Danaher Motion B8962 User manual

B8961 and B8962
Brushless Servo
Smart Drives
Operator’s Manual
P/N PCW-4744, Rev 1.9
This manual covers the following
IDC Products:
B8961-1 axis Brushless Servo
Smart Drive
B8962-2 axis Brushless Servo
Smart Drive

Table of Contents
Table of Contents
PRODUCT AND MANUAL OVERVIEW................................................................1
SHIPPING CONTENTS......................................................................................................................2
QUICK START......................................................................................................3
KEYPAD OPERATION.........................................................................................7
KEYPAD FEATURES ..........................................................................................................................7
Keypad Har dware Features ..........................................................................................................................9
Dipswitches..........................................................................................................................9
Contrast ................................................................................................................................9
Remote Mounting.................................................................................................................9
KEY PAD PROGRAMMING MENU STRUCTURE...........................................................................10
RUN Menus ......................................................................................................................................................10
PROG Running Programs..............................................................................................11
JOG Jogging the Motor ..............................................................................................11
TEST Test and Debugging functions ...........................................................................12
EDIT Menus .....................................................................................................................................................13
PROG Creating and Editing Motion Programs..............................................................13
SETUP System Set-up Menu ...........................................................................................14
POS Reset Current Position to Zero ..........................................................................15
LIST List User Memory Usage ....................................................................................15
TUNING Servo Tuning.......................................................................................................15
HELP Menus .....................................................................................................................................................16
At the Main Menu...............................................................................................................16
At the Menus and Sub-Menus .............................................................................................16
In the Editor .......................................................................................................................16
COPY Menus ....................................................................................................................................................16
PROG Copy a Program to Another Program.................................................................16
TO PAD Upload Memory to Keypad................................................................................17
FROM Download Memory to Control...........................................................................17
DEL Men u.........................................................................................................................................................17
RUN-TIME OPERATOR INTERFACE................................................................................................17
CONFIGURING YOUR SYSTEM ........................................................................19
SETUP MENU..................................................................................................................................20
MOTOR Motor/Drive Configuration ....................................................................................................20
ENC Encoder Configuration ............................................................................................................22
MECH Mechanical Configuration .....................................................................................................24
I/O Input & Output Configuration .............................................................................................28
JOG Jogging Configuration .............................................................................................................36
HOME Homing Configuration ............................................................................................................37
PROG Program-Run Configuration .................................................................................................39
RS232 RS-232C Configuration ............................................................................................................40
MISC Miscellaneous Configuration Parameter s .........................................................................40
TUNING YOUR SERVO SYSTEM....................................................................................................43
Compensator ......................................................................................................................44
RS-232C Users.....................................................................................................................44
Key Pad Tuning ..............................................................................................................................................45
Keypad Tuning Menu Tree ..................................................................................................45
GAINS Setting the Servo Gains ......................................................................................45

