Allen-Bradley 1746-HSTP1 User manual

Stepper Controller
Module
(Catalog No. 1746-HSTP1)
User Manual
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Important User Information
Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws,
regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown
in this guide are intended solely for purposes of example. Since there
are many variables and requirements associated with any particular
installation, Allen-Bradley does not assume responsibility or liability
(to include intellectual property liability) for actual use based upon
the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole
or part, without written permission of Rockwell Automation, is
prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
Attention statements help you to:
•identify a hazard
•avoid a hazard
•recognize the consequences
Allen-Bradley is a trademark of Rockwell Automation
ATTENTION
!
Identifies information about practices or
circumstances that can lead to personal injury or
death, property damage or economic loss
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.
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European Communities (EC)
Directive Compliance
If this product has the CE mark it is approved for installation within
the European Union and EEA regions. It has been designed and
tested to meet the following directives.
EMC Directive
This product is tested to meet the Council Directive 89/336/EC
Electromagnetic Compatibility (EMC) by applying the following
standards, in whole or in part, documented in a technical
construction file:
•EN 50081-2 EMC — Generic Emission Standard, Part 2 —
Industrial Environment
•EN 50082-2 EMC — Generic Immunity Standard, Part 2 —
Industrial Environment
This product is intended for use in an industrial environment.
Low Voltage Directive
This product is tested to meet Council Directive 73/23/EEC Low
Voltage, by applying the safety requirements of EN 61131-2
Programmable Controllers, Part 2 - Equipment Requirements and
Tests. For specific information required by EN 61131-2, see the
appropriate sections in this publication, as well as the Allen-Bradley
publication Industrial Automation Wiring and Grounding Guidelines
For Noise Immunity, publication 1770-4.1.
This equipment is classified as open equipment and must be
mounted in an enclosure during operation to provide safety
protection.
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iPublication 999-121 - December 1999
Table of Contents
Table of Contents
Preface
Using This Manual
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Contents of this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . P-2
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-3
On the Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Chapter 1
Module Overview
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Stepper Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Command Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Diagnostic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
LED Indicator Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Input/Output Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Terminal Block Release Screws . . . . . . . . . . . . . . . . . . . . . 1-5
Chapter 2
Installation and Wiring
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Starting and Stopping the Module . . . . . . . . . . . . . . . . . . . 2-2
Wiring for a Differential Interface. . . . . . . . . . . . . . . . . . . . 2-2
Wiring to Optocoupler Interface . . . . . . . . . . . . . . . . . . . . 2-3
Wiring to Optocoupler Interface (Continued) . . . . . . . . . . . 2-5
Wiring Information for TTL Interface . . . . . . . . . . . . . . . . . 2-5
Typical Input Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Typical Encoder Timing Diagram. . . . . . . . . . . . . . . . . . . . 2-7
Encoder Feedback Connections . . . . . . . . . . . . . . . . . . . . . 2-8
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Table of Contents ii
Chapter 3
Start Up and Troubleshooting
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
System Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Chapter 4
Module Operation
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operation Using the Pulse and Direction Outputs . . . . . 4-2
Fixed Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Origin (Home) Search Sequence of Operation. . . . . . . . 4-3
Resetting the Current Absolute Position. . . . . . . . . . . . . 4-3
Chapter 5
Configuration and Programming
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Programming Conventions . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Configuration and Status Bits. . . . . . . . . . . . . . . . . . . . . . . 5-1
Program Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SLC Processor Configuration . . . . . . . . . . . . . . . . . . . . . . . 5-1
Processor configuration using APS . . . . . . . . . . . . . . . . 5-2
Processor configuration using HHT (Catalog 1747–PT1). 5-2
Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Configuration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Configuration mode output image table . . . . . . . . . . . . 5-3
Configuration mode input image table . . . . . . . . . . . . . 5-6
Invalid Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Programming Command Mode . . . . . . . . . . . . . . . . . . . . . 5-8
Output Words – SLC Processor to Stepper Controller. . . 5-8
Output Command Word 0 Bit Definition . . . . . . . . . . . . . . . . . . . 5-8
Command Mode Output Words. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Output Command Bits for Word 0 . . . . . . . . . . . . . . . . 5-10
Absolute/relative move commands . . . . . . . . . . . . . . . . 5-11
Homing Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Home to Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Home to Proximity Limit Switch and Home Limit Switch 5-14
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Table of Contents iii
