PACSystems™ RX3i and Series 90™-30 IC693DSM324-AD/IC694DSM324-AD GFK-2354D DSM324i Motion Controller August 8, 2007 The DSM324i module can control up to four FANUC αi or βi-series digital servos. This 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 supports high-speed digital output control synchronous to axis motion. The module provides an electronic CAM Follower Function that allows the module to be used in many applications traditionally supported by mechanical cams. Product Documentation DSM324i Motion Controller for PACSystems™ RX3i and Series 90™-30 User's Manual, GFK-2347C or later Servo Product Specification Guide, GFH-001F or later Important Product Information (this document), GFK-2354D Release Information Release 1.6 of the DSM324i Motion Controller firmware includes the following new features: Support for Alpha is series motors and amplifiers Additional digital servo parameters New %AQ command to change digital servo parameters Analog outputs can be controlled by Commanded Velocity and motor Actual Current Motor encoder velocity in rpm can be reported to the PLC Velocity loop commanded velocity rpm limit is configurable Motor encoder rpm limiter Ability to disable absolute encoder low battery alarm These features are further described New Features and Enhancements on page 3. Release History Catalog Number Firmware Version IC693/694DSM324-AD 1.6 IC693/694DSM324-AC 1.5 IC693/694DSM324-AB 1.1 IC693/694DSM324-AA 1.0 Upgrades DSM324-Ax modules can be field upgraded to DSM324-xD modules using the firmware upgrade utility. The firmware upgrade kit 44A750894-G04 can be ordered from GE Fanuc or downloaded at no charge from the Tools and Support section of http://support.gefanuc.com/ STATUS OK CONFIG FSSB 1 2 3 4 DSM324i COMM FSSB 24V I/O 5V I/O 2 DSM324i Motion Controller, IC693DSM324-AC/IC694DSM324-AC GFK-2354D Functional Compatibility CPU Version Requirements Use of DSM324i firmware version 1.6 or higher requires PACSystems Rx3i firmware release 2.8 or later or Series 90-30 CPU firmware release 10.0 or later. Programmer Version Requirements Use of DSM324i firmware version 1.6 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). Problems Resolved by this Revision of Product (1.6) DSM324 24V input filters now operate correctly. In previous releases, the input filters for 24V inputs were always off, regardless of the Hardware Configuration settings. DSM324 Follower Ramp Active %I bit transitions correctly. The DSM Ramp Active %I bit did not always transition low after completion of a Follower Disable registration move. Erratic operation of the %I bit was dependent on the follower velocity, registration distance and ramp deceleration. Problem with absolute encoder rotary mode position re-initialization resolved. Under certain conditions, the DSM324 failed to initialize the position of an absolute encoder in rotary mode after a power cycle or Hardware Configuration download. The problem only occurred if the encoder had rotated between 32,768 and 65,535 revolutions after the position was initially set using Find Home or Set Position. Under the failure condition, the firmware reported Error Code 60 (Absolute Encoder Rotary Position Computation Error). DSM324 AQ Move, Jog and Move at Velocity commands now checked against Max Velocity parameter. The DSM324 firmware did not check Jog and Move at Velocity commands against the Max Velocity specified in Hardware Configuration before executing the command. Instead the path generator ran at the commanded velocity. Firmware then reported error F2 and limited the velocity by discarding the portion of path generator position change that represented excess velocity. DSM324 clears Overcurrent alarm D1 without amplifier power cycle In previous releases, overcurrent alarm D1 could only be cleared after cycling power on the servo amplifier. In Release 1.6 the D1 error can be cleared by toggling the %Q Clear Error bit without power cycling the amplifier. DSM324 High Motor Current Alarm with Beta 0.5/6000is and Beta 1/6000is motors The BE error (High Current alarm) may occur when torque limited acceleration is commanded to negative velocities faster than -5000 rpm. To prevent the error from occurring, reduce the acceleration rate so the motor does not operate in torque limit. If the acceleration cannot be reduced, enter Hardware Configuration Advanced Tab parameter 10019 (EMFCMP) with data value equal to 0. Previous releases did not support the EMFCMP parameter. DSM324i Motion Controller, IC693DSM324-ACB/IC694DSM324-AC 3 GFK-2354D New Features and Enhancements Release 1.60 of the DSM324i Motion Controller firmware provides the following new features and enhancements. Refer to the updated DSM324i Motion Controller for PACSystems Rx3i and Series 90-30 PLCs User’s Manual, GFK-2347 for additional details. Support for Alpha is series motors and amplifiers The DSM324i now supports these additional motors and associated amplifiers: a12/4000HVis a22/3000i a22/3000HVi a22/4000HVis a30/4000HVis a40/4000HVis a50/3000HVis FAN Additional digital servo parameters The DSM324i now supports the ability to change these additional digital servo parameters: 10006 = PK1V Velocity Loop Gain 1 (Integral) 10007 = PK2V Velocity Loop Gain 2 (Proportional) 10008 = PK3V Velocity Loop Gain 3 (Integral Decay) 10019 = EMFCMP Current Loop Compensation 10031 = FILTER TCMD Filter 10256 = BITPA20 Disturbance Input Function 10296 = DI_GAIN Disturbance input : gain 10297 = S_FREQ Disturbance input : start frequency 10298 = E_FREQ Disturbance input : end frequency 10299 = MPOINTS Number of disturbance input measurement points New %AQ command to change digital servo parameters A new AQ command (0C46 hex) has been added to change digital servo parameters. The AQ command is formatted as follows: First AQ word = 0C46 hex Second AQ word = Servo Tuning parameter number Third AQ word = Servo Tuning parameter data Analog outputs can be controlled by Commanded Velocity and motor Actual Current The Select Analog Output mode AQ command (47 hex) has two new modes: Modes 11, 21, 31, 41 = route axis 1-4 motor Actual Current to an analog output. Scaling is +/- 8.0v = max current. Modes 16, 26, 36, 46 = route axis 1-4 servo commanded velocity to an analog output. Scaling = 1.333v/1000rpm. 4 DSM324i Motion Controller, IC693DSM324-AC/IC694DSM324-AC GFK-2354D Motor encoder velocity in rpm can be reported to the PLC The Select Return Data %AQ commands (40 hex and 41 hex) have a new mode. Setting the mode to 27 hex will report the motor encoder velocity in rpm. The data is accurate to 1 rpm and uses a 2 millisecond filter. Select Return Data mode 27 hex can also be set in Hardware Configuration. Velocity loop commanded velocity rpm limit is configurable Hardware Configuration Advanced Parameter 13 sets the servo commanded velocity limit in rpm with a range of 60 to 8191 rpm. If the limit is higher than the allowed limit for the selected motor type (example Beta4/4000HVis has limit of 4409 rpm), the limit based on motor type will be used. The limit is applied to the velocity loop input, and therefore is effective for all motion generated by the position loop and velocity feedforward paths. It also applies to the Force Digital Servo Velocity command that bypasses the position loop. Even though the limit is set in rpm, it is applied as the nearest integer multiple of 14.648 rpm that is greater than or equal to the configured value. The motor will not be commanded beyond the rpm limit. Therefore, if the path generator commands a velocity higher than the motor rpm limit, the position error will increase up to the position error limit. Whenever the servo command exceeds the limit, the command will be set to the limit and axis warning code DF will be reported. Motor encoder rpm limiter Hardware Configuration Advanced Parameter 14 sets the motor encoder maximum positive rpm limit with a range of 10-8191 rpm. If the motor encoder speed exceeds the limit, axis Fast Stop error E5 will be reported. Response time of the limiter is 10 ms or less. Hardware Configuration Advanced Parameter 15 sets the motor encoder maximum negative rpm limit with a range of 10-8191 rpm. If the motor encoder speed exceeds the limit, axis Fast Stop error E6 will be reported. Response time of the limiter is 10 ms or less. Ability to disable absolute encoder low battery alarm Hardware Configuration Advanced Parameter 65501 disables the absolute encoder low battery alarm when the data value is 1. This feature allows the encoder to be used in Absolute mode without an external battery. When power is off, absolute encoder position is temporarily maintained by an internal capacitor backup. The only allowed data values for Advanced Parameter 65501 are 0 and 1. Restrictions and Open Issues DSM324 path generator can run at velocity slightly greater than programmed velocity This issue occurs only when the acceleration time is greater than 65535 path generator samples (32 - 262 seconds depending on axis configuration and acceleration mode). When the problem occurs, the velocity can only be off by 0.0015 percent of the programmed value. DSM324 External Quadrature Encoder configuration produces no invalid configuration error when Feedback Mode is Absolute The DSM324 firmware does not support absolute mode external encoders. If the Axis Feedback Source is configured as Ext Quadrature Encoder, the encoder is treated as incremental even if of the Feedback Mode is configured as Absolute. DSM324 servo jumps when servo reenabled after amplifier E-Stop When a servo is moving and the amplifier E-Stop input is opened, the servo immediately stops. When the E-Stop (C0) error is cleared, reenabling the amplifier may cause the servo to jump even though the DSM is commanding zero velocity. Under this condition the servo jump may be a fraction of a revolution or more than one revolution. To prevent the servo from jumping, cycle 24v control power on the servo amplifier before reenabling the servo.. DSM324i Motion Controller, IC693DSM324-ACB/IC694DSM324-AC 5 GFK-2354D Operational Notes 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. Specifications Power Requirements 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 per 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 6 DSM324i Motion Controller, IC693DSM324-AC/IC694DSM324-AC GFK-2354D Installation in Hazardous Locations 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.