts accumulator to zero at the point where DS switches to a logic zero Counts accumulated prior to the DS transition are lost Digital Serial Encoder Modes The GE Fanuc Digital serial enc
381. trol circuits are unaffected by temperature changes There are no personality modules The servos have a broad application range that is a wide load inertia range flexible acc dec and position feedback configurations etc Extensive customization features are available to optimize performance and overcome machine limitations IPM based servo amplifiers require 6096 less panel space than conventionally switched amplifiers and produce 30 less heat Series Integrated Digital Amplifier SVU GFK 1464C The Series Integrated Servo Amplifiers SVU packages the amplifier with an integral power supply in a stand alone unit This unit is the same physical size and footprint as the previous Series of GE Fanuc Servo Amplifiers The Integrated Series SVU Amplifiers use the same connections as the Series Amps except that the Emergency Stop circuit uses the internal 24v supply thus there is no longer a requirement for a 100v power supply The heat sinks on the SVU design will mount through the panel to keep heat outside the enclosure Since the a SVU Amplifiers do not provide regeneration to line capability discharge resistors may be required These are available in several sizes SVU style Series Servo Amplifiers are available in 5 sizes with peak current limit ratings from 12 to 130 amps Cables to connect the SVU Amps to the DSM302 and to the motors are available in various lengths Chapter 1 Product Overview
382. ts power capacity has not been exceeded Figure 2 6 shows how to connect the amplifier to the line filter Ground Lug 248024 13 8 14 9 15 amp n 13 a Power 18 a Source Line Filter Series Amplifier Connection Strip NOTE 220 Volt AC three phase power is required Figure 2 7 Connecting the Servo Amplifier to the Line Filter and Power Source Note You must supply the cable for both the connections between the line filter and the servo amplifier and the connection between the line filter and the power source Use 4 conductor 600V 60 C 140 F UL or CSA approved cable between the line filter and the servo amplifier The gauge of wire used for connecting the line filter to the power source must be sized based on the circuit breaker between the power source and the line filter and the number of servos connected to the line filter If a separate isolation transformer is used to supply AC power to the amplifiers a line filter is not required 5 Connect the Machine Emergency Stop to the Series Digital Servo Amplifier C Pin3 of connector located on the bottom of the Series SVU amplifier supplies 24 volts DC for the E STOP circuit Route this through the machine E STOP circuit so that there is 24 volts DC to pin 2 when not in E STOP If no E STOP switch is used this connection must be made with a wire jumper Note You must supply the cable for this connection Keyed connector plugs marke
383. ual Position Position Error 2 Ifthe follower is enabled the Program Command Position is set to the Program Reference Position 0 Since the Program Command Position is only updated by internally generated commands and not by the master command it will then indicate the position commanded by the stored program Absolute move commands from the stored program will be referenced to the Program Reference Position Position ranges in counts for the Actual and Program Command Position registers are indicated in the figure below Program Command Position Range Fixed Lo Limit max Hi limit max Fixed 2 8 8M 2B Actual Position Range 4 from Feedback With sustained commanded motion in the same direction the Program Command Position will roll over at 2 147 483 647 or 2 147 483 648 counts The Actual Position however will be confined by the configured high and low limits with maximum values of 8 388 607 and 8 388 608 counts 9 2 Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 GFK 1464C 2 Table 9 1 below indicates which source commands affect these position registers and the actual commanded velocities Program Command Position is updated only by internally generated move commands program commands Jog Plus Minus Find Home and Move at Velocity The Commanded Velocity returned in AI data also only indicates velocity commanded by these internally generated m
