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3202 Rev A Module Specifications
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1. bit 9 set to PRESET the Current Position and if appropriate the Diagnostic Feedback data This bit does not reset the Move Complete input bit bit 10 set to PRESET optical encoder bit 11 set to perform a RESET ERRORS operation on this channel Errors on the other channel will be unaffected bit 12 set to RUN BLEND MOVE PROFILE in the positive direction bit 13 set to RUN BLEND MOVE PROFILE in the negative direction bits 14 amp 15 reserved bit 16 reset for CONSTANT ACCELERATION set for SCURVE ACCELERATION bit 17 reset for TRIANGULAR S CURVE ACCELERATION set for TRAPOZOIDAL S CURVE ACCELERATION This bit is ignored if bit 16 is not set bit 18 reset for a TARGET POSITION move set for an ENCODER COUNT move bits 19 to 28 Reserved bit 29 Backplane Home Proximity bit e The backplane proximity bit is a set by the PLC to indicate to the 3202 module that you are nearing the location of the Home Limit Switch e The 3202 module will ignore the state of this bit unless the module was configured to accept backplane home proximity operations and if there is no homing operation taking place bit 30 reserved bit 31 MODE FLAG 1 for Configuration Mode 0 for Command Mode 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 29 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com g 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Blend Move Progr
2. 0 O Error Code Extended Error Code l Timed Out Error Path amei_3202 Error Text Cancel Apply Help Note The Source Element is a user defined tag at least 208 bytes in length with a DINT data type All of the other Message Instruction parameters should be programmed as shown above 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 30 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Message Configuration user defined tag Communication Tab When the Configuration window shown above is completed click on the Communication tab and set the path parameter to the 3202 module All of the remaining Communication parameters can remain at their default settings The following table shows the layout of the Blend Move data sent with the Message Instruction BLEND MOVE DATA Word Segment Function Word Segment Function 0 ALL Channel Number 25 8 Segment Length 1 N A Number of Segments 26 8 Target Speed 2 ALL Acceleration Type 27 8 Acceleration Deceleration 3 N A Final Deceleration 28 9 Segment Length amp Deceleration Type 4 1 Segment Length 29 9 Target Speed 5 1 Target Speed 30 9 Acceleration Deceleration 6 1 Acceleration Deceleration 31 10 Segment Length 7 2 Segment Length 32 10 Target Speed 8 2 Targ
3. A move operation can be held and resumed many times until one of the following has occurred e The move reaches its programmed target position e An error condition has occurred e Some other command is issued Immediate Stop The Immediate Stop command causes the current move operation to stop without any deceleration The step signal is simply stopped If the channel was moving when this command was issued the current position will become invalid and the Position Invalid Input Bit will be set The channel will have to be Preset or Homed again before an Absolute Move operation can be performed However it will be possible to perform a Relative Move or a Manual Move after an Immediate Stop command has been issued There will be no changes to the Status Bits if the Immediate Stop command is issued when motion was not occurring 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 19 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AMI 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Find Home CW Find Home CCW There are four homing options available They are Home Limit Switch Only Home Limit Switch with a backplane Home Proximity bit Marker Pulse Home with the Home Limit Switch Input acting as a Home Proximity Marker Pulse Home with a backplane Home Proximity bit When the homing operation is complete the 3202 will set the At Home input bit and then reset b
4. Two Channel ControlLogix Stepper Module Revision 4 0 Configuration Bits Bit 0 set when the Capture Input will be used With version 3 1 or higher firmware the Capture Input can be used in two ways 1 Using the Capture Input without the Quadrature Encoder will capture the Current Position Data 2 Using the Capture Input with the Quadrature Encoder will capture the Encoder Data Bit 1 set when an External Input is used The external input can be used to stop a Manual Move operation or to place an Absolute or Relative move in a hold state Bit 2 set when a Home Limit Switch Input will be used Bit 3 set when the Emergency Stop Input will be used Bit 4 set when a CW Limit Switch will be used Bit 5 set when a CCW Limit Switch will be used Even if they are not required by your application the ability to home the module and at least one end limit switch must exist in the configuration data If this is true in your system set bits 2 4 5 18 20 and 21 This configures the module for all of the inputs and sets the active state to active high Simply do not wire anything to the input terminals and the inputs will be ignored Bit 6 set for backplane Home Proximity operations Bit 7 reserved for future use Bit 8 set when Quadrature encoder will be used Bit 9 set when diagnostic feedback will be used Bit 10 1 when output pulse type is pulse train and direction 0 when output pulse type is CW pulse train and CCW
5. the move is decelerated to the Starting Speed and Stopped In this way a triangular velocity profile is generated If the move operation runs to completion without error the MOVE COMPLETE FLAG is set If an error does occur the MOVE COMPLETE FLAG will not be set and an error flag will be set The Move Complete status bit will be reset at the beginning of the next move operation It is possible to hold both Absolute or Relative moves either by issuing a backplane Hold Command or activating the External Input If the External Input is active when the Absolute or Relative move is initiated you will get one step in the specified direction before the 3202 module goes into a hold state 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 18 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAMA 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Hold Move The HOLD MOVE command causes the move operation to decelerate at the programmed deceleration rate to the Starting Speed and stop When this operation is successfully completed the module will set the Hold State Input status bit You have two options while the 3202 module is in a Hold state Either the Resume Move command can be issued with our without changing the velocity acceleration or deceleration parameters or an entirely new move profile can be sent to the 3202 module Note 1 Only the Hold Move bit must be set in the
6. 1 Current Position Counts of steps output 2 1 Current Encoder Encoder Counts using X4 Diagnostic Feedback Data decoding 3 1 Captured Data Counts 4 1 0 0 5 1 0 0 6 1 0 0 7 1 0 0 8 2 Status Word See Description Below 9 2 Current Position Counts of steps output 10 2 Current Encoder Encoder Counts using X4 Diagnostic Feedback Data decoding 11 2 Captured Data Counts 12 2 0 0 13 2 0 0 14 2 0 0 15 2 0 0 Status Word Layout bit 0 set when the axis is moving CW bit 1 set when the axis is moving CCW bit 2 set when the stepper controller is ina HOLD STATE bit 3 set when the axis is STOPPED This bit will not be set if the Move Complete At Home or Hold bits are set bit 4 set when the axis is AT HOME at the completion of a homing operation bit 5 set when the axis is ACCELERATING bit 6 set when the axis is DECELERATING bit 7 set when MOVE COMPLETE Valid for Absolute Relative and Blend Moves bit 8 set when the stepper controller is running a BLEND MOVE profile bit 9 reserved bit 10 set when POSITION INVALID bit 11 set when there is an INPUT ERROR A move can be initiated when there is an Input Error bit 12 set when there is a COMMAND ERROR must be reset before another command including an Immediate Stop will be accepted bit 13 set when there is a CONFIGURATION ERROR This bit is not set when the channel is disabled bit 14 set when there is a HOME INVALID ERROR bit 15 set when there i
7. 1254 Fax 860 584 1973 E mail Sales amci com m VY Py fi ae AMI 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Word 2 Acceleration Type Every two bits in this word define the acceleration type of each segment When the least significant bit of the two is reset the acceleration type of the segment will be Constant When the least significant bit of the two is set the state of the most significant bit determines the type of S curve acceleration If the most significant bit is reset triangular S curve acceleration will be used If the most significant bit is set trapezoidal S curve acceleration will be used The following table shows an example of how the bits in this word are used Segment MSB of pair LSB of pair Function 0 0 Constant Acceleration 1 0 1 Triangular S Curve Acceleration Bits 1 amp 0 1 1 Trapezoidal S Curve Acceleration 0 0 Constant Acceleration 2 0 1 Triangular S Curve Acceleration Bits 3 amp 2 1 1 Trapezoidal S Curve Acceleration 0 0 Constant Acceleration 15 0 1 Triangular S Curve Acceleration Bits 29 amp 28 1 1 Trapezoidal S Curve Acceleration 0 0 Constant Acceleration 16 0 1 Triangular S Curve Acceleration Bits 31 amp 30 1 1 Trapezoidal S Curve Acceleration Word 3 Final Segment Deceleration Value amp Deceleration Type Bits This word defines both the deceleration rate and type between the final segments