Home to Proximity Limit Switch and Marker . . . . . . . . . 5-14
Programming Simple Moves . . . . . . . . . . . . . . . . . . . . . . . 5-16
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Data File Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Using the N Files for Motion Commands. . . . . . . . . . . . 5-17
Quadrature Encoder Input . . . . . . . . . . . . . . . . . . . . . . 5-17
Use of Direct Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Programming Blended Moves . . . . . . . . . . . . . . . . . . . . . . 5-18
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Blend move programming routine . . . . . . . . . . . . . . . . 5-19
Module Status Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Input Word 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Input Word 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Input Words 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Input Words 4 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Diagnostics Feedback Test. . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Configuration Data for Loop Back Diagnostic Test. . . . . 5-26
Ladder Instructions for Loop Back Diagnostics Test. . . . 5-26
Command Mode Input Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Chapter 6
Application Examples
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Data table used for the program listing for
Sample Module Check Procedure . . . . . . . . . . . . . . . . . 6-1
Program Listing for Sample Module Check Procedure . . 6-1
Entering Negative Position Data . . . . . . . . . . . . . . . . . . 6-4
Converter Example . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Appendix A
Specifications
Industry Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
System Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Discrete Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Input/Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . A-3
Environmental Operating Conditions . . . . . . . . . . . . . . A-3
Storage Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Feedback Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Program Storage Requirements . . . . . . . . . . . . . . . . . . . A-3
Processor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . A-3
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Table of Contents iv
Appendix B
Input/Output Quick Reference
Index
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1Publication 999-121 - December 1999
Preface
Using This Manual
Overview
Read this chapter to familiarize yourself with the rest of the manual. It
provides information concerning the:
•contents of this manual
•intended audience
•conventions used
•hazards of injury or equipment damage
Contents of this Manual
This manual provides specific information relevant to the Stepper
Controller Module, Catalog Number 1746–HSTP1. The following table
identifies the chapters, titles and contents.
Chapter Title Contents
Preface Using This Manual An overview of this manual
1 Module Overview Module Overview, its operation and
hardware features
2 Installation and
Wiring
Interconnection diagrams for various
hardware interfaces for communication
with the Stepper Controller.
3 Start Up and
Troubleshooting
Start up, normal states of LED indicators,
troubleshooting and error handling
information.
4 Module Operation Describes interface selection, the Module’s
use of inputs and outputs, and operating
modes
5 Configuration and
Programming/Status
Provides the steps necessary to configure
the SLC™ Processor and Stepper Controller
6 Application Examples Illustrated sequencer, configuration and
command data files.
Appendix A Specifications Temperature, humidity, input output,
voltage, timing and cabling information.
Appendix B Input/Output Quick
Reference
A quick reference for the Input/Output
config and command bits and words.
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Publication 999-121 - December 1999
P-2 Using This Manual
Intended Audience
This manual is designed for the qualified first time user who has a
working knowledge of SLC 500™ products. If necessary, obtain the
proper training before using the Stepper Controller.
Conventions
The following terms are used throughout this manual:
Input file – refers to the Module's Input Data file. This file is updated
during the SLC Processor input scan
Output file – refers to the Module's Output Data file. This file is
updated during the SLC Processor output scan.
Module – refers to the Stepper Controller, catalog number
1746-HSTP1
Physical outputs – refers to actual outputs on the Stepper Controller
SLC Processor – refers to an SLC 500 family processor
Stepper Translator – refers to the interface between the Stepper
Controller and the stepper motor that converts pulse train outputs into
power signals used to run the motor.
Position Loop – refers to the ability of a controller to accurately
position a mechanism to a precise point based on a dynamic
comparison of command data and feedback from a sensor.
Engineering Units – refer to decimal fractions of units of
measurement; e.g., inches, millimeters and degrees.
CW – refers to rotation or movement in a clockwise direction.
CCW – refers to rotation or movement in a counter-clockwise
direction.
Rockwell Automation
Support
Rockwell Automation offers support services worldwide, with over 75
sales/support offices, 512 authorized distributors, and 260 authorized
systems integrators located throughout the United States. In addition,
Rockwell Automation representatives are located in every major
country in the world.
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Using This Manual P-3
Local Product Support
Contact your local Rockwell Automation representative for:
•sales and order support
•product technical training
•warranty support
•support service agreements
Technical Product Assistance
If you need to contact Rockwell Automation for technical assistance,
please review the information in this manual. If the problem persists,
call your local Rockwell Automation representative.