384. ude of the A B ratio can be from 1 10 000 to 32 1 Thus very precise ratios such as 12 356 12 354 or 32 000 1024 can be used The Follower A B Ratio AQ command can be used to change the A B ratio at any time even while following However an invalid ratio will generate a status error and be ignored An invalid ratio is a ratio with B equal to or less than zero or A B magnitude greater than 32 1 or less than 1 10 000 Ratios from 1 1024 to 1024 1 can be obtained with a DSM302 if the slave axes are cascaded When axis 2 follows encoder 3 and axis 1 follows axis 2 if both ratios are 32 1 the slave master ratio of axis 1 to encoder 3 is 1024 1 When following with a non 1 1 ratio the velocity profile of the master and follower will look somewhat different Horizontal lines indicating constant velocity and slanted lines indicating acceleration and deceleration will be different If the A B ratio is less than 1 1 the follower velocity and acceleration will be less than the master Likewise if the A B ratio is greater than 1 1 the follower velocity and acceleration will be greater than the master The duration of motion and time that the slave axis will accelerate decelerate or stay at constant velocity are the same for the master and follower The distance moved which in a velocity profile is the area between the graph and the time axis will be that of the master multiplied by the A B ratio If A 1s zero no following motion will be generat
385. ues can be changed during program execution but the change must occur before the DSM302 begins executing the Type 3 Cmd Move Wait or Dwell previous to the Type 3 Cmd that uses the parameter This is due to the pre processing of program blocks that occurs within the DSM302 Note that a JUMP command clears pre processing and forces a program block to be re processed 7 26 Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Below is an example of a motion program using Parameters The values of Parameters 1 5 are pre loaded with a COMREQ command from the PLC at least two program blocks before usage Remember that program blocks are not the same as sections of the motion program that are labeled with the BLOCK command Command Data Comments BLOCK 1 1 Set velocity of first move value in Parameter 1 ACCEL P 2 Set acceleration of first move value in Parameter 2 CMOVE AL P 3 ABS LINEAR Reach velocity of second move 20000 at position Par 3 BLOCK 2 VELOC 20000 Set velocity of second move 20000 PMOVE IL 20000 INC LINEAR Normal PMOVE DWELL P 4 Dwell for Parameter 4 time PMOVE IL P 5 INC LINEAR PMOVE to value in Parameter 5 Strobe 1 occurs on Axis 1 during move to Param 5 position DWELL 1000 Dwell for one second LOAD P 6 Load Parameter 6 parameter BLOCK 3 PMOVE IL P 224 INC LINEAR Move to strobed position for Strobe 1 on axis 1 DWELL 2000 Dwell for two secon
386. ulated velocity will be clamped at 80 of the configured velocity limit In both Chapter 5 Motion Mate DSM302 to PLC Interface 5 23 5 24 4 23 4 24 cases a warning message is reported and the real distance make up time is longer than programmed but the distance is still corrected properly Setting a Follower Ramp Distance Make Up Time of 0 allows the Ramp feature to accelerate the axis without making up any of the accumulated counts In this instance the Follower axis velocity will not exceed the master velocity For applications where the Follower axis only needs to be synchronized to the master velocity and lost counts do not matter set the distance make up time 0 Typical velocity profile during the follower ramp cycle is shown below pf master velocity Follower Disabled Make up a distance l r Make Up Time 1 Velocity i Time Velocity time Profile Follower Enabled at t 0 See Chapter 8 Follower Motion Follower Axis Acceleration Ramp Control section for a much more detailed discussion of this feature Set Follower Winder Position Counts This command sets the Winder Position when a follower axis is operating in WINDER mode The position must be within the present Winder Zone Length boundaries or an error will be reported Refer to Chapter 8 Follower Motion for a detailed explanation of the WINDER mode
387. ump To identification label and 2 it identifies the section of the program that is currently executing via the two Command Block Number Status words 2 commands are optional a program block can contain a single Type 3 command Type 2 commands and Conditional Jumps do not take effect until the DSM executes the next Type 3 command While the DSM302 is executing a program block the following program block is processed into a buffer command area This buffering feature minimizes block transition time Thus parameters used in a move must be loaded before the move two blocks previous completes execution In other words in order to minimize the block to block transition time a new block is pre processed during previous block execution Program block parameters must be loaded before the preceding block begins execution When a DSM302 is executing a 2 Axis program the program commands are scanned independently by each axis and only the data designated for that axis is executed Note that some commands do not specify an axis Block Jump Call and End and therefore apply to both axes A 2 Axis program can contain Sync Block commands to synchronize the axes at designated points When the first axis reaches the Sync Block it will not execute the next block until the other axis has also reached the Sync Block Refer to Example 18 Multiaxis Programming later in this chapter for an example of this Prerequisites for Progr