8. Command Word A Command Error will be generated and the Hold Command ignored if any other command bits set at the same time Note 2 Because the module is already decelerating it will ignore a Hold Move command issued during the deceleration part of the profile Note 3 A Blend Move cannot be held If a Hold Move command is issued during a Blend Move operation the module will generate a command error motion will continue until the blend move is complete when the Command Error bit will be reset Note 4 A Hold Move command issued during an Encoder Move operation will be ignored Note 5 A Hold Move command issued during a manual move generates a command error and will cause a controlled stop The position will not become invalid Note 6 Issuing a Hold Command during a Homing operation will cause a command error to be immediately generated but the home operation will run to completion Resume Move The RESUME MOVE command resumes a previously held Absolute or Relative Move If the Resume Move command is the first one issued after a Hold Move operation and no errors have occurred motion will start from the point where it was stopped The Hold State status bit will also be reset If Triangular S Curve or Trapezoidal S Curve acceleration is required the appropriate acceleration type bit s must be set at the same time the Resume Move bit is set When the move operation has been successfully completed the Move Complete Flag will be set
9. Off Note The Home Input shown above can be either the Home Limit Switch or the Backplane Proximity bit 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 21 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Home Limit Switch Active when the Home Command is issued 2 Turns at the programmed speed in the direction opposite to the requested homing operation until the home limit switch turns off 1 Home Limit Switch Active gray used to indicate width of home limit switch 3 Decelerates when the Home Limit Switch turns off Pad 4 Returns at the starting speed to where the home limit switch was detected End Limit Switch Active when the Home Command is issued 2 Motor turns at the programmed speed in the direction opposite of the requested homing operation going on and off 4 Motor decelerates a y i and stops D ee ee l 1 End Limit Switch active when home command is issued 5 Runs at the starting speed until the home input again turns on Continues to Marker Pulse if applicable 3 Home input is detected Note 1 The Home Input shown above can be either the Home Limit Switch or the Backplane Proximity bit Note 2 The above diagram is only true if the active End Limit Switch is the same as the issued home command for example if the CW Limit Switch is active and a CW home command
10. installed in conduit with ac power lines or high power ac dc I O lines To reduce or eliminate the influence of electrical noise on the system the step and direction cable shields must be connected to chassis ground terminals 13 or 14 Also the shields must be connected to only one end of the cable run and treated as conductors at any junctions Do not ground the shields at the junction box If the signal cable must cross power feed lines it should do so at right angles Route the cable at least five feet from high voltage enclosures or sources of rf radiation The Module Common terminals must be connected to the COM of the supply that powers the discrete inputs A Stepper Driver with Single Ended Step and Direction inputs can also be referenced here The Chassis Ground pin is connected to the PLC s chassis ground 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 8 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Diagnostic Feedback Wiring Revision 4 0 Pin Numbers Signal Names 16 to 2 Step to A Channel 1 18 to 4 Step to A 20 to 6 Direction to B 22 to 8 Direction to B 15 to 1 Step to A Channel 2 17 to 3 Step to A 19to5 Direction to B 21to7 Direction to B Differential Wiring Diagram 20 Gear Drive Plymouth Industrial Park Terryville CT 06786
11. is issued If the CW Limit Switch is active and a CCW home command is issued than the unit will home normally as if the end limit switch was not active 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 22 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com m VY Pf i ae AMI 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Manual Move CW Manual Move CCW This command performs the Manual Move operation at the programmed speed in the specified direction Motion will occur as long as the command bit remains set The Target Position register must be zero during all Manual Move operations The state of the Encoder Move command bit is ignored when performing a Manual Move If the programmed speed is less than or equal to the starting speed the starting speed is not used and the acceleration and deceleration parameters are ignored The motor will jump to and run at the programmed speed without any acceleration The speed cannot be changed when the module is running in this constant speed mode If itis a Command Error will be generated and the motion will be stopped If the programmed speed is greater than the starting speed the axis begins the move at the starting speed accelerates until the programmed speed is reached and continues to move at the programmed speed until one of the following occurs The Manual Move command bit is turned off The Extern
12. pulse train Bit 11 reserved for future use Bit 12 0 for limit switch home operations 1 for marker pulse home operations Bits 13 tol5 reserved for future use Bit 16 determines the active level of the Capture Input Bit 17 determines the active level of the External input Bit 18 determines the active level of the Home Limit Switch input Bit 19 determines the active level of the Emergency Stop input Bit 20 determines the active level of the CW Limit Switch Bit 21 determines the active level of the CCW Limit Switch Bits 22 to 27 Reserved for future use Bit 28 Set to disable the channel Bits 29 and 30 Reserved for future use Bit 31 1 for configuration mode operations 0 for command mode operations Input Active Level Defines the active level of the inputs These bits will be set for high level active or Normally Open NO or reset for low level active or Normally Closed NC Please note that the active level of the inputs is taken into account only when the input has been defined as being used 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 15 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Starting Speed The starting speed has a range of 1 to 1 000 000 pulses sec and is the pulse frequency at which every move begins and ends Some portions of the homing operations are also perfo
13. running If this occurs the command error bit will be set while the blend move profile runs to completion when the Command Error bit will be reset The Configuration Error bit will be set under the following conditions 1 If an invalid configuration has been sent to the module 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 36 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 The Home Invalid bit will be set under the following conditions St de a o an Issuing a Homing command with the Target Position registers not equal to zero Issuing a Home command if the Programmed Speed is less than the starting speed Issuing a Home command in a direction that does not have an End Limit Switch configured Issuing a Home command with the reserved words not equal to zero If both End Limit Switches are reached during a homing operation This error will only occur when the motor has reversed direction after encountering the first End Limit switch If the opposite End Limit Switch is reached during a homing operation For example if the CCW Limit Switch is first reached during a CW homing operation Improper wiring or placement of the limit switch would most likely cause this error The Invalid Profile bit will be set under the following conditions 1 Ifthe Programmed Speed is less than the starting speed 2 I
14. AAMA 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 The 3202 module is a two axis stepper controller that occupies one slot in a ControlLogix rack This unit receives profile data from the PLC and outputs Step and Direction signals or Clockwise Counter Clockwise pulses to a stepper driver Inputs on the module allow homing and emergency stop operations Differential incremental encoders can be attached to the unit to provide feedback information The 3202 uses sixteen 32 bit input words and sixteen 32 bit output words The two channels are totally independent from each other and can be configured and programmed to perform different operations Because the 3202 module does not use a non volatile memory it must be configured at every power up Sample programs showing how to program the 3202 module are available from the following page of our website http www amci com sampleprograms asp 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 1 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com m VP fi ae AMI 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 General Information Important User Information The products and application data described in this manual are useful in a wide variety of different applications Therefore the user and others responsible for applying these products described herein are responsible for deter
15. If either of the End Limit Switches become active during any move operation except for homing and if the same end limit is reached during a Manual Move For example if the CW Limit Switch is reached during a CW Manual Move If both End Limit Switches are reached during a homing operation This error will only occur when the motor has reversed direction after encountering the first End Limit switch If the opposite End Limit Switch is reached during a homing operation For example if the CCW Limit Switch is first reached during a CW homing operation Improper wiring or placement of the limit switch would most likely cause this error The Input Error bit will be set under the following conditions 1 If the Emergency Stop input has been activated If either of the End Limit Switches become active during any move operation except for homing and if the same end limit is reached during a Manual Move For example if the CW Limit Switch is reached during a CW Manual Move 3 Starting a manual move in the same direction as an active end limit switch 4 If both End Limit Switches are reached during a homing operation This error will only occur when the motor has reversed direction after encountering the first End Limit switch 5 If the opposite End Limit Switch is reached during a homing operation For example if the CCW Limit Switch is first reached during a CW homing operation Improper wiring or placement of the limit switch would most likely ca
