September 22, 2000 GFK-1775B IMPORTANT PRODUCT INFORMATION READ THIS INFORMATION FIRST Product: IC693 DSM Module (DSM314) with Firmware Version 2.0 IC693DSM314-AC Introduction Some of the information in this document is not available elsewhere, so we recommend you save it for future reference. This document covers the following subjects: • General description of the DSM314 module. • Special Operational Notes • Features and Functionality notes • Restrictions and Open Problems notes General Description of the DSM314 Product Description The IC693DSM314 Module (DSM314) can control up to four analog servos or two digital servos plus one analog servo. This controller also supports high speed Local Logic which allows the DSM to perform limited logical decisions and math synchronous with the position loop update rate. Local Logic also supports high speed digital output control synchronous to axis motion. Additionally, an electronic CAM follower function is supported by the module, starting with firmware release 2.0. This allows the module to be used in many applications traditionally supported by mechanical CAMs. The strobe position capture accuracy is significantly better than the DSM302. With the support of VersaPro 1.5, CAM Editor 1.0, and CPU release 10.00 firmware, the DSM314 achieves single point of programming with all motion, Local Logic, and CAM programs and hardware configuration stored in the PLC CPU. Programs are then transferred via the backplane to each DSM314 at power-up. The basic capabilities of the DSM314 are described below: High Performance Digital Signal Processor (DSP) provides vector control of AC servos Servo loop update: Digital mode: 250 µsec (torque), 1 mSec (velocity), 2 mSec (position) 1 Axis Analog mode, no Local Logic: 0.5 mSec (position) 1 Axis Analog mode with Local Logic: 1.0 mSec (position) 2 Axis Analog mode, no Local Logic: 1.0 mSec (position) 2-3 Axis Analog mode with Local Logic: 2.0 mSec (position) 3-4 Axis Analog mode, no Local Logic: 2.0 mSec (position) Block processing time under 5 mSec Velocity Feed Forward and Position Error Integrator to enhance tracking accuracy Local Logic Electronic CAM Fast Backplane Status Access Read/Write Support (SVREQ #46) High resolution of programming units Position: -536,870,912 .. +536,870,911 User Units (at 1:1 User Units / Counts) Velocity: 1 .. 1,000,000 User Units / sec (at 1:1 User Units / Counts) Acceleration: 1 .. 1,073,741,823 User Units / sec / sec (at 1:1 User Units / Counts) 2 Important Product Information: IC693DSM314 Module GFK-1775B Ease of Use Single Point of Programming Simple and powerful instruction set One or two axis motion programs with synchronized block start on axis 1 & axis 2 Up to four concurrent single axis motion programs Integrated Motion programming, Local Logic programming, and Electronic CAM programming in VersaPro Motion, Local Logic, and CAM Programs are transferred across the PLC backplane User scaling of programming units Generic programming using command parameters as operands for Acceleration, Velocity, Move and Dwell commands Configured with VersaPro software Automatic data transfer between PLC tables and the DSM314 without user programming Ease of I/O connection with factory cables and terminal blocks as well as a serial port for connecting programming devices Versatile I/O Control of digital AC servos & Analog servos with ± 10v Velocity Command Interface 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 the PLC Incremental quadrature encoder input for Follower mode 13 bit analog output for each auxiliary axis can be controlled by PLC or used as servo tuning monitor Product ID IC693DSM314-AC H/W Id: AP3B1 (44A737294-G01R03 or later) S/W Id: Firmware version: 2.0 App. 44F725986-417AC Firmware Update Kit Update kit number for this firmware release (version 2.0) is 44A749487-G02 Applicable Documents GFK-1742A, DSM314 for IC693 PLCs User’s Manual Important Product Information: IC693DSM314 Module 3 GFK-1775B Special Operational Notes IC693 CPU Firmware Use of the DSM314 requires that version 10.00 or higher of the IC693 CPU firmware be installed in the CPU module. CPU firmware version 10.00 (or higher) is only available for CPUs 350, 352, 360, 363, and 364. VersaPro Use of DSM314 firmware version 2.0 requires that version 1.50 or higher of VersaPro be utilized to configure and program the DSM314 module. The DSM314 is not compatible with any other PLC programming software or with the DOS-based Motion Programmer software. Additionally, the Electronic CAM function requires the CAM Editor version 1.0. The CAM Editor package is integrated with VersaPro and can be ordered as an add-on to