388. unconditional jump command simply tells the DSM302 to continue program execution at the destination block number A conditional jump only executes if the specified condition occurs Examples of both types of jumps follow Unconditional Jumps GFK 1464C Example 6 Unconditional Jump In the example below the program executes a PMOVE dwells for 2 seconds then unconditionally jumps back to the beginning of the program at block 1 Thus the PMOVE repeats until an end of travel limit Pos EOT or Neg EOT or Overtravel Limit Switch is reached A more practical application would be to program a series of moves that needed to be repeated continuously then Chapter 7 Programmed Motion 7 11 add a jump back to just before the first move to close the loop In that case the program would continue to repeat the series of moves until a Q or AQ command from the ladder program stops or alters it ACCEL 10000 VELOC 30000 BLOCK 1 PMOVE 200000 INC LINEAR DWELL 2000 JUMP UNCOND 1 45263 Figure 7 10 Unconditional Jump Conditional Jumps A conditional jump is a JUMP command with a CTL bit specified in the command Conditional jumps are Type 1 commands in that they affect program path execution but they are also similar to Type 2 commands because they do not take effect until a Type 3 command following the JUMP command is executed When a conditional JUMP command is executed the DSM302 examines the specified CTL bit If the bit is ON p
389. und in the f Series Servo Motor Descriptions Manual GFZ 652332EN How to interpret overload duty curves The servomotor can be driven out of the continuous torque operating zone but intermittently Duty cycle charts show the Duty 96 and the ON time in which motor can be operated under the given overload conditions The ON heat generating and OFF heat dissipating limitations of a motor are calculated using the following procedure 1 Calculate Torque percent by formula below The ON time for a motor can be specified within the torque percent TMD LoadTorque Continuous RatedTorque 2 Calculate OFF time by formula Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C GFK 1464C 100 1 DutyPercent tr OFF Time ON Time Example It is desired to operate the 8 2 3000 servomotor under a load of 3 Nm at low speed in a 20 degree C ambient environment for 5 minutes Because the continuous rated torque of the B 2 3000 15 2Nm we should examine the duty calculations Torque percent TMD 3 2 1 5 150 From the overload duty curve of the 2 3000 Duty percent of the motor when it runs with TMD 150 for five minutes is About 37 OFF time 5 100 37 1 8 5 min After the motor runs under the above conditions therefore it must be kept at a stop for at least 8 5 minutes to dissipate heat build up Higher ambient temperatures will a
390. uration allowing the Home Cycle to only wait for a marker transition Find Home must be maintained ON until the marker is located Clearing the Find Home Q bit before the marker is located will end the Home Cycle without setting Aux Axis 3 Position Valid Vol bit 3 09 Jog Plus When this command bit is ON the axis moves in the positive direction at the configured Jog Acceleration and Jog Velocity rates The axis will move as long as the Jog Plus command is maintained and the configured Positive End Of Travel software limit or Positive Overtravel switch is not encountered The Overtravel switch inputs can be disabled using the OT Limit configuration parameter Jog Plus may be used to jog off of the Negative Overtravel switch if the Clear Error Q bit is also maintained on See Chapter 6 Non Programmed Motion for more information on Jogging with the DSM302 3 10 Jog Minus When this command bit is ON the axis moves in the negative direction at the configured Jog Acceleration and Jog Velocity rates The axis will move as long as the Jog Minus command is maintained and the configured Negative End Of Travel software limit or Negative Overtravel switch is not encountered The Overtravel switch inputs can be disabled using the OT Limit configuration parameter Jog Minus may be used to jog off of the Positive Overtravel switch if the Clear Error Q bit is also maintained on See Chapter 6 Non Programmed Motion for more information on Jogging with th