16. K bit status bit 30 the Channel Disabled bit status bit 28 and the Configuration Error bit status bit 13 e a Channel Configuration Input Data 0 1 Mirror of Configuration Bits 1 1 Mirror of Starting Speed 2 1 0 3 1 Bits 16 to 31 Major Revision Bits 0 to 15 Minor Revision 4 1 0 5 1 0 6 1 0 7 1 0 8 2 Mirror of Configuration Bits 9 2 Mirror of Starting Speed 10 2 0 11 2 Bits 16 to 31 Major Revision Bits 0 to 15 Minor Revision 12 2 0 13 2 0 14 2 0 15 2 0 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 17 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Chapter 4 Command Mode Operations The following is a description of the various commands that the module accepts and the operations that it will perform while in Command Mode When switching from Configuration Mode to Command Mode the position will be invalid and the Current Position will be zero Absolute Relative Move The current position must be valid in order to perform an ABSOLUTE MOVE A HOME or PRESET operation will have to be performed before the position becomes valid The distance moved that is the number of pulses issued by the 3202 is equal to the difference between the Target Position and the Current Position For example if the Current Position is 5000 a
17. Module Common Channel 2 CCW Limit Switch Module Common Channel 1 A Encoder Input OO Channel 2 A Encoder Input Channel 1 A Encoder Input O O Channel 2 A Encoder Input Channel 1 B Encoder Input O O Channel 2 B Encoder Input Channel 1 B Encoder Input O O Channel 2 B Encoder Input Channel 1 Z Encoder Input O O Channel 2 Z Encoder Input Channel 1 Z Encoder Input OO Channel 2 Z Encoder Input Chassis Ground shields O O Chassis Ground shields Channel 1 Step or CW Output O O Channel 2 Step or CW Output Channel 1 Step or CW Output O O Channel 2 Step or CW Output Channel 1 Dir or CCW Output O O Channel 2 Dir or CCW Output Channel 1 Dir or CCW Output OO Channel 2 Dir or CCW Output Channel 1 Capture Input OO Channel 2 Capture Input Channel 1 External Input O O Channel 2 External Input Channel 1 Home Input O O Channel 2 Home Input Channel 1 Emergency Stop Input O O Channel 2 Emergency Stop Input Channel 1 CW Limit Switch O O Channel 2 CW Limit Switch OO O O Wiring Notes The 3202 module uses a DS26LS31 differential line driver in series with a 10Q resistor for the stepper step and direction outputs Stepper signals are generally low voltage low power signals If you are using A B guidelines for cabling installation treat the cable as a Category 2 cable It can be installed in conduit along with other low power cabling such as communication cables and low power ac dc I O lines It cannot be
18. T 06786 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com page 3 AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Chapter 1 Installing the 3202 module The 3202 can be installed in any ControlLogix module slot as long as power supply requirements are met The 3202 module requires 510mA from the 5Vdc supply to operate 1 Align the module s circuit board with the top and bottom card guides in the rack 2 Gently slide the module into the rack until the top and bottom latches secure the module in place To remove the module depress the top and bottom latches and slide the module out of the rack Note gt The ControlLogix backplane is hot swappable That is the 3202 module can be inserted and removed under power Configuring the ControlLogix system for the 3202 module Open RSLogix 5000 and the project in which you want to install the AMCI 3202 module Right click on I O Configuration in the Project Tree Select New Module Select the following module type and description from the list that appears oy he Type 1756 MODULE Description Generic 1756 Module This module will appear as an Unknown Device when viewed from RSNetworx Click on OK 5 Enter the following module properties Name Your Choice must begin with a letter Description Your Choice Comm Format Data DINT must be Data DINT Slot location of 3202 module 6 Enter the Connection Paramete
19. Tel 860 585 1254 Fax 860 584 1973 Differential Input Note Pin numbering in paranthesis is for axie 2 The pulse and direction cable shields must be connected to chassis ground input pins 13 and 14 page 9 E mail Sales amci com Gi 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Single Ended Encoder Wiring The 3202 module is designed to work with 5 Vdc differential encoders Use the following table and diagrams to attach single ended encoders to the 3202 module A current limiting resistor RLim must be installed for encoders that do not operate at 5Vdc 3202 module RLim Sourcing Output Encoder A B or Z inputs Encoder Output A B or Z inputs Encoder Power Supply Common 3202 module Sinking Output Encoder A B or Z inputs Encoder Power Supply A B or Z inputs Encoder Output RLim Encoder Power Current Limiting Supply Resistor RLim 5Vdc none 12Vdc 1KQ 15Vdc 1 2KQ 24Vdc 2 7KQ 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 10 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAMA 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Chapter 2 Calculating Move Profiles Before starting a move operation the 3202 module completely calculates each portion of the move profile That is it calculates how many steps of the move profile will be req
20. Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com m VY Pf i ae AMI 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Calculation Notes 1 The acceleration and deceleration values sent to the 3202 module as part of the move profile have units of steps second second 2 The acceleration and deceleration values have a minimum value of 1 000 steps second second and a maximum of 2 000 000 steps second second 3 Ifthe number of steps to accelerate plus the number of steps to decelerate is greater than the number of steps programmed in the target position registers than the 3202 module will run a Triangular Velocity Profile 4 Ifthe number of steps to accelerate plus the number of steps to decelerate is less than the number of steps programmed in the target position than the 3202 module will run a Trapezoidal Velocity Profile Velocity Starting Speed Ds Total Number of Steps Da Dd Tt Ta Td Ds Vs Da Distance to Accelerate steps Ds Distance at the programmed speed steps Dd Distance to decelerate steps Vs Programmed Speed steps sec Tt Total Profile Time seconds Starting Speed The starting speed has a range of 1 to 1 000 000 pulses sec and is the pulse frequency at which every move begins and ends That is the first and last pulses of the move profile will be at the starting speed Some portions of the homing operations are also performed
21. al Input if configured is activated The Immediate Stop output bit is set The Emergency Stop Input is activated The End Limit Switch in the same direction as the motion is reached The Programmed speed Changes If the Manual Move command bit is turned off or if the External Input is active the axis will decelerate at the programmed rate to the starting speed and stop retaining a valid position If the Immediate Stop Output bit or the Emergency Stop Input is used the axis will stop without deceleration and the position will become invalid If the initial programmed speed is greater than the starting speed the speed of a Manual Move operation can be changed without stopping the motion If the velocity data is changed while the axis is moving the module will accelerate or decelerate to the new speed which can be less than the starting speed The acceleration and or the deceleration parameters can also be changed although these changes do not take affect until the programmed speed is changed Both the acceleration and deceleration parameters must be valid when the speed is changed If the changed velocity acceleration or deceleration parameters are invalid motion will stop command and invalid profile errors will be generated and the position will become invalid An additional feature of the Manual Move parameter is the ability to do a One Shot Manual Move With the programmed speed set to zero a 0 1 transition of the Manual Move bit w
22. amming A Blend Move consists of up to sixteen segments consisting of a Relative Segment Length a Target Velocity the Acceleration and Deceleration parameters The entire Blend Move profile is made up of 52 32 bit words 208 bytes and is programmed all at one time using a Message Instruction The blend move operation will be run each time bit 12 or 13 in the output Command word transitions from 0 to 1 The following is an example of the Message Instruction Button to Message ae Configuration Input Condition MSG EN Type CIP Generic DN Message Control user_defined_tag C ER Programming the configuration data clears the stored blend profile data The message instruction sends data to the 3202 module only when the rung transitions from false to true 3 The user_defined_tag used for Message Instruction Control must have the MESSAGE data type 4 Clicking on the button in the Message Instruction opens the Message Configuration Window shown below eo Message Configuration user defined tag Configuration Tab Message Configuration blend_message x Configuration Communication Tag User defined tag with a DINT Message Type CIP Generic data type Service Custom Source Element fblend_data 0 Md Type Source Length 208 Bytes Service 3 Code ac Hex Class 4 Hex Destination PO Instance 200 Attribute 0 Hex New Tag O Enable Enable Waiting O Start O Done Done Length
23. at the starting speed The Starting Speed can be any value less than or equal to the programmed speed of the slowest move Although it is not necessary the smoothest transition from rest to the programmed speed will be achieved with a Starting Speed equal to the square root of the acceleration value You may have the starting speed set to too small a value if you have a larger than expected delay between two of your move operations For example a starting speed of 1 step per second will result in a 1 second delay between move operations 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 12 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AMI 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Chapter 3 Configuration Programming The Configuration Mode provides the ability to select the proper setup configuration to match the stepper application without having to set any switches The configuration file consisting of two 32 bit words on each channel allows the following parameters to be defined If a CW Limit Switch will be used and its input active state If a CCW Limit Switch will be used and its input active state If an Emergency Stop will be used and its input active state If an External Input will be used and its active state a a The External Input can be used to stop a Manual Move operation or to place an Absolute or Relative move in a hold state If the Ext