VersaPro. The part number for the CAM Editor 1.0 is IC641VPSCAMA. Essential Configuration Parameters VersaPro configuration software version 1.50 or later must be used to configure the DSM314 module, release 2.0. The following configuration parameters will typically not default to the settings required for many applications and must be changed by the user or are features not available in this firmware release. Motor1 Type, Motor2 Type: For digital servos motor type must be changed to match the specific type number of the motor used. Select type 0 only if no servo is used or in ANALOG mode. Analog Servo Command Torque is not supported in this firmware release Acceleration Feed Forward Percentage Acceleration Feed Forward Percentage is not supported in this firmware release Feedback Source Feedback Source must use default or Ext Quadrature Encoder. Ext Quadrature Encoder is used with Digital Mode Axis-1 only. Other choices are not supported in this firmware release Feedback Mode If Feedback Source is set to Ext. Quadrature Encoder, then Feedback Mode is always Incremental (even if set to Absolute) Ramp Makeup Mode Ramp Makeup Mode must use Makeup Time. Ramp Makeup Velocity Ramp Makeup Velocity is used when the Follower Disable Action is Inc Position or Abs Position, and the follower slave axis reverses direction after a Follower Disable Trigger. The ability to reverse direction after a Follower Disable Trigger is an improvement in firmware release 2.0. Advanced Parameters Only the first two Advanced Parameters in Hardware Configuration are supported in this firmware release PLC %Q Bits PLC %Q bits are, by design, RETENTIVE in nature. These bits ONLY become NON-RETENTIVE after their location is used (programmed) in a PLC program. All motion-causing %Q bits such as Drive Enable, Start Motion program, Jog, etc. must be controlled from a programmed PLC coil reference for safe operation. 4 Important Product Information: IC693DSM314 Module GFK-1775B Grounding Bars and Clamps The DSM314 for IC693 PLCs User’s Manual describes the I/O cable grounding requirements required for a system to meet CE Mark installation guidelines. These guidelines include the use of grounding bars and clamps. A Grounding Bar may be ordered as part number 44B295864-001R02 and a Ground Clamp as part number A99L-0035-0001. Cables Two I/O, two command, and one communication cable are available for use with the DSM314, as described below. Consult the factory regarding custom length cables. IC693CBL324: 1 meter terminal board connection I/O cable IC693CBL325: 3 meter terminal board connection I/O cable IC800CBL001: 1 meter servo command cable IC800CBL002: 3 meter servo command cable IC693CBL316: Motion programmer communications cable Caution The I/O and command cables listed above are custom manufactured with special shielding and internal construction. Substituting non-approved cables may adversely affect the servo system. Terminal Boards Two terminal boards for user I/O connections are available for use with the DSM314, as described below. IC693ACC335: Servo terminal board IC693ACC336: Auxiliary terminal board These terminal boards provide screw terminal connections for I/O signals such as Position Strobes, Home Switches, Limit Switches, Analog Inputs, and Analog Outputs. For additional information, refer to Chapter 3 of GFK-1742, DSM314 for IC693 PLCs User's Manual. Caution The terminal blocks contain Metal Oxide Varistor (MOV) circuit protectors, which prevent excessive electrical energy from affecting the DSM314. The maximum recommended input voltage for any of the 24v I/O circuits is 30 VDC with respect to earth ground (S terminal) or circuit common. Strobe Input Differences between Analog and Digital Mode The strobe input faceplate pins for Axis 1 and Axis 2 depend on the DSM servo mode (Analog or Digital). In Digital Mode, the Axis 1 and 2 strobe inputs use faceplate inputs IN1 and IN2, which can be either single ended or differential. In Analog mode, the Axis 1 and 2 strobe inputs use faceplate inputs IO5 and IO6, which are single ended only. Axis 3 & 4 always use IO5 and IO6 as the strobe inputs. NOTE The input circuits for IO5 and IO6 contain 4.7k pull-up resistors to internal +5v. If no signal is connected to these inputs, the input will always appear to be ON. Normally a single ended TTL or CMOS driver must be used to drive these circuits from the strobe sensor. Important Product Information: IC693DSM314 Module 5 GFK-1775B The strobe inputs are summarized in the table below. Servo Type Axis 1 Strobe Inputs Axis 2 Strobe Inputs Axis 3 Strobe Inputs Axis 4 Strobe Inputs Digital IN1_A, IN2_A (Single Ended or