B8961 and B8962 User Manual
Toggle Tuning Stimulus.......................................................................................................46
Monitor Monitor Port .........................................................................................................46
PROGRAMMING YOUR APPLICATION ............................................................47
SMART DRIVE PROGRAMMING OVERVIEW.................................................................................47
CREATING OR EDITING PROGRAMS WITH THE KEYPAD ...........................................................47
COMMAND SUMMARY ..................................................................................................................48
VARIABLES AND ARITHMETIC .......................................................................................................49
VARIABLES......................................................................................................................................49
LEGAL VERIABLE NAMES...............................................................................................................49
BUILT-IN VARIABLES .......................................................................................................................50
NON-VOLATILEVARIABLES............................................................................................................52
ARITHMETIC OPERANDS AND EQUATIONS .................................................................................53
BOOLEAN OPERATORS- & (AND), (OR)......................................................................................53
LOGICAL OPERATIONS ON EXPRESSIONS ...................................................................................54
INCREMENTING AND DECREMENTINGVARIABLES.....................................................................54
EXPRESSIONS .................................................................................................................................54
MULTI-AXIS OPERATION ...............................................................................................................55
SIMPLE GO COMMANDS ...............................................................................................................55
TYPICAL PROGRAMMING EXAMPLES...........................................................................................58
READING AN ANALOG INPUT.......................................................................................................59
CONFIGURING AN ANALOG OUTPUT..........................................................................................60
PROGRAMMING COMMANDS ..........................................................................61
PROGRAMMING WITH SERIAL COMMUNICATION ........................................91
SECTION 1:RS-232 PROTOCOL.....................................................................................................91
Making RS-232C Connections to the S6961/2 .....................................................................................91
Troubleshooting Serial Command Problems .......................................................................................92
Daisy Chaining Smart Drives ...................................................................................................................92
SECTION 2:APPLICATION DEVELOPER SOFTWARE.....................................................................93
Installing Application De veloper..............................................................................................................93
Common Installation Er rors and Remedies ........................................................................................94
SECTION 3:USING APPLICATION DEVELOPER™..........................................................................95
Setup Wizar d....................................................................................................................................................95
Axis Setup .........................................................................................................................................................99
I/O Setup.........................................................................................................................................................102
Miscellaneous (Misc) Setup ......................................................................................................................103
File Menu .......................................................................................................................................................104
Program Editor ............................................................................................................................................105
View Configuration ....................................................................................................................................106
Communications .........................................................................................................................................106
Run Men u......................................................................................................................................................107
SECTION 4:RS-232C IDEAL™COMMAND REFERENCE...............................................................108
Overview ........................................................................................................................................................108
Sample File ....................................................................................................................................................108
Command Syntax .......................................................................................................................................110
Serial Setup Commands ............................................................................................................................112
Serial Prog ramming Commands ...........................................................................................................118
Commands Not Used In Host Mode .....................................................................................................120
Serial Immediate Status Commands ....................................................................................................122
Serial Supervisory Commands ...............................................................................................................127

Table of Contents
HARDWARE REFERENCE ...............................................................................131
B8961 AND B8962 SMART DRIVE MOUNTING...........................................................................131
FK1 and FK2 Fan Kit ................................................................................................................................132
RPACK-1 and RP ACK-2 Mounting Installation ..................................................................................132
Remote Keypad Mounting ........................................................................................................................132
B8000 SMART DRIVE HARDWARE SPECIFICATIONS..................................................................133
B8961 AND B8962 HARDWARE CONNECTIONS ........................................................................134
B8961 AND B8962 INPUT AND OUTPUT SCHEMATICS .............................................................135
TROUBLE SHOOTING .....................................................................................137
SYMPTOMS AND SOLUTIONS .....................................................................................................137
IDC PRODUCT SUPPORT ...............................................................................139
FACTORY AUTHORIZED DISTRIBUTORS ....................................................................................139
REGIONAL OFFICES.....................................................................................................................139
TOLL FREE TECHNICAL SUPPORT...............................................................................................139
CAD LIBRARY...............................................................................................................................139
WARRANTY & REPAIRS..................................................................................139
INDEX..............................................................................................................140
APPENDIX A: IDC ACTUATOR RATIOS..........................................................143
CONFIGURING INCH & MM UNITS ON SMART DRIVES USED WITH IDC ACTUATORS..................143
Methods For Configuring Ratio ..............................................................................................................143
IDC ACTUATOR RATIOS...............................................................................................................143
N, T, R2, R3, R4, NM, RM Series ...............................................................................................................143
APPENDIX B: EMC INSTALLATION................................................................147
ELECTROMAGNETIC COMPATIBILITY (EMC) INSTALLATION GUIDELINES.............................147
Introduction ..................................................................................................................................................147
Separation and Shielding ..................................................................................................148
Grounding.........................................................................................................................149
Physical Installation ...................................................................................................................................150
AC Power Line Filtering .............................................................................................................................150
Motor Output P ower Ca ble Shielding ...................................................................................................151
Declaration of Confromity .......................................................................................................................152
APPENDIX C: FAN KIT OPTION .....................................................................153
APPENDIX D: REGEN PACK OPTION ............................................................155