24. ated There was no change to the functionality just to the documentation Information was added on the maximum input frequency of the encoder inputs A note was added on how the module will be displayed in RSNetworx Information on what will cause the configuration error and position invalid bit to be set was added The ability to capture either the encoder data or the current position data was added to the module Revision 3 1 was released on 8 13 03 The following changes were made 1 2 3 4 The Assembly Instance and Input Size for Listen Only operations was added Details on the Stopped Bit were added Details on the Move Complete bit were added Added details that a Home Invalid and Invalid Profile error will cause the Status LED to flash red Revision 3 2 was released on 12 11 03 The following changes were made 1 2 A note was added that RPI times below 3ms might occasionally cause the 3202 module to temporarily stop communicating with the PLC The stepper output specifications were changed from 5V to 5V differential A note was also added that the typical voltage level of the outputs will be 3 5 to 4Vdc Revision 4 0 was released on 7 3 06 The following changes were made Sorbo NMS General Information was added Table of Contents was added Module Specifications wiring information and front panel description was moved to the front of the specifications A diagram of output signals types was added A
25. cceleration is not allowed during homing operations Revision 1 3 was released on 10 4 02 The following change was made 1 The example program was incorrect The current position data is in Local 3 Ldata 1 not Local 3 I data 0 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 38 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Revision 2 0 was released on 10 22 01 The following changes were made 1 The 3202 is now a Rev A module The module s connector pin layout was changed The location of the encoder inputs has been changed and the unit no longer requires an external power supply Errors in the Blend Move programming word layout were corrected Diagrams showing how to wire single ended encoders that operate at different voltage levels were added The power supply requirements were changed Revision 3 0 was released on 2 26 03 The following changes were made 1 MAMA The minimum RPI time was changed from 0 3ms to 0 5ms A recommended RPI time of 3ms was also added This change was made because there is a chance of a momentary loss of communication between the module and the PLC at the faster times A wiring diagram showing how to connect the step and directions signals to a driver with differential inputs was added to the specifications The cause of the various error bits was upd
26. chapter on calculating move profiles was added The recommended RPI time was changed from 3ms to 5ms The sample programs were removed from the specifications and replaced with links to the online versions of the sample programs File 3202_specifications_rev_4 0 Date 7 6 06 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 39 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com
27. d including Encoder Preset that has data in the registers that contain the Programmed Speed Acceleration or Deceleration parameters Issuing a Homing Command with S Curve Acceleration selected Attempting to Preset the Encoder position when the module has not been configured to use an encoder Command Errors generated by Manual Move Operations Performing a Manual Move with data in the Target Position registers Placing a non zero value in the Target Position registers for a Manual Move that is occurring If the speed of a Manual Move is changed to zero Changing the speed of a Manual Move whose initial speed was less than or equal to the starting speed If invalid changes are made to the velocity acceleration or deceleration parameters of a Manual Move that is occurring Note that changes to the Acceleration and Deceleration parameters are only taken into account when the 3202 module detects a change in the Velocity parameter Command Errors generated by Blend Move Operations If a Blend Move operation was initiated before the profile was programmed using a message instruction If a blend move profile is started with data in the target position programmed speed acceleration or deceleration parameters If a blend move profile is programmed while a blend move operation is in progress If this occurs the final segments deceleration will be used to immediately stop the motion If the hold command is issued while a blend move profile is
28. d at the starting speed 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 13 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Configuration Mode Consumed Data Sixteen 32 bit words sent from the PLC to the 3202 module While in configuration mode the output registers have the following format a ee Channel Oana Units Range 0 1 Configuration Bits See description below 1 1 Starting Speed Steps Second 1 to 1 000 000 2 1 0 Must be zero 3 1 0 Must be zero 4 1 0 Must be zero 5 1 0 Must be zero 6 1 0 Must be zero 7 1 0 Must be zero 8 2 Configuration Bits See description below 9 2 Starting Speed Steps Second 1 to 1 000 000 10 2 0 Must be zero 11 2 0 Must be zero 12 2 0 Must be zero 13 2 0 Must be zero 14 2 0 Must be zero 15 2 0 Must be zero Note 1 At power up both channels will be disabled They will remain disabled as long as configuration data is not written to the module Note 2 If Configuration Mode is entered while a move is occurring the Command Error bit will be set the move will run to completion and then the module will enter Configuration Mode 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 14 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications
29. e 24 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com m VY Py fi ae AMI 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Blend Move This command allows the user to create more complicated move profiles consisting of two to sixteen segments as the following diagram illustrates 3 Runs at the first 4 Runs at the final 2 Accelerates from the starting speed prdeeainedispeed programined speed to the first programmed speed 5 Decelerates to the starting speed using the final segment deceleration parameter and Velocity stops 1 Jumps to the starting speed Position Each segment is defined by four parameters Acceleration Type Constant Triangular S Curve or Trapezoidal S curve Relative Segment Length Target speed Acceleration Deceleration Rate Fueps The minimum amount of information necessary to define a new move segment is the Target Speed The Segment Length and the Acceleration Deceleration rate do not have to change from one segment to the next An Invalid Profile Error will be generated if the Target Speed parameter is not different in two consecutive blend move segments The blend move programming is done at one time using a Message Instruction with the segments of the blend move profile stored in the internal memory of the 3202 This data will remain in the module s memory until power is removed from the module the configuration data is programmed o
30. e OK Flag This bit will be set as long as the module is operating This bit may briefly be reset when the module changes from Configuration Mode to Command Mode 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 37 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Revision History Revision 0 0 was released on 2 6 02 and was the initial version of the specifications Revision 0 1 was released on 6 14 02 The following changes were made to the specifications 1 2 3 The ability to disable an unused channel at power up was added A channel disabled status bit was added status word bit 28 The backplane home proximity bit was moved from bit 30 to bit 29 Input Status bit 29 now indicates when the home proximity output bit set The function of the LEDs was changed A solid red status LED now indicates when the module failed power up diagnostics A solid red OK LED now indicates a module fault The requirement of an external 24Vdc power supply has been removed The unit now has an internal isolated power supply to drive the pulse and direction output signals Connector pins 35 and 36 are now External Common Revision 1 0 was released on 9 18 02 The following changes were made to the specification 1 WP we 8 9 10 11 Blend Move operations were changed from being absolute to relative move
31. elow Constant Acceleration The module accelerates at a constant rate until the programmed speed is reached This is the only option for homing operations Velocity Acceleration 4 lt M T Time T Time Triangular S Curve Acceleration The module accelerates slowly at the beginning of the acceleration faster at the middle of the acceleration and again slowly at the end of the acceleration The acceleration rate is never constant Acceleration T lt gt lt gt T Time T 2 T 2 Velocity Time Trapezoidal S Curve Acceleration The module accelerates slowly at the beginning of the acceleration at a constant rate at the middle of the acceleration and again slowly at the end of the acceleration Velocity f Acceleration Time f T Time T 4 T 2 T 4 Notes 1 The defined acceleration type is also applied to the deceleration Constant acceleration has the shortest acceleration time and Triangular S Curve has the longest acceleration time 3 The constant portion of the Trapezoidal S Curve Acceleration is 50 of the total acceleration time 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 27 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com ANGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Chapter 5 Command Mode Output Data Sixteen 32 bit words sent from the PLC to the 3202 module Revision 4 0 All stepper motor operations are per