Differential) IN1_B, IN2_B (Single Ended or Differential) Analog IO5_A, IO6_A (Single Ended) IO5_B, IO6_B (Single Ended) IO5_C, IO6_C (Single Ended) IO5_D, IO6_D (Single Ended) Follower Disable and Abort Operation When the follower function is active, the DSM Abort %Q bit DOES NOT disable the follower function. The user can immediately halt motion by turning off the Enable Follower %Q bit. Thus, the Abort %Q bit halts programmed motion, and the Enable Follower %Q bit halts follower motion. This operation is different from DSM314 releases 1.0 and 1.1. In these earlier releases, the Abort %Q bit halted both programmed motion and follower motion. CAM in Absolute Mode can Lose Synch if Master Drive is Disabled If the Master Drive is Disabled and then Renabled, the CAM axis will lose master counts that result from master axis motion while the master axis is disabled. In Absolute mode, this can cause the CAM axis to lose synch from the absolute master value. It is recommended that when the CAM command is operated in absolute mode, the CAM be aborted when the master axis is disabled. Problems Resolved by this Release (2.0) Inconsistent operation of Absolute Rotary Mode When the configuration for Software EOT is set to Disabled and the DSM is in rotary mode, commanded and actual positions are allowed to roll over at the configured limits. An Absolute mode %AQ move command works as expected – the axis always moves within 1 revolution to the absolute position specified in the command. However, if a motion program with a combination of incremental and absolute moves is used, an absolute move may cause unexpected results - the axis may move many revolutions when the user expected it to move only within one revolution. If %AQ move commands are used instead of a motion program, the axis works as expected. This has been corrected in firmware version 2.0. Select analog output mode cannot be sent from axis 4 AQ command registers The Select Analog Output mode command (AQ command 47h) can only be sent from the AQ command registers for Axis 1-3. If the command is sent in the axis 4 command registers it will not have any effect. This has been corrected in firmware version 2.0. Follower Registration Move is referenced to previous cycle When a Follower registration move (Follower Disable mode = Inc Position) is initiated by a faceplate input (CTL bit), the actual registration distance relative to the position at the instant the faceplate input turns on is 0-2 ms less 6 Important Product Information: IC693DSM314 Module GFK-1775B than the programmed registration distance. The only noticeable effect will be on a local logic program which corrects for 2 ms sampling variations using slave axis strobe data and the local logic position increment command. The strobe position must be compared to the Actual Position of the cycle before the strobe rather than the cycle after the strobe. This has been corrected in firmware version 2.0. Problems Resolved by Previous Release (1.1) None New Features and Functionality of this Release (2.0) Electronic CAM An electronic CAM is analogous to a mechanical CAM but will never mechanically wear out. Electronic CAMs also provide flexibility for quick transition between different profiles without the need for mechanical cam replacement. The DSM314 CAM profiles are configured with a new easy to use graphical editor addition to VersaPro 1.5. Electronic CAMs are used in the machine industry to perform complex motions that require tight coordination between axis. Often the cam profile follows the input from a master encoder mounted on the machine but can also follow another controlled axis within the same DSM314 module. Some examples of applications that can benefit from cam profiling are: • Rotary cutoff • Flying shear • Profiled container filling • Material handling Consult the User's Manual (GFK-1742A) or VersaPro on-line help for more information. New Features and Functionality of Previous Release (1.1) External Position Feedback (DIGITAL Mode Only) External position feedback allows the user to control the servo position loop of axis-1 from a position feedback device (Quadrature Encoder) that is different from the position encoder mounted on the motor. The standard digital servo motor feedback (from the serial encoder) will be used for motor commutation and feedback for the remaining loops. Axis 1 in the DSM314 can be configured to use an external encoder connected to the Axis 3 C connector. Reference DSM314 for IC693 PLCs User’s Manual for more details on the axis connectors. In VersaPro Hardware Configuration, the Axis 3 mode must be set to Auxiliary Axis (in the Settings tab). In the Axis # 1 tab