AMCI 3502 User manual

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3502 Module
SLC 500 Motion Controller
Module Overview
The 3502 module is a one-axis stepper controller that occupies one slot in a SLC 500 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 for homing,
over travel, and emergency stop. A 5V differential incremental encoder can be attached to the
unit to provide feedback information.
The 3502 module uses 8 input and 8 output registers to communicate with the PLC. Status
bits, the Current Position, and Encoder Count Value, are reported to the Input Registers. The 8
output registers have two purposes. First, they are used to configure the module with
parameters such as Output Type, Homing Type, Inputs Used, Input Active Level, and Starting
Speed. Second, they are used to send the move commands, along with the distance, speed,
and acceleration and deceleration rates used to define the move profile.
Some of the data used by the 3502 can exceed 32767, the value that can be contained in one
16 bit register. Because of this, these parameters are divided into two words, the Most
Significant Word (MSW) and the Least Significant Word (LSW). The MSW has the 1000s places
and the LSW has the 1s, 10s and 100s places. Negative values are handled using a sign
magnitude format where the Most Significant Bit in the MSW is set to indicate a negative value.
For example:
Value MSW
(decimal)
MSW
(hex)
LSW
(decimal)
LSW
(hex)
-12,345 -32,756 16#800C 345 16#0159
12,000 12 16#000C 0 16#0000
-12,000 -32,756 16#800C 0 16#0000
345 0 16#0000 345 16#0159
-345 -32768 16#8000 345 16#0159
Because the 3502 module does not use a non-volatile memory, it must be configured at every
power up.
Sample programs for the 3502 are available from the following page of our website.
https://www.amci.com/industrial-automation-support/sample-progams/
Waste Electrical and Electronic Equipment (WEEE)
At the end of life, this equipment should be collected separately from
any unsorted municipal waste.

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3502 Module
SLC 500 Motion Controller
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 determining 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 examination 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 [phone]
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 [phone]. 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 description of the problem ready before you call.

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3502 Module
SLC 500 Motion Controller
Table of Contents
Installing the 3502 Module Chapter 1 4
I/OConfiguration 4
Module Specifications 5
FrontPanel&LEDFunctions 6
OutputSignals 6
Connector Pinout and Wiring 7
DiscreteInputWiring 7
Single Ended Encoder Wiring 8
DiagnosticFeedbackWiring 8
Calculating Move Profiles Chapter 2 9
Configuration Programming Chapter 3 11
ConfigurationBits 13
InputActiveLevel 13
StartingSpeed 13
Invalid Configurations 14
Configuration Mode Input Data 14
Command Mode Operations Chapter 4 15
Absolute&RelativeMoves 15
HoldMove 16
ResumeMove 16
ImmediateStop 16
FindHome+/(CW),FindHome-/(CCW)17
Jog Move +/(CW), Jog Move -/(CCW) 19
OneShotJog 20
PresetCurrentPosition 20
PresetEncoderPosition 20
ResetErrors 20
BlendMove 21
DiagnosticFeedback 22
Command Mode Output Data Chapter 5 23
CommandWords 23
CommandBits 23
BlendMoveProgramming 25
Command Mode Input Data Chapter 6 27
StatusBits 27
InputWordFunctions 28
Status&ErrorBitFunctions 29
Manual Revision History 31

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3502 Module
SLC 500 Motion Controller
Chapter 1: Installing the 3502 module
WARNING Disconnect power before installing or remove the 3502 module.
1. Verify that your system’s power supply has adequate reserve current capacity. The
3502 module requires 200mA at +5Vdc.
2. Align the module with the grooves in the top and bottom of the SLC rack system and
slide the module backwards until the tabs on the plastic housing lock the module in
place.
SLC 500 Rack Configuration
1. Double Click on I/O Configuration in the Project Tree.
2. Select the desired unused slot, scroll to the bottom of the list of available modules and
double click on Other – Requires I/O Card Type ID.

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3502 Module
SLC 500 Motion Controller
3. Type a value of 3535 in the “Other” type IO card window that opens.
4. Input Data (data from the 3502 module to the PLC) will appear in Input Image Table
registers I:X.0 to I:X.7, where X is the slot number. Output Data (data from the PLC to
the 3502 module) will be written to registers O:X.0 to O:X.7, where X is the slot
number.

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3502 Module
SLC 500 Motion Controller
Module Specifications
Backplane Current Draw: 200mA @5Vdc
External User Power: 90mA @ 24Vdc
Stepper Outputs
Output Voltage: +5Vdc differential (3.5Vdc to 4Vdc peak typical)
Maximum Output Current: 20mA
Maximum Output Frequency: 250kHz
Encoder Inputs
5V differential encoder only
A, B, and Z Maximum Input Current: 10mA per channel @5Vdc
The A and B signals must both be connected to the 3502 module to have the encoder data
increment or decrement.
Discrete Inputs
Input Type: Sinking
Input Voltage Range: On = 8 to 24Vdc
Off = 0 to 2Vdc
Input Current: 15mA @ 24Vdc
Response Time (On and Off): 5s
Scanning Time: The input must be on for 250ms to be detected by the module.
Active State: The discrete inputs can be configured to be Active High (for use with a
normally open contact) or Active Low (for use with a normally closed
contact).
Input Functions: External Input, Home Input, Home Proximity Input, Emergency Stop, CW
Limit Switch, and CCW Limit Switch. (The External Input only affects Jog
Moves. The Home and Home Proximity Inputs only affects Homing
operations.)
Environmental Conditions
Operating Temperature: 0 to 60° C
Relative Humidity: 5 to 95% (non-condensing)
Storage Temperature: -40 to 85° C