32. ernal Input is active when a move operation is initiated the 3202 module will generate only one step in the specified direction 5 Ifthe Capture Input will be used and its active state 6 Ifa Home Limit Switch will be used and its input active state 7 Ifa Quadrature Encoder will be used with the system 8 Ifthe channel will be configured for Diagnostic Feedback Diagnostic Feedback allows the unit to count its own output pulses by wiring the outputs to the encoder inputs 9 The output type either CW and CCW Pulses or Pulse and Direction 10 The type of homing operation that will be performed There are four Homing possibilities 1 Home Limit Switch Only 2 Home Limit Switch with a backplane bit acting as a Home Proximity 3 Marker Pulse Home with the Home Limit Switch Input acting as a Home Proximity 4 Marker Pulse Home with a backplane bit acting as a Home Proximity Note 1 When configured to use a Proximity Input the 3202 module will ignore any other home inputs until the proximity input is detected Note 2 The Backplane Proximity bit is a set by the PLC to indicate to the 3202 module that you are nearing the location of either the Home Limit Switch or the encoder s Marker Pulse Note 3 The Marker Pulse option also requires the presence of the Quadrature Encoder 11 The Starting Speed The starting speed is the pulse frequency that every move begins and ends at Some portions of the homing operations are also performe
33. et Speed 33 10 Acceleration Deceleration 9 2 Acceleration Deceleration 34 11 Segment Length 10 3 Segment Length 35 11 Target Speed 11 3 Target Speed 36 11 Acceleration Deceleration 12 3 Acceleration Deceleration 37 12 Segment Length 13 4 Segment Length 38 12 Target Speed 14 4 Target Speed 39 12 Acceleration Deceleration 15 4 Acceleration Deceleration 40 13 Segment Length 16 5 Segment Length 41 13 Target Speed 17 5 Target Speed 42 13 Acceleration Deceleration 18 5 Acceleration Deceleration 43 14 Segment Length 19 6 Segment Length 44 14 Target Speed 20 6 Target Speed 45 14 Acceleration Deceleration 21 6 Acceleration Deceleration 46 15 Segment Length 22 7 Segment Length 47 15 Target Speed 23 7 Target Speed 48 15 Acceleration Deceleration 24 7 Acceleration Deceleration 49 16 Segment Length 50 16 Target Speed 51 16 Acceleration Deceleration Word 0 Channel Number This parameter has a range of 1 or 2 and defines which of the two channels the blend move data is assigned to A value other than 1 or 2 will generate an Invalid Profile error Word 1 Number of Segments This parameter defines the number of blend move segments that are being programmed This parameter has a range of 2 to 16 A value outside of this range will generate an Invalid Profile Error Any data contained in the segments beyond the number defined by this parameter will be ignored 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 31 Tel 860 585
34. f any of the move parameters are outside of their valid ranges 3 If any of the reserved output registers are not set to zero 4 Ifthe defined profile overflows the internal registers of the 3202 module 5 Changing the speed of a Manual Move whose initial speed was less than or equal to the starting speed 6 Changing the Manual Move Speed to zero 7 Starting a Manual Move with the Target Position not equal to zero 8 Placing a non zero value in the Target Position registers for a Manual Move that is occurring 9 If invalid changes are made to the velocity acceleration or deceleration parameters of a Manual Move that is occurring Note that changes to the Acceleration and Deceleration parameters are only taken into account when the 3202 module detects a change in the Velocity parameter 10 Initiating an Encoder Move when the module has not been configured to use an encoder 11 If the blend move channel number is not equal to 1 or 2 12 Setting the number of Blend Move Segments to be less than 2 or greater than 16 13 If a Blend Move segment does not reach the Programmed Speed That is if the distance that it takes to accelerate to the programmed speed exceeds the length of the segment 14 Programming a Blend Move segment with no change in the Programmed Speed from the previous segment 15 Programming a Blend Move Profile before configuring the module 16 If the sum of the Blend Move Segment Lengths exceeds 8 388 607 The Modul
35. formed in command mode This mode is entered after a successful configuration file has been transferred to the stepper controller by resetting the Mode Flag bit 31 In Command Mode the PLC program can issue commands and activate different operations or moves A move profile typically consists of a Target Position Programmed Speed Acceleration and Deceleration parameters The following table shows the function of the output words Ou na d Channel Function Units Range 0 1 Command Word See description below 1 1 Target Position Steps 8 388 608 to 8 388 607 2 1 Programmed Speed Steps Second Starting Speed to 1 000 000 3 1 Acceleration Steps Second Second 1 000 to 2 000 000 4 1 Deceleration Steps Second Second 1 000 to 2 000 000 5 1 Reserved 6 1 Reserved 7 1 Reserved 8 2 Command Word See description below 9 2 Target Position Steps 8 388 608 to 8 388 607 10 2 Programmed Speed Steps Second Starting Speed to 1 000 000 11 2 Acceleration Steps Second Second 1 000 to 2 000 000 12 2 Deceleration Steps Second Second 1 000 to 2 000 000 13 2 Reserved 14 2 Reserved 15 2 Reserved Command Mode Programming Information 1 Only a single bit can be set at any one time in the Most Significant Command Word 2 A Command Error will be generated if a move operation is started before the previous move steps sec become invalid operation has completed A move operation should onl
36. ill cause the stepper controller to output 1 pulse in the specified direction Please note that in One Shot Manual Move mode the motion Direction bit will remain on and the Status LED will flash as long as the Manual Move command bit remains set The Stopped status bit will not be set when the Manual Move command bit is reset If the End Limit Switch in the same direction as motion is reached during a Manual Move the axis will stop without deceleration and the input error and position invalid input bits will be set For example reaching the CW Limit Switch during a CW Manual Move will stop the motion However an End Limit Switch in the direction opposite to motion will not stop a Manual Move operation For example reaching the CCW Limit Switch during a CW Manual Move This feature allows the module to be moved off of an active end limit switch 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 23 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Preset Current Position and Diagnostic Feedback Position This command will set the Current Position and the Diagnostic Feedback value if appropriate to the value present in the Target Position Registers If the position is currently invalid presetting the position will cause the position to become valid The programmed speed acceleration and deceleration parameters mu
37. itch goes On then Off Waits 2 seconds 7 Returns to the Home Limit Switch at the starting speed 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 20 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Backplane Home Proximity Bit with Home Limit Switch 3 Detects backplane proximity bit and 2 Runs at the decelerates to the starting speed programmed speed Pa 4 Runs at the starting speed s 5 Detects Home Limit Switch and stops 1 Accelerates to programmed aN Marker Pulse and Proximity Switch Either backplane bit or the Home Limit Switch treated as a Proximity Switch 2 Runs at the 3 Marker Pulse Ignored 4 Detects Proximity Switch and programmed speed Decelerates to the starting speed 1 Accelerates to Sy 5 Runs at the starting speed programmed speed Le lt 6 Detects 1 Marker Pulse after the Proximity and Stops Reaching an End Limit Switch during a Homing Operation 1 Runs at the Programmed Speed 2 Reaches the end Limit Switch stops without deceleration and waits for two seconds ee Turns at the programmed speed opposite gt to the requested direction hie 5 Returns at the starting speed to where the Home Input was detected Continues to Marker Pulse or Home Limit Switch if applicable 4 Waits for the Home Input to turn On then
38. later firmware the inactive to active transition of this input will cause either the current encoder data or the current position data to be captured and placed in the input registers With version 2 2 or earlier firmware only the current encoder can be captured In either case this value will remain until the next inactive to active transition of the input External Input When this input becomes active during a move operation the stepper motor will decelerate and stop while keeping track of the current position During a Manual Move the External Input will initiate a controlled stop During an Absolute or Relative move the External Input will cause the module to make a controlled stop to a hold state If the External Input is active when a move operation is initiated the 3202 module will generate only one step in the specified direction Emergency Stop The Emergency Stop Input causes the current move operation to stop without any deceleration The pulse signal is simply stopped If the channel was moving when this command was issued the current position will become invalid and the Position Invalid Input Bit will be set The channel will have to be Preset or Homed again before an Absolute Move operation can be performed However it will be possible to perform a Relative or a Manual Move after the Emergency Stop Input has been used Home Input Reaching the Home Input during a homing operation will cause the 3202 module to reset both the C