the Feedback Source must be set to Ext Quadrature Encoder. The external feedback feature is not available for Axis 2. NOTE The quadrature encoder must be wired in phase with the encoder that is in use on the digital servo motor. An easy way to check the wiring for correct operation is as follows. Wire the external encoder to the module. Configure Axis 3 Mode as an Auxiliary Axis. Do not enable the Ext Quadrature Encoder feature for Axis 1 at this point. This simple configuration will allow the DSM to report the position read Important Product Information: IC693DSM314 Module 7 GFK-1775B from the digital servo motor-mounted encoder (axis 1) and the external quadrature encoder (axis 3). The user should also verify that the Axis Direction configuration parameter for both axis 1 and axis 3 are set to Normal. Turn on the %Q Enable Drive bit and place the command code for Force Digital Servo Velocity to 0 in the %AQ table. Confirm that the servo amplifier is enabled (the motor should exhibit holding torque). The %Q Enable Drive bit must be maintained ON in order for the Force Digital Servo Velocity command to function. Send the command code for Force Digital Servo Velocity. The user should send a small value such that the servo motion will not harm the driven load. Confirm that the motor position reported for axis 1 and the encoder position for axis 3 have the same phase. For example: If the reported axis 1 position is positive and increasing, then the reported axis 3 position should also be positive and increasing. If the positions are out of phase (i.e. positive/negative) then reverse the encoder channel A and channel B inputs for the external encoder and repeat the above test. If this does not fix the problem, consult the documentation that came with your encoder. Once the encoder and motor feedback devices have the same phase, the user can proceed with setting up the external encoder feature. In the tab Tuning #1, the user must enter a Velocity at Max Cmd value. The Velocity at Max Cmd data must be the velocity at which the external quadrature encoder would be rotating if the digital servo motor were running at 4096 rpm. The data does not imply that the digital servo motor can run at 4096 rpm, it is only used to set up the DSM internal gain factors for position loop gain and velocity feedforward. The reader should note that the above process of setting Velocity at Max Cmd would need to be redone if the User Units to Counts ratio for axis 1 is changed. The Velocity at Max Cmd data units are axis 1 user units/sec. The user must calculate the axis 3 encoder output in cts/sec and convert to axis 1 user units/sec. The maximum allowed value for Velocity at Max Cmd is 1 million cts/sec (DSM hardware and firmware limit), which is enforced by VersaPro Hardware Configuration. When Axis 1 is configured for external feedback, the Find Home cycle will still use the 24v Home Switch input from the A connector even though the external encoder is connected to the C connector. Similarly, the Axis 1 Overtravel Limit Switch inputs will be from the A connector. Axis 1 strobes will use the axis 3 inputs from the C connector (IN5_C and IN6_C) and are subject to analog strobe timing specifications. Axis 3 strobe will not operate, although the level of the axis 3 strobe inputs will still be reported to Local Logic and CTL bits. NOTE External quadrature encoders which have the same resolution as the digital servo motor’s serial encoder (8192 cts/rev) cannot be configured properly if they are geared to run more than 1.7x faster than the digital servo motor. External quadrature encoders geared at 1:1 with the digital servo motor cannot have resolution greater than about 14,000 cts/rev. Features and Functionality of Release 1.0 (Initial Release) Local Logic Programming The DSM314 includes Local Logic capability. The Local Logic program works in conjunction with the PLC logic program and motion program to yield a flexible programming environment. Specifically, Local Logic programs provide the user with the ability to perform math and logic that is deterministic and synchronized with the DSM Position Loop execution rate. This ability is critical to many applications where the accuracy and/or speed require this tight synchronization. In release 1.0, some Local Logic variables are not extended to Axis 3 or 4. Consult the User's Manual (GFK-1742) or VersaPro Local Logic Variable Table for more information. 