Chapter 1 - Product and Manual Overview
1
Product and Manual Overview
IDC’s B8961 and B8962,one and two axis Smart Drives,combine a DSP based
servo amplifier with a powerful,but easy to use,machine controller.We offer a
single axis version (B8961) and a dual axis version (B8962).The B8962 has two
axes of independently configurable amplifiers.Both products incorporate IDC’s 5
amp continuous,10 amp peak,120/230VAC,digital servo amplifier with a
motion/machine controller in a single,compact package.Up to 24 digital I/O are
available to control other machine functions.Up to 8 of these can be configured as
analog inputs or outputs.
The B8000 Series Smart Drives feature a 5 amp continuous, 10 amp peak, digital
brushless servo drive using state of the art DSP technology to provide high
performance closed loop servo control to a wide variety of permanent magnet
brushless and brushed servo motors and actuators offered by Industrial Devices
Corporation.
The Vector Control used by the servo amplifier offers higher bandwidth torque
and velocity control when compared with sinusoidal or hall effect commutated
brushless servo amplifiers.This results in an expanded torque speed curve that
leads to higher throughput machines.The easy servo setup offered by the keypad
configuration or via Application De veloper gives high speed,high torque,brushless
servo motor performance,with an ease of use rivaled only by a stepper system.
IDC’s IDeal ™Smart Drives provide excellent value when your application calls for
any of the following:
•A small,1-2 axis machine controller
• A “motion node”to a master PLC or PC
• A cost effective operator interface
• Thumbwheel data inputs
• Flexible I/O capabilities
•On-board OPTO I/O modules (analog or digital)
The B8000 Series Smart Drives also feature a programming/operator interface.The
intent of the Smart Drive’s keypad is to allow you to quickly and easily configure
and program your system.Initial setup and configuration,in most cases,will require
only a few minutes using the keypad.While Smart Drives fully support PC based
RS232 programming,the setup and configuration sections of this manual often
emphasize the keypad approach.RS232 commands and setup definitions are in a
separate chapter.We strongly recommend using a keypad with your first B8000
Series Smart Drive application. You will also find it an invaluable troubleshooting
and machine commissioning aid during subsequent applications.
The following manual has been designed to help you successfully install,program
and operate your IDeal Programmable Smart Drive System.Each section of the
manual emphasizes the common theme “Ease of Use”.If you have any questions
that this manual does not adequately answer, please contact our factory application
engineers.
The manual begins with this Overview, followed by a Quick Star t chapter to help
you quickly confirm basic system operation.Next the manual describes
Communication with Your Control via the keypad interface.RS-232 interface
details are covered in Chapter 7, RS-232 Operation .

B8961 and B8962 User Manual
2
Chapter 4 covers the procedure for Configuring Your System to your specific
equipment and application requirements. It includes step-by-step keypad instructions
on scrolling through and entering setup parameters.This chapter covers initial motor
settings,I/O configuration,and defining the mechanics of your system.IDC’s
Windows based Application De veloper also follows the same menu structure
described here. .
Chapter 5, Programming Your Control , provides detailed program and application
examples and strategies.Other topics include variable usage,user menus,math
functions,and analog I/O. Our IDEAL ™command language is generally regarded as
the easiest motion control language in the industr y. It is both easy to remember
and intuitive,without sacrificing flexibility or power.
In Chapter 6, Command Ref erence, this alphabetical listing of Smart Drive commands
explains in detail syntax, ranges,defaults, and provides programming examples.
Chapter 7, RS-232 Operation ,is for users who plan to use the Smart Drive in an
RS232 hosted mode,or who wish to program and configure the drive via RS232.
IDC’s Application De veloper program follows a standard Windows dialog box
structure to make configuring and programming the Smart Drive control straight
forward.This section also covers RS232 command syntax and definition for users
who are not using Windows.
The Har dware Reference chapter provides detailed I/O schematics,as well as
motor drawings,cables and specifications.The Troubleshooting chapter lists a
series of common application problems along with their symptoms and solutions.
Included with this manual is the Application De veloper cd-rom. IDC’s Application
Developer and Servo Tuner software are automatically installed on your hard drive
by running the setup program on the Application De veloper cd-rom.This disc also
includes a readme file containing the latest information on software features.Many
demo programs are included with AppDeveloper.
If you cannot find the information that you need in this manual,please contact the
Applications Department.[phone].
Shipping Contents
1. B8961 or B8962 Smart Drive control
2. 120 VAC power cable
3. Application Developer software cd-rom
4. Installed OPTO modules (optional)
5. Fan Kit (optional)
Note:Units ordered as B8961NPs or B8962NP do not include the following keypad
items:
1. Keypad programming/operator interface (Part #FP220)
2. Keypad remote extension cable (6 ft)
3. Keypad remote mounting gasket