39. linking Green Motion on either channel OK A Solid Green Module OK no motion in progress at least one channel configured Off Both channels disabled OK LED Solid Red Module Fault Blinking Red Communication between module and PLC interrupted Blinking Green PLC is in Program Mode or one way communication module only sends data to the PLC or slot is not correctly configured for the module Solid Green Module Owned two way communication Output Signals The 3202 module can be programmed to output either Step and Direction signals or CW CCW steps There is no advantage to either type you must simply configure each channel of the 3202 module to match the input type of your driver The two signals types are illustrated below Step and Direction Output Step Output CCW Motion or Decreasing Counts Direction Output a a la es CW Motion or Increasing Counts CW and CCW Step Outputs atoe MI ty e o CCW Output 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 7 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Connector Pin Out The input connector consists of a Removable Terminal Block with the Rockwell Automation Part Numbers 1756 TBCH 36 position cage clamp or 1756 TBS6H 36 position spring clamp The terminal block is not supplied with the 3202 module Channel 1 CCW Limit Switch
40. mining the acceptability for each application While efforts have been made to provide accurate information within this manual AMCI assumes no responsibility for the application or the completeness of the information contained herein Throughout this manual the following two notices are used to highlight important points WARNINGS tell you when people may be hurt or equipment may be damaged if the procedure is not followed properly CAUTIONS tell you when equipment may be damaged if the procedure is not followed properly No patent liability is assumed by AMCI with respect to use of information circuits equipment or software described in this manual The information contained within this manual is subject to change without notice UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS INC BE RESPONSIBLE OR LIABLE FOR ANY DAMAGES OR LOSSES INCLUDING INDIRECT OR CONSEQUENTIAL DAMAGES OR LOSSES ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS MANUAL OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN Standard Warranty ADVANCED MICRO CONTROLS INC warrants that all equipment manufactured by it will be free from defects under normal use in materials and workmanship for a period of 18 months Within this warranty period AMCI shall at its option repair or replace free of charge any equipment covered by this warranty which is returned shipping charges prepaid within one year from date of invoice and which upon examinati
41. nd the Target Position is 7500 than the unit will output 2500 pulses After the Absolute Move has been completed the Current Position will be 7500 The direction of motion of an Absolute Move is determined by the relationship between the Current Position and Target Position If the Target Position gt Current Position than CW motion will occur If the Target Position lt Current Position than CCW motion will occur The current position does not have to be valid to perform a RELATIVE MOVE The Target Position defines the distance in number of pulses to travel relative to the Current Position For example if the Current Position is 5000 and the Target Position is 7500 than the unit will output 7500 pulses After the Relative Move has been completed the Current Position will be 12 500 The direction of motion of a Relative Move is selected by the sign of the Target Position A positive Target Position will generate a CW move while a negative Target Position will generate a CCW move The ABSOLUTE or RELATIVE MOVE operations can produce two different velocity profiles Normally the move operations start at the Starting Speed accelerate to the Programmed speed at the defined acceleration rate continue at the Programmed speed until it is time to decelerate back to the Starting Speed and Stop This generates a trapezoidal velocity profile However if the move operation does not reach the Programmed speed by the time the deceleration is to begin
42. on proves to be defective in material or workmanship and not caused by accident misuse neglect alteration improper installation or improper testing The provisions of the STANDARD WARRANTY are the sole obligations of AMCI and excludes all other warranties expressed or implied In no event shall AMCI be liable for incidental or consequential damages or for delay in performance of this warranty Returns Policy All equipment being returned to AMCI for repair or replacement regardless of warranty status must have a Return Merchandise Authorization number issued by AMCI Call 860 585 1254 with the model and serial numbers along with a description of the problem A RMA number will be issued Equipment must be shipped to AMCI with transportation charges prepaid Title and risk of loss or damage remains with the customer until shipment is received by AMCI 24 Hour Technical Support Number Technical Support in the form of documents FAQs and sample programs is available from our website www amci com 24 Hour technical support is also available on this product For technical support call 860 583 7271 Your call will be answered by the factory during regular business hours Monday through Friday 8AM 5PM EST During non business hours an automated system will ask you to leave a detailed message and the telephone number where you can be reached The system will page an engineer on call Please have your product model number and a desc
43. oth the current position and the encoder position to zero If the capture value is present it too will be reset to Zero The Find Home commands require that at least one End Limit Switch either CW or CCW be configured The 3202 will not accept a Find Home CW command when there is no CW Limit Switch configured Likewise it will not accept a Find Home CCW command when there is no CCW Limit Switch configured If either of these operations are attempted the COMMAND ERROR Input bit will be set S Curve acceleration profiles are not allowed during a homing operation Initiating a home operation with S curve accelerations will cause a command error to be generated If during a Home operation either of the End Limit Switch endpoints are reached the module will stop outputting pulses essentially an emergency stop wait for two seconds reverse direction and start searching for the appropriate homing signal again It is important not to have the velocity set to high during a homing operation The sudden stop and change in direction at high speeds may cause the motor to lock up The following diagrams illustrate the different homing options Home Limit Switch Only 3 Detects the Home Limit 2 Runs at the Switch programmed speed e 1 Accelerates to A 4 Decelerates to stop programmed i and waits 2 seconds lt 5 Accelerates to the programmed speed opposite to the requested direction 6 Decelerates when the Home Limit Sw
44. programmed speed and the starting speed The two Most Significant bits in this 32 bit are used to define the deceleration type Bit 31 Bit 30 Function 0 0 Constant Acceleration 0 1 Triangular S Curve Acceleration 1 1 Trapezoidal S Curve Acceleration Segment Length e The sum of all of the segment lengths cannot exceed 8 388 607 e The segment lengths must be positive Acceleration Deceleration Parameters This parameter defines the rate of change of the speed between two adjacent segments If the speed in the next segment is greater than the speed in the current segment then this parameter will be used as an acceleration value If the speed in the next segment is less than the speed in the current segment then this parameter will be used as a deceleration value 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 32 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Chapter 6 Command Mode Input Data Sixteen 32 bit words sent from the 3202 module to the PLC Sample Programs showing how to program the 3202 module are available from the following page of our website http www amci com sampleprograms asp 32 bit Input Channel ommend vade put Units Word Data 0 1 Status Word See Description Below 1
45. r a new blend move profile is sent to the unit The Blend Move Profile is programmed as a series of Relative Moves so the position does not have to be valid for the blend move operation to take place The first segment starts at the Starting Speed and accelerates to the specified Programmed speed The starting speed for the next segment is equal to the programmed speed of the current segment The final segment will decelerate from the final programmed speed to the starting speed and then stop Itis not possible to program a direction reversal in the blend move profile Because the 3202 stores the data for the Blend Move Profile in its memory the programmed profile can be run more than once and from any location Two command bits allow the blend move profile to be run in either direction Please note that it is possible to perform other move or home operations between performing the blend move profiles 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 25 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Encoder Move The 3202 has the ability to perform an Encoder Move where the number of counts made by an incremental encoder determines the distance of the move If bit 18 of the command word is set when an absolute or relative move is initiated the 3202 module will begin a move profile using the programmed velocit
46. r home operation will not have any affect on the 3202 module s profile e Before performing a Target Position absolute or relative move it will be necessary to reset bit 18 the command word e An Encoder Move will take place even if a working encoder is not attached to the module If this occurs motion will continue until it is stopped by an Emergency Stop Input the External Input or an Immediate Stop command e Ifthe Encoder Move bit bit 18 is reset while an Encoder Move is occurring the move will not stop at the encoder count and the Emergency Stop Input or Immediate Stop command bit will have to be used to stop the move Diagnostic Feedback By wiring the pulse and direction outputs to the encoder inputs this feature can be used to verify program and module operation When in diagnostic feedback mode the module counts its own pulses and reports the position data in the Current Encoder Diagnostic Feedback input register The maximum input frequency that the module can accurately measure in Diagnostic Feedback mode is 500kHz 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 26 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAMA 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Acceleration Types With the exception of homing operations all of the move operations defined above allow the type of acceleration to be selected The three options are described b