8 Important Product Information: IC693DSM314 Module GFK-1775B Follower Configuration and Sources The DSM314 supports a virtual (time based) Auxiliary master axis that can be configured in place of one or more of the controlled axes. Other axes on the same module can be independently configured to follow this virtual axis or a real encoder master. Other follower mode enhancements include: • User defined units can be used in follower mode • An independent acceleration setting is now available for follower make-up move • Registration move option added to follower disable action list (incremental position) • Separate %I bit to indicate the follower ramp is active • Configurable follower enable and disable triggers 4 Axis Analog/ 2 Axis Digital Servo and 1 Axis Analog Control The DSM314 provides the user with 4 Axis Analog Servo or 2 Axis Digital Servo Control plus an additional Analog axis. Improved Strobe Resolution Strobe resolution is +/- 2 counts with 10 microsecond of additional variance. If a strobe occurs during extreme accelerations, the resolution will decrease slightly. Single Point of Programming with VersaPro 1.10 The motion programming tool suite is integrated into the VersaPro programming and configuration package. All module programming occurs through this package. No additional connections, other than the CPU connection, are required. Incremental Encoder Support Set Position is allowed on the first revolution when digital servos are configured for incremental mode. Fast Backplane Status Access Functionality The Fast Backplane Status Access function (Service Request #46) provides another PLC sweep mode. In this sweep mode, the CPU transfer a limited amount of digital I/O information to and from the module(s). Thus, sweep times can be decreased during certain critical sections. The backplane Fast Backplane Status Access function will write 4 bits to, and read 8 bits from the DSM314. Position Loop Update Rate The DSM314 will dynamically adjust the position loop update rate for optimal performance based on the number and type of axes configured: 2 ms if Any Axis is Digital or 3-4 Axes Analog or 2 Axis Analog with Local Logic 1 ms for 2 Axis Analog (no Local Logic) 1 ms for 1 Axis Analog (with Local Logic) 0.5 ms for 1 Axis Analog (no Local Logic) Backplane Motion and Local Logic Program Transfer Each time the PLC powers-up, the DSM314 programs are loaded via the backplane to each module. This allows multiple DSM314 modules to share the same program and also allows swapping DSM314 modules during troubleshooting without transferring programs. Enhanced I/O Assignment All I/O references are identical for each of the 4 axes Output arbitration between PLC control and Local Logic program control can be configured by the user There are 32 CTL bits CTL bits and output bit assignments are configurable Important Product Information: IC693DSM314 Module 9 GFK-1775B Enhanced Parameter Resolution and Ranges vs. DSM302 Resolution Changes: Position Loop Time Constant: From 1ms in the DSM302 to 0.1ms in the DSM314 Velocity Feedforward: From 1% in the DSM302 to 0.01% in the DSM314 Torque Limit AQ Command: From 1% in the DSM302 to 0.01% in the DSM314 Range Changes: Position Range: Increased from -8,388,608/+8,388,607 User Units (UU) in the DSM302 to -536,870,912 / +536,870,911 UU in the DSM314 Accel Range: Increased from 134,217,727 User Units per Seconds Squared (UU/S2 ) in the DSM302 to 1,073,741,823 UU/S2 in the DSM314 Parameter Based Subroutine Calls Motion program subroutine calls can be dynamically altered by using parameter-based references instead of the fixed references. In-Zone Bit Based on Position Error Only In the DSM302, the In-Zone %I bit was controlled by the Position Error status and the Moving %I bit. In the DSM314, the In-Zone %I bit is controlled only by the Position Error status, allowing this bit to be used to determine if an axis is accurately following the command during a move. Reversal Compensation Changes The reversal compensation value is not reflected in the commanded position or actual position values, allowing a more accurate determination of axis position in systems with backlash. Restrictions and Open Problems Restriction/Problem Description Cyclic-Circular CAM with Negative-going Master - problem w/CAM blend and 2nd CAM is ABS The following problem is restricted to a cyclic-circular CAM in absolute master mode in a sequence of CAMs with the master going backward: If the master has already rolled over (moved a few counts) in the previous CAM and the slave did not roll over (because the previous CAM exited), the slave will not automatically rollover backwards into the next sequential CAM without an intervening Move command. Otherwise, this could generate a velocity limit error as the slave attempts to move without rolling over to the corresponding value matching the current master position.