391. ured Jog Acceleration and or Jog Velocity will be used The axis movement will stop for a minimum of two milliseconds in the n Zone range then the next program command will execute Velocity VELOC This modal command specifies the velocity of axis motion Once encountered this command will remain in effect until overridden by a later Velocity command Wait WAIT This command synchronizes the start of axis motion with an external input or event reported in CTLO1 CTL12 The start of motion is suspended until the bit being monitored is true Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter Motion Mate DSM302 to PLC Interface 5 This chapter defines the data that is transferred between the CPU and the Motion Mate DSM302 automatically each PLC sweep without user programming This data is categorized as follows W Input Status Data Transferred from Motion Mate DSM302 to CPU O Status Bits 64 bits of I data O Status Words 40 words of AI data typically for standard mode applications 50 words of AI data typically for follower mode applications 64 words of AI data typically for applications requiring additional analog inputs W Output Command Data Transferred from CPU to Motion Mate DSM302 O Discrete Commands 64 bits of Q data O Immediate Commands 6 words of AQ data typically for standard mode applications 9 words of AQ data typically for follower mode applications 12
392. utputs Ov 24v optically isolated inputs INCOM 24v Input Common 24 v 125 ma OUTI DC SSR output OUT2 OUT3 24v 30 ma ENBL SSR output Differential Differential 5v outputs Servo Axis 1 2 Circuit Function Strobe Input 1 Strobe Input 2 IN2P_A RR Ser Encoder Data IN3P_A MA A QV A Servo Ready Input Servo Ready Input IN4 A Pin INIP_B IN2P_B IN3P_B aa 107 108 INIP INIM_A Servo PWM Alarm aaa PLC 24v Output Ser Encoder Req Ser Encoder Req PLC 5v Output 105 IO6 107 A IO8 A OVA 3 3 UTIP A OUTIP_B 18 UTIM_A 2 UT2P_A OU 13 OU IN9 A INIO A A INCOM A OUT3P_A PLC 5v Output Servo MCON IR Phase Current NIP A IS Phase Current AIN2P A RR OUT3M A ENBLI A ENBL2 A OUT3M ENBLI B 15 ENBL2B 33 AINIP B 7 125 AOUT_A 3 24 10v Analog Inputs AOUTI 10v Analog Out PLC Analog Out ACOM Analog Out com Analog Out Com SHIELD Cable Shield Cable Shield Motion Mate DSM302 for Series 907 30 PLCs User s Manual December 2002 ACOM A SHIELD A AOUT B ACOM B SHIELD B N2PB 8 AIN2M B 24 Axis Term Board Terminal 0 1 4 1 9 2 1 3 1 1 7 1 5 4 12 S OO nN GFK 1464C Analog Servo Axis 1 2 Circuit and Pin Assignments This tab
393. value in 9610017 from a BCD Operator Input device is converted to an integer value and placed in 0150 when switch 10001 is closed Also RO151 is cleared to zero Note that on the output of the BCD4 TO_INT instruction 0150 is shown as a single word integer value displayed as a signed 5 digit number However when 0150 is used in the second rung as the input to the double integer Multiply instruction DINT the CPU automatically combines it with the next address 0151 to form a double integer word displayed as a signed ten digit number When used this way RO151 is called an implied address since it is not shown on the screen Be aware that you must not use R0151 for any other purpose it should be held to a value of zero otherwise the value placed into 0150 in the first rung would be corrupted The same principle applies in the case of double word R0208 R0209 the use of R209 is implied by the fact that 0208 is displayed as a double integer word So 0209 should be reserved for this use only In the second rung the value in 0150 is multiplied by 1000 This provides scaling of the input value by a factor of 1000 If scaling were not desired the value 1 would be used instead Appendix DSM Parameter Download Using the COMM Instruction B 15 NOW ACTIVATE THE COMM REQ TO SEND THE PARAMETER DATA TO THE DSM302 e ke koe ke kk ek kc KK KK k k k KK k k
394. velocity and the reported Aux Axis 3 Actual Velocity The PLC can ramp the Internal Master Velocity AQ command in small steps until the internal master velocity and the Aux Axis 3 Actual Velocity are close to each other At that point the PLC can turn off the Select Internal Master Q bit to switch the follower loop master input to the external Aux Axis 3 Encoder Example 10 Aux Axis 3 Velocity and Internal Master Synchronization To synchronize the internal master and Aux Axis 3 velocity the Internal Master Velocity is stepped up to an expected Aux Axis 3 encoder velocity When Aux Axis 3 Actual Velocity is within 128 cts sec of this velocity the PLC program will turn the Select Internal Master Q bit OFF to switch the master source to the Aux Axis 3 encoder The shaded area indicates the time when the Select Internal Master Q bit is ON a45336 1 Encoder 3 Internal Master 2 Master Sources t Following Axis t Figure 8 10 Encoder 3 and Internal Master Synchronization Enabling the Follower with External Input GFK 1464C An external trigger signal applied to one of the inputs CTLO1 CTL16 can be used to enable the follower axis The input used for the Enable Trigger is selected with the configuration software When no input is selected the follower is enabled and disabled directly by the Enable Follower Q bit When an input is selected for the Enable Trigger and the Enable Follower Q bit is set the next positive transition of