47. ription of the problem ready before you call 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 2 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com ANGE Table of Contents Installing the 3202 Module Calculating Move Profiles Configuration Programming Command Mode Operations Command Mode Output Data Command Mode Input Data Revision History 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Chapter 1 Installing the 3202 module Configuring a ControlLogix system Module Specifications Discrete Input Specifications Front Panel amp LED Functions Output Signals Connector Pinout and Wiring Notes Diagnostic Feedback Wiring Differential Output Wiring Single Ended Encoder Wiring Chapter 2 Chapter 3 Configuration Bits Input Active Level Starting Speed Invalid Configurations Configuration Mode Input Data Chapter 4 Absolute amp Relative Moves Hold Move Resume Move Immediate Stop Find Home CW Find Home CCW Manual Move CW Manual Move CCW Preset Current Position Preset Encoder Position Reset Errors Blend Move Encoder Move Diagnostic Feedback Acceleration Types Chapter 5 Command Words Command Bits Revision 4 0 BOOCMINRAWAAA Blend Move Programming message instructions 30 Chapter 6 Status Bits Input Word Functions Status amp Error Bit Functions 20 Gear Drive Plymouth Industrial Park Terryville C
48. rmed at the starting speed Note The Starting Speed can be any value less than or equal to the programmed speed of the slowest move Although it is not necessary the smoothest transition from rest to the programmed speed will be achieved with a Starting Speed equal to the square root of the acceleration value You may have the starting speed set to too small a value if you have a larger than expected delay between two of your move operations For example a starting speed of 1 step per second will result in a 1 second delay between move operations Invalid Configurations The 3202 module will not accept all possible configurations The following is a list of the invalid configurations 1 A configuration without the ability to home the module A configuration without at least one End Limit Switch either CW or CCW Note The ability to home the module and at least one of the end limit switches have to be configured They do not have to actually be used in the stepper application Using Quadrature Encoder and Diagnostic Feedback Using a Marker Pulse Home without the Quadrature Encoder Diagnostic Feedback with CW and CCW pulse outputs A starting speed outside the range of 1 lt starting speed lt 1 000 000 Setting the module to use the Capture Input without configuring the module to use the encoder Firmware versions 2 2 or lower Firmware versions 3 1 or higher do not have this restriction 8 Setting any of the unused bits in
49. rs from the following table The Listen Only columns will only be used by any additional processors that are installed in the rack chassis CONNECTION PARAMETERS Instance bit words Instance bit words 242 0 2 0 7 Click on Next gt 8 Set the RPI Rate Packet Interval Time to the desired value Sms is the recommended value The minimum RPI is 0 5ms However below 3ms the unit may occasionally lose communication with the PLC 9 Click on Finish gt gt 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 4 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 The 3202 module will now appear in the project tree and three new data tags will have been created Local X I Data Y Local X O Data Y and Local X C Data Y where X is the slot number and Y is the word number The status current position encoder position and captured encoder value are located in the Input tags With the exception of the programming of the blend move profile which uses a message instruction all commands are sent to the 3202 module through the Output tags The 3202 module does not use the Configuration tags Module Specifications e Backplane Current Draw 510mA 5Vdc e Throughput Time 250 us Inputs must be on for 250us to be scanned by the module e Minimum recommended RPI time 3ms Stepper Outp
50. s The ability to perform blend moves in either direction was added There are now two command bits that initiate a blend move bit 12 performs a blend move in the positive direction and bit 13 performs a blend move in the negative direction The acceleration type bits were moved from bits 13 and 14 to bits 16 and 17 The type of move target position or encoder move was moved from bit 15 to bit 18 The reserved input was changed to the capture input The encoder capture function was moved from the external input to the capture input The rack configuration data was added to the specifications The M3202 rev board had incorrect encoder wiring and the wiring information was changed to reflect this An example program was added The Preset Position Command text was changed because it also affects the Diagnostic Feedback data The Preset Encoder command does not affect the diagnostic feedback data The Captured Encoder value will now be cleared by a home operation The Backplane Home Proximity configuration bit was moved from bit 13 to bit 6 Revision 1 2 was released on 10 1 02 The following changes were made to the specification 1 2 3 4 A note on how the acceleration type must be selected when resuming a move was added A note on how changing the speed of a manual move that was started less than or equal to the starting speed was added Acceleration vs time plots were added to the acceleration type information S Curve A
51. s an INVALID PROFILE 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com page 33 AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Status Word Layout Continued bit 16 set when the CAPTURE INPUT is active bit 17 set when the EXTERNAL INPUT is active bit 18 set when the HOME LIMIT SWITCH input is active bit 19 set when the EMERGENCY STOP input is active bit 20 set when the CW LIMIT SWITCH input is active bit 21 set when the CCW LIMIT SWITCH input is active bits 22 to 27 Reserved bit 28 channel disabled set when the channel has not been configured after power up bit 29 set when the backplane home proximity output bit is set even if no home operation is occurring bit 30 MODULE OK bit set when the module is working correctly bit 31 MODE FLAG 1 configuration mode 0 for command mode CURRENT POSITION This word reports the Current Position based on the number of pulses that have been output to the stepper driver This value may be different from the Encoder Position A negative Current Position value will be displayed as a negative decimal number If viewed in binary this will be 2s compliment format When switching from Configuration Mode to Command Mode the Current Position will be reset to zero The current position data is not limited by the 8 388 607 range of the outpu
52. st be zero when this command is sent to the module Preset Encoder Position This command will set Current Encoder Value to the value present in the Target Position registers The programmed speed acceleration and deceleration parameters must be zero when this command is sent to the module Reset Errors This command clears all nonfatal errors detected by the stepper controller A nonfatal error is one that can be recovered from For example requesting an Absolute Move when the position is not valid is a nonfatal error When there is a Command Error the controller will not perform any other operations until the Reset Errors command is issued General Command Mode Operation Notes 1 Only one command bit can be set at any one time 2 A Command Error will be generated if a move operation is started before the previous move operation is completed A move operation should only be started if the Move Complete Stopped or Hold status bits are set 3 Only a 0 to 1 transition of any of the control bits listed above will cause the specified operation to take place 4 If either the CW or CCW Limit Switches are reached during a normal move or manual move operation the module will treat the input as an emergency stop meaning that the motor will stop and the position will become invalid 5 Itis possible to home the 3202 module off of an end limit switch 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 pag
53. t parameters It instead uses all 32 bits in the data word and has a range of 0 to ffff_ffffh Please note that because the Most Significant Bit is used to indicate the sign the value will become negative when it changes from 7fff_ffffh to 1000_0000h ENCODER POSITION This word reports the position based on the feedback from an encoder attached to the stepper motor This value may be different from the Current Position A negative Encoder Position value will be displayed as a negative decimal number If viewed in binary this will be 2s compliment format As with the current position data the Encoder Position uses all 32 bits in the data word and has a range of O to ffff_fffth CAPTURED DATA This word reports the data captured when the Capture Input transitions from inactive to active The value captured will depend on how the 3202 module is configured If the module s configuration did not include the Quadrature Encoder the Current Position Data will be captured If the module s configuration did include the Quadrature Encoder the Encoder Data will be captured Only modules with firmware versions 3 1 or later can capture the Current Position data Firmware versions 2 2 or lower can only capture the encoder data Negative Captured Data value will be displayed as a negative decimal number If viewed in binary this will be 2s compliment format As with the current and encoder position data the Captured Encoder Position uses all 32 bi
