PACSystems™ RX3i and Series 90™-30 IC694DSM324-AB/IC694DSM324-AB GFK-2324B DSM324i Motion Controller June 27, 2005 The DSM324i Module can control up to four FANUC βi-series digital servos. This new controller also supports high speed Local Logic that 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. This allows the module to be used in many applications traditionally supported by mechanical CAMs. Release History Catalog Number Firmware Version IC693/694DSM324-AA 1.00 IC693/694DSM324-AB 1.10 Features High Performance Digital Signal Processor (DSP) provides vector control of GE Fanuc AC servos Servo loop update: - Digital mode: 62.5 µsec (torque), 125 µsec (velocity) - 1 Axis mode no Local Logic: 0.5 msec (position) - 1 Axis mode with Local Logic: 1.0 msec (position) - 2 Axis mode no Local Logic: 1.0 msec (position) - 2-3 Axis mode with Local Logic: 2.0 msec (position) - 3-4 Axis 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 High resolution of programming units Position: -536,870,912 .. +536,870,911 User Units (at 1:1 User Units / Counts) Velocity: 1 ..8,388607 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) STATUS OK CONFIG FSSB 1 2 3 4 DSM324i COMM FSSB 24V I/O 5V I/O 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 and Electronic CAM Programming Backplane Motion, Local Logic, and CAM Program Transfer User scaling of programming units 2 DSM324i Motion Controller, IC693DSM324-AB/IC694DSM324-AB GFK-2354B Generic programming using command parameters as operands for Acceleration, Velocity, Move and Dwell commands Configured with Proficy® Machine Edition Logic Developer software Automatic data transfer between Host Controller and the DSM324i 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 GE Fanuc βi Series Digital servos Home and overtravel switch inputs for each servo axis Two Position Capture Strobe Inputs for each axis can capture axis and/or master position with an accuracy of +/-1 counts plus 10 microseconds of variance. 5V, 24V and Analog I/O for use by the host controller Three Incremental Quadrature Encoder inputs. Four incremental quadrature encoder inputs are possible if the encoder marker is not used Quadrature Encoder input for follower master axis Analog Output can be controlled by the host controller or used as digital servo tuning monitor High speed digital output (four 24V and four 5V) via on-board Local Logic control Overview The DSM324 integrates high-performance motion control with the logic-solving functions of the RX3i PACSystems and Series 90-30 control systems. Amp. 1 Machine 1 Encoder 1 Amp. 2 Machine 2 Encoder 2 Encoder 3 (Follower Master) D S M 3 2 4 Configuration and Programming Software: -Configuration -Motion Programming -Local Logic Programming -CAM Profiles Operator Interfaces For more information about configuring and installing the DSM324 module, see the DSM324i Motion Controller for PACSystems RX3i and Series 90-30, GFK-2347. For details about interfacing the DSM324i with the GE Fanuc βis servo motors, refer to the Servo Product Specification Guide, GFH-001. Product Documentation DSM324i Motion Controller for PACSystems RX3i and Series 90-30 User's Manual, GFK-2347 Servo Product Specification Guide, GFH-001 Important Product Information (this document), GFK-2354B DSM324i Motion Controller, IC693DSM324-AB/IC694DSM324-AB 3 GFK-2354B Specifications Power Supply Voltage: Power Supply Current Draw by DSM: 5 VDC from Host Controller backplane 860 mA plus encoder supply current (see next item). Available +5V Current/Module to supply external encoder, if used: 500 mA (if used, must be added to module +5v current draw) PACSystems RX3i Main Rack Model 310 CPUs: 5 DSM324i modules in CPU baseplate per PWR 040 Series 90-30 Expansion/Remote Racks (5 and 10-slot expansion or remote baseplates - 8 total baseplates per system) 2 DSM324i modules in remote baseplate with PWR321 3 DSM324i modules in expansion baseplate with PWR330/331 6 DSM324i modules in expansion/remote baseplate with PWR330/331 PACSystems RX3i Maximum 32 total DSM324i modules per PACSystems RX3i system Series 90-30 Main Rack Model 364, 374 CPUs: 1 DSM324i module in CPU baseplate with PWR321/322/328 4 DSM324i modules in CPU baseplate with PWR330/331 Main Rack Model 350, 352, 360, 363 CPUs: 2 DSM324i modules in CPU baseplate with PWR321/322/328 5 DSM324i modules in CPU baseplate with PWR330/331 Expansion/Remote Racks (5 and 10-slot expansion or remote baseplates - 8 total baseplates per system) 2 DSM324i modules in remote baseplate with PWR321/322/328 3 DSM324i modules in expansion baseplate with PWR330/331 6 DSM324i modules in expansion/remote baseplate with PWR330/331 Series 90-30 Maximum 20 total DSM324i modules per Series 90-30 PLC system Operational Notes CPU Firmware Use of DSM324i firmware version 1.1 or higher requires PACSystems Rx3i firmware release 2.8 or later or Series 90-30 CPU firmware release 10.0 or later. Programmer Software Use of DSM324i firmware version 1.1 or higher requires Machine Edition Logic Developer – PLC Version 5.0, Service Pack 2 or later. The DSM324i is not compatible with Logicmaster 90, Control, VersaPro or the DOSbased Motion Programmer (IC641SWP065). Essential Configuration Parameters PROFICY Machine Edition Logic Developer – PLC (version 5.0, Service Pack 2 or later) software must be used to configure the DSM324i module. 