395. verses OT Limit Sw Selects whether the DSM300 Series module uses the hardware over travel limit switch inputs DISABLED the limit switch inputs may be used as general purpose motion program flow control and program branching inputs i e CTLO5 CTLO8 bits ENABLED indicates that the DSM300 will check the axis over travel inputs continuously every 2 milliseconds whenever the I Drive Enabled input is true If either limit switch opens the input goes to logic zero Off all motion is immediately commanded to stop No deceleration control is active the servo velocity command is set to zero The solid state axis enable relay will not open until after the Q Enable Drive command is set to zero An error code indicating which limit is tripped is reported to the AI Axis Error Code At this point only one DSM302 action is allowed the appropriate Q Jog and Q Clear Error bits may be used simultaneously to back away from Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C the Limit Switch The Q Clear Error bit must be maintained ON to Jog off the limit switch The user may also manually move the disabled axis off the limit switch After the alarm is clear normal operation may resume Force D A commands ignore the limit switches and should be used with caution 2 03 Pos Err Lim Position Error Limit User Units The Position Error Limit is the maximum Position Error Commanded Position Actual Position
396. vo turns the key clockwise the bolt does not move until the key turns to a certain point The Reversal Compensation feature adds in the necessary lost motion to quickly move the servo to where motion will begin on the feedback device The DSM302 removes the compensation distance when a move in the negative direction is commanded and adds the compensation distance before a move in the positive direction The 6AT Actual Position status word will indicate the actual distance moved including the reverse compensation distance The machine actual position is therefore equal to the AI Actual Position Reversal Compensation distance after moves in the positive direction and immediately at start up The actual value required for a particular application must be empirically determined Default 0 Note Reversal compensation applies only to the Standard mode of operation it cannot be used in Follower mode DisDly Servo Drive Disable Delay milliseconds The time delay from zero velocity command to the drive enable digital servo MCON signal switching off Disable Delay is effective when the Enable Drive Q bit is turned off or certain error conditions Stop Mode occur Disable Delay should be longer than the deceleration time of the servo from maximum speed Because turning OFF the Enable Drive Q bit stops the DSM302 from commanding the servo there are times when the drive enable signal should stay ON For example if the servo runs into an End of Tr
397. when the PLC resets or reconfigures the module The PLC can monitor the bit to determine if it must re send other AQ commands such as n Position Zone or Jog Acceleration This would only be necessary if the AQ commands were used to override DSM302 configuration data programmed with the PLC configuration software Load Parameter Immediate This command is executed from the PLC to immediately change a DSM302 data parameter value It can be sent from either Axis 1 or Axis 2 Command registers Data parameters are only used by motion programs A command for each parameter change is required Note that Parameter 0 is not supported by all Configuration and Programming Software packages Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Chapter Non Programmed Motion 6 The DSM302 can generate motion in an axis in one of six ways without the use of any motion programs E Find Home and Jog Plus Minus use the Q bits to command motion W Move at Velocity Move Force Digital Servo Velocity Force Analog Output and Position Increment use AQ immediate commands During Jog Find Home Move at Velocity Move and Force Digital Servo Velocity any other commanded motion programmed or non programmed will generate an error The only exception is the Position Increment AQ command which can be commanded any time See the description of Position Increment motion below for more details Non programmed motions
398. wing axis is falling behind the master V 245334 Ratio 1 1 Following Axis Master Axis Figure 8 8 Velocity Clamping Unidirectional Operation 8 8 Setting one of the Velocity Limits to zero results in unidirectional follower motion Any master axis counts in the zero limited direction are ignored When a Velocity Limit is zero no error is generated by counts in the zero limited direction The n Velocity Limit I bit however does reflect the presence of counts in the zero limited direction Example 9 Unidirectional Operation In this example the negative Velocity Limit is set to zero As shown in the velocity profile below the following axis follows the positive counts but 1gnores the negative counts Note that when the master is moving negative the Velocity Limit Vol bit is ON but no status error is generated V 245335 Ratio 1 1 Master Source Following Axis Figure 8 9 Unidirectional Operation Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Synchronizing Aux Axis 3 Velocity and the Internal Master Synchronization of the external Aux Axis 3 encoder velocity and the internal master velocity may be needed to prevent the follower control loop from commanding large accelerations when the Select Internal Master Q bit is switched OFF This synchronization can be achieved by using the PLC to monitor the difference between the commanded internal master