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3502 Module
SLC 500 Motion Controller
Front Panel
Output Signals
The 3502 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 the 3502 module to
match the input type of your driver. The two types of signals are illustrated below.
Step and Direction Output
CW and CCW Step Outputs
Ste
p
Out
p
ut
CW Motion or Increasin
g
Counts
CCW Motion or Decreasin
g
Counts
CW Output Increasin
g
Counts
Decreasin
g
Counts
Direction Out
p
ut
CCW Output
RUN
Off: Module not powered or not operating correctly
Solid Green: Module Operating Correctly
CW
Off: Motion not occurring in the CW direction
Solid Green: Motion occurring in the CW direction
CCW
Off: Motion not occurring in the CCW direction
Solid Green: Motion occurring in the CCW direction
ERR
OFF: No Command Errors exist
Solid Red: An Error occurred during Command operations
FLT
OFF: No Configuration Error exists
Solid Red: The 3502 is either not configured or has been sent invalid Configuration
Data.
STEPPER

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3502 Module
SLC 500 Motion Controller
Connector Pin Out
The input connector is included with the 3502 module and consists of an eighteen position
Removable Terminal Block. The following diagram shows the wiring of this Terminal Block.
Note: Pin 1 is located on the upper left when the Terminal Block is plugged into the unit.
Wiring Notes:
The 3502 module uses a 9638 differential line driver in series with a 10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 installed in conduit with ac power lines or high
power ac/dc I/O lines.
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 (pin 18) must be connected to the common of the 7 to 24Vdc User
Power Supply. The common of the supply that powers the discrete inputs must also be
connected here. A Stepper Driver with Single Ended Step and Direction inputs can also
be referenced here.
Discrete Inputs Wiring
The following diagram shows how to wire the 3502 module’s discrete sinking inputs to a
sourcing sensor.
CCW Limit Switch
1
3
5
7
9
11
1
13
15
17
2
4
6
8
10
12
14
16
18
7 to 24Vdc User Power
+B Encoder In
p
ut
+Z Encoder In
p
ut
-Ste
p
or -CW out
p
ut
-Direction or -CCW out
p
ut
CW Limit Switch
Home Proximit
y
In
p
ut
External In
p
ut
Module Common
-A Encoder In
p
ut
-B Encoder In
p
ut
-Z Encoder In
p
ut
+Ste
p
or +CW
+Direction or +CCW out
p
ut
Emer
g
enc
y
Sto
p
In
p
ut
Home In
p
ut
+A Encoder In
p
ut
Discrete Input
(pins 6,7, 8, 9, 10, or 11)
Module Common (pin 18)
Sourcing Sensor
Power Supply
+ 8 to 24Vdc
Common
3502 Module

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3502 Module
SLC 500 Motion Controller
Single Ended Encoder Wiring
The 3502 module is designed to work with +5Vdc differential encoders. Use the following table
and diagrams to attach single ended encoders to the 3502 module. A current limiting resistor
RLim must be installed for encoders that do not operate at 5Vdc.
Encoder’s External
Power Supply
Current Limiting
Resistor RLim
5Vdc none
12Vdc 1K
15Vdc 1.2K
24Vdc 2.7K
3502 module Sourcing Output Encoder
3502 module Sinking Output Encoder
Diagnostic Feedback Wiring
Pin Numbers Signal Names
2 to 12 +Step to -A
3 to 13 -Step to +A
4 to 14 +Direction to -B
5 to 15 -Direction to +B
+A, +B, or +Z
-A, -B, or -Z
R
Lim
Encoder Output
Encoder Power Supply Common
R
Lim
Encoder Power Supply
Encoder Output
+A, +B, or +Z
-A, -B, or -Z

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3502 Module
SLC 500 Motion Controller
Chapter 2: Calculating Move Profiles
Before starting a move operation, the 3502 module completely calculates each portion of the
move profile. That is, it calculates how many steps of the move profile will be required 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.
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.
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
Da = Ta * (Vo + Vs)/2
Vo = Starting Speed (steps/second)
Vs = Programmed Speed (steps/second)
Ta = Time to accelerate (seconds)
Da = Distance to accelerate (steps)
a = Acceleration rate (steps/second/second)
The acceleration rate entered in these equations must have units of steps/second/second, not
the steps/ms/second used by the 3502 module. See the Calculation Notes below for a
complete explanation.
Velocit
y
Starting
Speed
Time
Trapezoidal Profile
Velocit
y
Starting
Speed
Time
Triangular Profile
Velocit
y
Time
Vo
Vs