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. Motor Type For digital servos, motor type must be changed to the correct GE Fanuc motor type. Select type 0 only if no servo is used. 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. 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 The 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. 4 DSM324i Motion Controller, IC693DSM324-AB/IC694DSM324-AB GFK-2354B Host Controller %Q Bits Host Controller %Q bits are by design, RETENTIVE in nature. These bits ONLY become NON-RETENTIVE after the location is used (programmed) in a Host Controller program. All motion causing %Q bits such as Drive Enable, Start Motion program, Jog, etc. must be controlled from a programmed Host Controller coil reference for safe operation. Cables Two I/O cables, an FSSB command cable and one communication cable are available for use with the DSM324i, as described below. Consult the factory regarding custom length cables. Cable Description IC693CBL324 1 meter terminal board connection 5V I/O cable IC693CBL325 3 meter terminal board connection 5V I/O cable IC693CBL319 1 meter terminal board connection 24V I/O cable IC693CBL311 3 meter terminal board connection 24V I/O cable A66L-6001-0023#L150R0 FSSB Cable 0.15 meter A66L-6001-0023#L1R003 FSSB Cable 1 meter A66L-6001-0023#L3R003 FSSB Cable 3 meter A66L-6001-0026#L1R003 FSSB Cable 1 meter/sheath A66L-6001-0026#L5R003 FSSB Cable 5 meter/sheath A66L-6001-0026#L10R03 FSSB Cable 10 meter/sheath A66L-6001-0026#L20R03 FSSB Cable 20 meter/sheath IC693CBL316 Motion programmer communications cable Terminal Boards Two terminal boards for user I/O connections are now available for use with the DSM324i, as described below. IC693ACC336 5V I/O terminal board 44A726268-001 24V I/O 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-2347, DSM324i Motion Controller for PACSystems RX3i and Series 90-30 User's Manual. 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. CAM in Absolute Mode can Lose Synch if Master Drive is Disabled If the Master axis is disabled and then re-enabled, the CAM axis will lose master counts that result from master axis motion that occurs 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. DSM324i Motion Controller, IC693DSM324-AB/IC694DSM324-AB 5 GFK-2354B New Features in Release 1.1 This release provides support for Alpha 22i Servos and is restricted to specifically approved customer applications. Problems Resolved by Release 1.1 Restriction/Problem Description Axis1 motor velocity output mapping to analog output not functional. In Release 1.0 of the DSM324i firmware, axis1 motor velocity when mapped to the module analog output does not indicate the axis 1 motor velocity. Release 1.1 of the DSM324i firmware solves this problem. Restrictions and Open Problems Restriction/Problem Description Follower makeup time error EC can be followed by error code EB The module correctly reports the error code EC when the follower makeup time is not long enough. However, in some instances, this can be followed by error code EB that indicates an error in the calculations has occurred. Either error can be eliminated by setting Ramp Makeup Time and Ramp Makeup Acceleration (if required) to higher values. DSM324i Velocity Loop Gain scaling different from Users Manual Velocity loop gain calculation in manual defined as Velocity Loop Gain = (Load Inertia/Motor Inertia) * 16, is different from the implementation in the DSM324i firmware defined as Velocity Loop Gain = (Load Inertia/Motor Inertia) * 32. This restricts the (Load Inertia/Motor Inertia) Ratio to 8:1. Documentation Error Restriction/Problem Description Velocity Loop Gain calculation in DSM324i users manual (GFK-2347) is not correct. This error will be corrected in versions A and later of the manual. Velocity loop gain calculation in the manual defined as Velocity Loop Gain = (Load Inertia/Motor Inertia) * 16 should be Velocity Loop Gain = (Load Inertia/Motor Inertia) * 32. 6 DSM324i Motion Controller, IC693DSM324-AB/IC694DSM324-AB GFK-2354B The following information is for products bearing the UL marking for Hazardous Locations: • WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2; • WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING MODULES; AND • WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS. • EQUIPMENT LABELED WITH REFERENCE TO CLASS I, GROUPS A, B, C & D, DIV. 2 HAZARDOUS LOCATIONS IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D OR NON-HAZARDOUS LOCATIONS ONLY. • Control circuit modules require one No. 14 AWG through 22 AWG or two No. 16 AWG through 22 AWG stranded or solid copper conductors. The tightening torque range for the control terminals is 9.6—11.5 in.-lb. Use only wire rated for 90°C. Observe any additional ratings that are provided with the module.