399. with PW330 331 3 DSM302 modules in expansion remote baseplate with PWR321 322 7 DSM302 modules in expansion remote baseplate with PWR330 331 23 total DSM302 modules per PLC system with PWR321 322 32 total DSM302 modules per PLC system with PWR330 331 The total power consumption of all modules in a baseplate must be calculated so that the total load capacity of the supply is not exceeded Refer to GFK 0356 Series 90 30 PLC Installation Manual for detailed information on load requirements for Series 90 30 modules The available power supplies are 7 C693PWR321 Standard AC DC Power Supply allows 15 watts 3000 ma for 5 VDC 1C693PWR322 24 48 VDC Power Supply allows 15 watts 3000 ma for 5 VDC C693PWR330 High Capacity AC DC Power Supply allows 30 watts 6000 ma for 5 VDC L 1C693PWR331 High Capacity 24 VDC Power Supply allows 30 watts 6000 ma for 5 VDC Note Refer to GFK 0867B GE Fanuc Product Agency Approvals Standards General Specifications or later version for product standards and general specifications Note Installation instructions in this manual are provided for installations that do not require special procedures for noisy or hazardous environments For installations that must conform to more stringent requirements such as CE Mark see GFK 1179 Installation Requirements for Conformance to Standards 3 6 Motion Mate DSM302 for Series 90 30 PLCs User s Manual Decemb
400. with firmware release 1 40 support for analog servos was added to the DSM302 The GE Fanuc SL Series analog servos are documented in the SL Series Servo User s Manual GFK 1581 m Digital Signal Processor DSP provides Vector Control of GE Fanuc AC Servos m Block Processing time under 5 milliseconds m Velocity Feed forward and Position Error Integrator to enhance tracking accuracy m High resolution of programming units Position 8 388 608 8 388 607 User Units Velocity 1 8 388 607 User Units sec Acceleration 1 134 217 727 User Units sec sec Motion Mate DSM302 1 1 Easy to Use Versatile I O 1 2 Simple and powerful Motion Program instruction set Simple 1 or 2 axis motion programs with synchronized block start Program support for a short motion program which can be created in Logicmaster 90 30 20 Micro configuration software Non volatile storage for 10 programs and 40 subroutines User scaling of programming units User Units Flash update of system firmware Generic programming using command parameters as operands for Acceleration Velocity Move and Dwell Commands Configured with Logicmaster 90 30 20 Micro software version 8 02 or later Automatic Data Transfer between PLC tables and DSM302 without user programming Ease of I O connection with factory cables and terminal blocks as well as a serial port for connecting programming devices Control of GE Fanuc Digital AC serv
401. words of AQ data typically for applications requiring additional analog outputs Note Throughout this chapter words shown in italics refer to actual PLC machine data references 1 96A AI AQ GFK 1464C 5 1 Section 1 lI Status Bits The following I Status Bits are transferred automatically from the DSM302 to the CPU each sweep The actual addresses of the Status Bits depend on the starting address configured for the 1 references see Table 4 1 Module Configuration Data The bit offsets listed in the following table are offsets to this starting address All reference section designations pertain to this chapter Bit Description Axis Ref Offset 1 05 1 06 1 07 1 08 Table 5 1 l Status Bits Bit Description Axis oma 4 00 Module Error Present 01 PLCControl Active 02 New Configuration Received 03 Reserved o 04 CTLOI Over travel 24v 05 CTLO2 Over travel 24v elo A 07 CTL04 Strobe 1 Level 5v 10 5 46 Reserved 47 Reserved o eS pe 50 Reemed o 51 Reserved Reserved a pr S S Position Strobe 2 5v S Servo Ready 4 B 5v ef 01 02 03 04 04 04 04 04 04 04 04 04 04 mle Din 20 Moving jSevol 109 21 InZone j Sevol 1 10 Reserved