The Rockwell Automation Technical Support number is:
1-603-443-5419
On the Web
For information about Allen-Bradley, visit the following World Wide
Web site:
http://www.ab.com/
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P-4 Using This Manual
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1Publication 999-121 - December 1999
Chapter
1
Module Overview
Chapter Objectives
The Module overview will permit you to understand the basic
functions of the Module and hardware requirements.
Stepper Controller
The Module, catalog number 1746–HSTP1, is an SLC 500 family
compatible device. It can be used with any SLC 500 Processor.
The Module is configured through the SLC 500 backplane and
requires no switch settings. Motion can be programmed in either
direction for over ±8,000,000 counts of absolute position.
An optional incremental encoder may be used to verify the position
reached by the axis. The Module does not automatically close a
position loop in engineering units. The feedback hardware can accept
frequencies of up to 250 kHz for use as either loop back diagnostics
or differential incremental encoder feedback devices.
The Module can be programmed for either incremental or absolute
moves, depending on the application.
The Module supports two differential outputs, to suit the type of
Stepper Translator used, which provide the following control
commands:
•CW or non-directional pulse output
•CCW or direction signal output
Discrete inputs are provided for:
•External Interrupt
•Home Limit Switch
•Home Proximity Input
•CW Travel Limit Switch Input
•CCW Travel Limit Switch Input
•Pulse Train Enable/Disable Input
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Publication 999-121 - December 1999
1-2 Module Overview
Differential inputs are provided for:
•Encoder Channel A and A NOT
•Encoder Channel B and B NOT
•Encoder Marker Channel
Figure 1.1 Stepper Module Overview
Operating Modes
The Module operates in three different modes: configuration,
command, and diagnostic. The three operating modes are summarized
below.
Configuration Mode
The configuration mode is commanded by setting the mode flag (bit
15 in output word 0) to 1. In this mode, the Module is configured
through the SLC Processor to perform specific operations that the user
desires. The configuration mode defines the basic operation of the
Module.
SLC
Power
Supply
Stepper
Controller
7 to 24V DC
User Power
Supply
The 24V may be obtained from the SLC Power Supply depending on application power requirements.
Motor and translator furnished by the customer.
SLC
Processor Standard
I/O Module
Optional
Encoder
Optional Feedback Wiring
Control Wiring to Translator
Stepper
Motor
Power
Wires
Stepper
Translator
1
2
1
2
IMPORTANT The Module does not operate until it has been
configured at least once.
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Module Overview 1-3
The Module can be configured to:
•Determine which inputs are used.
•Determine the active level of inputs used.
•Set whether just the encoder marker or a prox limit switch and
encoder marker combination is used for homing.
•Determine if a quadrature encoder will be used.
•Select whether the Module output is a pulse train with direction
command or a CW pulse train and CCW pulse train.
•Select between configuration mode and command mode.
NOTE: Some output combinations are not valid. For example, using
feedback diagnostics and quadrature encoder or using a marker pulse
and a home limit switch. If any invalid combinations are sent, the
configuration error input bit will be set.
Command Mode Operation
All stepper motor operations are performed in command mode.
This mode is entered by setting the mode flag (bit 15 in output
word 0) to 0.
In command mode, the SLC Processor can issue commands and
activate different operations or moves. The actions you can
command are:
•Absolute Moves
•Relative Moves
•Hold Moves
•Resume Moves
•Immediate Stop Operations
•Homing Operations
•Jogging Operations
•Blend Moves
•Preset Operations
•Reset Errors
Diagnostic Mode
Use the configuration mode to select the diagnostic mode of
operation. Once selected, the diagnostic mode allows you to test your
program and wiring by connecting the loop back wires at the
translator. The purpose of loop back diagnostics is to test the system
wiring for electrical noise. The number of pulses received at the
feedback should equal the commanded number of pulses at the end
of the move. If they are not equal, the system may be experiencing
problems due to electrical noise.
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Publication 999-121 - December 1999
1-4 Module Overview
LED Indicator Diagnostics
There are five diagnostic LED indicators provided as shown below.
Their purpose is to aid in identifying operational problems.
Figure 1.2 LED Indicators
Processor and System O.K.
Commanding a
Counterclockwise Move
An error occurred during
command mode operations
RUN
CCW
ERR
Controller Commanding
Clockwise Motion
No configuration file present
or invalid configuration
CW
FLT
RUN
CCW
ERR
CW
FLT
STEPPER
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Publication 999-121 - December 1999
Module Overview 1-5
Input/Output Terminals
These terminals supply power and inputs to the Module and outputs
to attached devices. Each can accommodate two #14 gauge wires.