54. the configuration words 9 Selecting Marker Pulse home without also selecting to use either the Home Input which will act as a proximity limit or the Backplane Proximity bit 10 Selecting Marker Pulse home with both the Home Input and the Backplane Proximity bit 11 Setting any of the unused words to a value other than zero SON NP oe The 3202 has to be configured before starting any operations When the Configuration Mode bit is set in the output registers the stepper controller enters Configuration Mode When in this mode the stepper controller will stop its operations and set the Configuration Mode status bit in the input registers It then waits for the configuration file to be transferred If there is no current Configuration File present or if the transferred Configuration File is not valid the Configuration Error Input bit will be set If the transferred configuration file is accepted and if it is different from the current configuration the configuration data will be mirrored in the input registers 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 16 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AMG 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Configuration Mode Input Data While in configuration mode the input registers will mirror the configuration data that was sent to the 3202 module in the output registers The exceptions are the Module O
55. ts in the data word and has a range of 0 to ffff_ffffh The Captured Data value cannot be reset from the PLC and will be cleared by a homing operation 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 34 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 The Stopped Bit will be set under the following conditions a When a CW or CCW Manual Move operation has been completed When the Emergency Stop input has been used to stop a move operation When the Immediate Stop command bit has been used to stop a move operation When either the CW or CCW Limit switches have been reached during any move operation except Homing The Stopped bit will not be set after an Absolute or Relative Move after a Homing Operation after a Blend Move or when a move operation is in a Hold State The Move Complete Bit will be set under the following conditions After an Absolute Move a Relative Move or a Blend Move have been successively completed The Move Complete bit will be reset when the next move operation is initiated The Position Invalid will be set under the following conditions 1 After a configuration operation has occurred This will be true even if the position was valid before the configuration operation occurred After an Immediate Stop command has been issued If the Emergency Stop input has been activated
56. uired for acceleration and how many steps will be required for deceleration Depending on the data used to define the move profile this can result in two types of velocity profiles either a Trapezoidal Profile or a Triangular Profile A Trapezoidal Profile jumps from rest to the Starting Speed accelerates to the Programmed Velocity at the commanded acceleration rate continues at the Programmed Velocity to a predetermined point and then decelerates to the target position at the commanded deceleration rate to the starting speed and stops Velocity Trapezoidal Profile Starting Speed mort rrr nA nnn Time However if the length of a commanded move is not long enough to attain the programmed velocity before the deceleration point is reached a Triangular Velocity profile will be generated Velocity Triangular Profile Starting Speed Time Regardless of the type of Velocity Profile that is being run the following equations can be used to determine both the time to accelerate and the number of steps needed to accelerate These formulas can also be used to calculate the time and distance to decelerate Ta Vs Vo a Velocity Da Ta Vo Vs 2 Vo Starting Speed steps second Vo Vs Programmed Speed steps second Ta Time to accelerate seconds Da Distance to accelerate steps a Acceleration rate steps second second Time 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 11
57. urrent Position and if applicable the Encoder Position to zero The Home Input has no function unless a homing operation is being performed Each channel of the 3202 module must be configured with the ability to home the module This is true even if your system does not require a Home Input CW amp CCW Limit Switch Inputs During most move operations the CW and CCW Limit Switches act as an Emergency Stop input There are two exceptions The first is during a homing operation where the direction of motion will be reversed and the module will start looking for the Home Input in the opposite direction The second is if the opposite end limit switch is reached during a Manual Move operation For example if the CW limit switch is reached during a CCW Manual Move In this case the module will ignore the End Limit Switch input Each channel of the 3202 module must be configured with at least one of these Limit Switch Inputs 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 6 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Front Panel LED Function Ye FF PF AMC STEPPER Status LED Listed by priority Solid Red Module failed power up diagnostics STATUS Blinking Red Configuration Error Command Error Input Error Home Invalid Error or an Invalid Profile Error Set when error detected on either channel B
58. use this error 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 35 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 A Command Error will be generated under the following conditions 1 2 an po 10 11 12 13 14 15 16 17 18 19 20 Configuring the unit while a move operation is occurring The move will run to completion and then the Configuration will be allowed to occur clearing the command error If more than one Command bit is set The exceptions are bits 16 and 17 the acceleration type bits and bit 18 the encoder move bit Bit 29 the backplane home proximity bit can be set at any time If the Target Position Programmed Speed Acceleration or Deceleration parameters are outside of their valid ranges If the programmed speed is less than the starting speed This applies to Absolute Moves Relative Moves Homing operations and Blend Moves However Manual Moves can be run at speeds less than the starting speed If any of the reserved output registers are not set to zero Performing an Absolute Move when the Current Position is not valid Issuing a Hold Command when there is no Absolute or Relative move in progress For example during Manual Moves Blend Moves or Home operations Issuing a Resume command when the channel is not in a Hold state A Preset Comman
59. uts e 5V differential 3 5V to 4Vdc peak typical e Maximum Output Current 20mA e Maximum Output Frequency 1MHz Encoder Inputs 5V differential encoder only A B and Z Maximum Input Current 10mA per channel 5Vdc A B and Z Maximum Input Frequency with X4 decoding 1MHz The 3202 module uses X4 decoding on the encoder signals Only a 5V differential encoder can be directly attached to each channel of the 3202 module Encoders at other voltage levels can be connected if current limiting resistors are used e A move profile does not have to be in progress in order for the unit to count encoder pulses e The A and B signals must both be connected to the 3202 module to have the encoder data increment or decrement e Because X4 decoding is used the maximum frequency of the A and B signals is 250kHz e When used for Diagnostic Feedback the encoder inputs have a maximum input frequency of 500kHz 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 page 5 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Discrete Inputs e Input Type Sinking Input Voltage Range On 8 to 24Vdc Off 0 to 2Vdc e Input Current 15mA 24Vdc e Response Time On and Off Sus e The module interrogates the Discrete Inputs a maximum of every 250us e The Input Functions are described below Capture Input With version 3 1 or
60. y and acceleration parameters The programmed position is now the number of encoder counts to move When this encoder count is reached the 3202 module will begin to decelerate at the programmed deceleration rate and stop After motion has stopped the 3202 module will set status bit 7 the Move Complete bit The following must be considered when using the Encoder Move function e The 3202 module uses X4 decoding on the encoder inputs so the number of counts per turn of the encoder will be four times the encoder s resolution For example if a 1000 line encoder is being used the 3202 will report 4000 counts per turn This is the number that must be used when determining the position data of your encoder move e Absolute Encoder moves will be negative motion in the Counter Clockwise direction if the target position is less than the current encoder position e Relative Encoder moves will be negative motion in the Counter Clockwise direction only if the target position is negative e If the 3202 module is not configured to accept encoder inputs attempting an encoder move will cause a command error to be generated e It is not possible to hold an encoder move A backplane hold command issued during an encoder move will be ignored e Activating the External Input during an encoder move will cause the module to execute a controlled stop but will not put the channel in a hold state e Setting bit 18 of the command word during a manual move o
61. y be started if the Move Complete Stopped or Hold status bits are set 3 A negative Target Position value will be programmed as a negative decimal number If viewed in binary this will be 2s compliment format 4 The Position parameter has a range of 8 388 608 lt Target Position lt 8 388 607 5 The Programmed Speed has a range of Starting Speed lt Programmed Speed lt 1 000 000 6 The acceleration and deceleration parameters have a range of 1 000 lt acceleration deceleration lt 2 000 000 and is measured in steps sec sec 7 Switching the PLC to Program Mode will cause any move operation to stop and the position to 20 Gear Drive Plymouth Industrial Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 E mail Sales amci com page 28 AAIVIGE 3202 Rev A Module Specifications Two Channel ControlLogix Stepper Module Revision 4 0 Command Word Layout bit 0 set to start an ABSOLUTE MOVE operation bit 1 set to start a RELATIVE MOVE operation bit 2 set to perform a HOLD MOVE operation bit 3 set to perform a RESUME MOVE operation bit 4 set to perform an IMMEDIATE STOP operation bit 5 set to start a FIND HOME CW operation bit 6 set to start a FIND HOME CCW operation bit 7 set to starta MANUAL MOVE CW operation Reset this bit to stop the Manual Move Operation bit 8 set to start a MANUAL MOVE CCW operation Reset this bit to stop the Manual Move Operation
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