402. xamples Example 10 Jump Stop The following is an example conditional jump with a jump stop An enhancement on Example 5 DWELL would be to watch an external CTL bit that would indicate a problem with the positive motion If the CTL bit never turns on the profile for the following program will be identical to the profile shown in the DWELL example If the CTL bit turned on during the first PMOVE or the DWELL the reverse movement would immediately commence The following profile would appear if the CTL bit turned on during the first PMOVE at the dashed line and the Jog Acceleration was 75000 Because the first move completed early due to the CTL bit and a faster acceleration Jog Acceleration versus programmed acceleration the second move would not have to move as far to get back to 0 position as it did in the DWELL example Note that because the motion programmed at the jump destination is in the opposite direction as the initial motion the profile would be identical if the moves were CMOVEs instead of PMOVEs ACCEL 30000 a45268 VELOC 15000 V BLOCK JUMP CTLOO 2 PMOVE 120000 ABS LINEAR DWELL 4000 BLOCK 2 PMOVE 0 ABS LINEAR CTL09 ON Figure 7 13 Jump Stop Chapter 7 Programmed Motion 7 17 Example 11 Jump Followed by PMOVE In this JUMP example the command after the JUMP is a PMOVE in the same direction The velocity profile below shows the acceleration and movement for the first CMOVE and the deceleration to
403. xis 3 Encoder has configured High and Low Count Limits When a limit is reached the position rolls over to the other limit and continues changing Performing a Home Cycle for the master encoder can initialize actual Position for Aux Axis 3 An Aux Axis 3 encoder Home Cycle does not generate any motion Instead it sets the Actual Position AI data to the configured master source Home Position at the next marker pulse when the Home Switch input is ON It also sets the Position Valid Aux Axis 3 lI bit when it sets the position See Chapter 5 Discrete Commands Find Home Aux Axis 3 for details about the Aux Axis 3 encoder Home Cycle Example 1 Following Aux Axis 3 Encoder Master Input In this example a graph of velocity v versus time t shows the velocities of the master input Aux Axis 3 and the axis that is following the master The DSM302 is configured with Master Source ENC3 INT and the Select Internal Master Q bit is OFF The A B ratio is 1 1 The velocity profile of the following slave axis is identical to the master input 245327 A B Ratio 1 1 Follower Master Figure 8 1 Following Encoder 3 Master Input Motion Mate DSM302 for Series 90 30 PLCs User s Manual December 2002 GFK 1464C Internal Master Velocity Generator The DSM302 can internally generate a velocity up to one million counts per second When ENC3 INT is configured as the Master Source and the Select Internal Master b
404. y Program command velocity Master command velocity Commanded Velocity AI status word is Updated by Program command velocity only GFK 1464C Chapter 9 Combined Follower and Commanded Motion 9 3 9 4 Table 9 1 Continued Command Input Effect on Position Registers COMMAND Follower Input Enabled Follower Input Enabled Follower Registers Affected by input Affected by input Other Internally Actual Position AI status word is updated Generated Move Commanded Position AI status word is updated Actual Position Position Error Program Command Position is updated but not used Actual Velocity AI status word is updated Commanded Velocity AI status word is updated Commands Home Jog and Move at Velocity by Internal command velocity only Yes Actual Position AI status word is updated Find Home by Internal command Master command is not Commanded Position 1 status word is updated allowed Actual Position Position Error Program Command Position is updated but not used Actual Velocity A status word is updated by Internal command velocity Master command velocity Commanded Velocity AI status word is updated by Internal command velocity only The Program Command Position can be synchronized to the Actual Position AI value in 3 ways e Find Home Q command execution e Set Position command e Execute Motion Program n Q command if the follower is not enabled The effect of these
405. y formula 2X t using the given X 4 inches and t 1 second 2 4 inches 1 second 8 inches second To calculate Acceleration the simplest formula is V T 8 inches second 1 second 8 inches second second The Position Distance X is the entire distance moved X X Xa or 16 inches Chapter 7 Programmed Motion 7 29 Triangular Velocity Profiles The triangular velocity profile minimizes servo acceleration rate and requires a higher servomotor velocity when compared to a trapezoidal profile of the same distance and time Use a triangular profile for fast short moves Equations n Position Area Vpk l V t t x Velocity gt ta i ty Viz 2 x time UG geen ae oe PU tT Torque gt Td 2 k t Figure 7 23 Triangular Velocity Profile Non Linear or S Curve Acceleration S Curve or jerk limited acceleration calculation is simple to do if the linear calculation is accomplished first The APM and DSM motion controllers use 100 jerk limiting To convert a linear acceleration to 100 jerk limited acceleration you either double the Acceleration value 2 A or double the time used for acceleration 2t Using S Curve acceleration at the same acceleration rate A as linear acceleration will require twice the time t reaching velocity If the time duration of the move must remain the same and the servo has sufficient peak torque use twice the acceleration 2 A to reach velocity i

Motion Mate DSM302 for Series 90

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