Figure 1.3 Input/Output Terminals
Terminal Block Release
Screws
These captive screws are attached to the terminal block. As the screws
are loosened, the terminal block moves away from the Module. This
feature facilitates replacement of the Module without rewiring.
7-24V DC user power (1)
CW + or non directional pulse output (2)
CW - or non directional pulse output (3)
CCW + pulse or direction signal output (4)
CCW - pulse or direction signal output (5)
External interrupt input (6)
Home limit switch input (7)
Home Proximity limit switch input (8)
CW limit switch input (9)
CCW limit switch input (10)
Pulse train enable/disable input (11)
A Hi (Loopback + non directional pulse) (12)
A Lo (Loopback - non directional pulse) (13)
B Hi (Loopback + direction) (14)
B Lo (Loopback - direction (15)
+ Encoder Marker (16)
- Encoder Marker (17)
0 V user power (DC common) (18)
Release Screw
(CCW loosen)
Release Screw
(CCW loosen)
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1-6 Module Overview
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1Publication 999-121 - December 1999
Chapter
2
Installation and Wiring
Chapter Objectives
This chapter provides information which permits you to properly
unpack, install and wire the interfaces between the Module and the
various Stepper Translators that can be used with the Module. Also
covered are typical input circuitry (direct input and encoder input),
and encoder timing information and encoder feedback connections.
General Precautions
In addition to the precautions listed throughout this manual, the
following statements which are general to the system must be read
and understood.
Installation
1. Install the Module in the designated slot in your SLC controller
rack. Refer to your SLC controller user manual.
2. Wire the input and output devices as instructed in the following
information.
ATTENTION
!
This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control
precautions are required when installing, testing,
servicing or repairing this assembly. Component
damage may result if ESD static control procedures
are not followed. If you are not familiar with static
control procedures, reference A–B publication 8000–
4.5.2, “Guarding Against Electrostatic Damage” or
any other applicable ESD protection handbook.
An incorrectly applied or installed Module can result
in component damage or a reduction in product life.
Wiring or application errors, such as, undersizing the
motor, incorrect or inadequate AC supply, or
excessive ambient temperatures may result in
malfunction of the system.
Only personnel familiar with the Module and
associated machinery should plan or implement the
installation, start-up and subsequent maintenance of
the system. Failure to comply may result in personal
injury and/or equipment damage.
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Publication 999-121 - December 1999
2-2 Installation and Wiring
Wiring
Refer to the following information on typical interface requirements
before beginning this procedure.
To meet the installation requirements of Underwriters Laboratories
Inc. standard UL 508 for industrial control equipment, follow the
guidelines below.
•Use 60/75° C copper wire when wiring the 1746–HSTP1 system.
•Tighten the terminals on the 1746-HSTP1 to 5 lb/in.
•Use Class 1 or Class 2 wiring for the terminals on the 1746–
HSTP1 system.
For more information, refer to standard UL 508 or the National Electric
Code.
Starting and Stopping the
Module
Wiring for a Differential
Interface
Several manufacturers of Stepper Translators provide differential
inputs. If your Stepper Translator can accept differential line driver
outputs, follow the interconnection diagram below to connect the
Stepper Controller to the translator.
ATTENTION
!
The following information is merely a guide for
proper installation. The Allen-Bradley Company
cannot assume responsibility for the compliance or
the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or
associated equipment. A hazard of personal injury
and/or equipment damage exists if codes are
ignored during installation.
ATTENTION
!
The Module Enable/Disable control circuitry includes
solid-state components. If hazards due to accidental
contact with moving machinery or unintentional flow
of liquid, gas or solids exist, an additional hardwired
stop circuit is required.
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Publication 999-121 - December 1999
Installation and Wiring 2-3
Figure 2.1 Differential Input
Wiring to Optocoupler
Interface
The following diagrams show the circuitry used to interface the
Module to a Stepper Translator through two different optocoupler
devices. The first diagram shows an optocoupler designed for a
common power supply connection. The second diagram shows an
individually isolated optocoupler. It is your responsibility to determine
which type is used in your specific application, and to ensure that
connections are properly made.
16 AWG
7-24V DC
(+) (-)
User
Power Supply
(-) (+)
Driver
External Internal
Stepper Controller
1
2
3
4
5
18
Voltage
Regulator
Electrical Cabinet
Ground Bus
Typical Input Connection
(Refer to page 6-6)
16 AWG
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