Chapter 2 - Quick Start
3
Quick Start
The purpose of the Quick Start chapter is to help an experienced motion control
user quickly set-up and bench test a B8000 Series Smart Drive with an IDC
supplied motor/encoder package.The following directions assume that the user is
familiar with servo motors,encoders,servo amplifiers,servo controls,and their
related electrical connections.Please refer to Chapter 4, “Configuring Your
System” if you have questions on any of these procedures.
For ease of set-up,we recommend that you use a keypad,and in this chapter it is
assumed that a keypad is used for set-up,even if an RS232 connection will be used later.
Caution: All connectors are KEYED to prevent “backwards”
installation. The connectors should fit snugly, but do not need to
be forced.
Caution: Do not plug the motor/encoder connector into the drive
until instructed. The motor and encoder can be damaged by an
incorrect motor setting.
Apply Power
Connect the B8000 Series Smart Drive to 120VAC
using the supplied AC power cable and connector.
The AC power input terminals are labeled and
located at the top of the Smart Drive.When power is
applied,the display briefly shows Model number and Software Revision,then
changes to the Main Display.The Main Display continuously shows the position of
each axis on the top line and the status of Inputs 1-8 and Outputs 1-8 on the
bottom line.
Select the Motor Type
1. Press the EDIT key. Press SETUP (F2),then MOTOR
(F1),then TYPE (F1).
2. The display should show NONE.Use the áand â
keys to change the motor choice.If you have a
B8962,use the ßand àarrows to change to axis
two to verify the motor choice.
3. Once the proper motor and voltage level has been
selected,press ESC to save your choices.
4. You will be prompted to Enable each axis.Choose YES (F1).
If using a non-IDC motor, please call the factory for details on obtaining a motor
data file for your motor. If you already have this custom motor data file, see the
Using Non-IDC Motor section of Chapter 7, RS-232 Operation .
+0.0000 +0.0000
00000000 00000000
------ áEDIT â------
PROG SETUP POS
Axis One Motor Type
B23:110 VAC

B8961 and B8962 User Manual
4
Connect The Motor and Encoder Cable(s)
Power down the drive and connect the pre-wired motor and encoder cables to the
Smart Drive.The 20 pin motor/encoder cable plugs into the bottom of the Smart
Drive.The MS connectors are keyed at the motor end.See the diagram below for
more information.If necessary, please refer to the Har dware Reference chapter for
wiring diagrams.
End-of-travel inputs are jumpered at the factory. See the Har dware Reference
section for IDC supplied limit switch wiring schematics.
After all motor and encoder cables are firmly connected, reapply power and
continue on with the Quick Star t directions.
Jog the Motor
1. Press RUN. Press JOG (F2).
2. Press the ßor àkey to jog (and áand âkeys
to jog axis two on the B8962).
3. Change the Jog Speed by pressing High (F2) or Low (F1) and jog again.
Run [TEST MOVE] Program
Press ESC to return to the Main Display.
1. Press RUN. Press TEST(F3).Press MOVE(F3)
2. Select the axis to test.(F1,F2,or F3) The axis
selected will move forward and backward one distance unit.(Distance units
default to motor revolutions.)
Caution: The motor will be
enabled when the drive is
powered up.
------ RUN ------
PROG JOG TEST
------ TEST MOVE ------
Axis 1 Both Axis 2

Chapter 2 - Quick Start
5
Create and Run a Simple Program
Press ESC to return to the Main Display.
1. Press EDIT. Press PROG (F1). Enter 1.(Edit program #1.)
AC1 Press F2 & 2 & 1 & ENTER
VE10 Press F1 & 2 & 1 & 0 & ENTER
DI3 Press F2 & 1 & 3 & ENTER
GO Press F1 & 3 & ENTER
EN Press F3 & 6 & ENTER
2. Press ESC to save the program and return to the Main Display.
3. Press RUN, then PROG (F1),then enter 1.(Run program #1.) The program
should move the motor 3 revolutions.
Discrete Input Test
Connect a 12”test wire to one of the COM screw terminals found on the side of
the drive.One by one,touch the test lead to each Input screw terminal and verify
that the input status shown on the Main Display toggles between 0 and 1.
Discrete Output Test
1. Press RUN. Press TEST (F3). Press OUTPUT (F2)
2. Press the ßor àkey to select an output number.
3. Press the âor áto turn the output ON or OFF.
4. Press ESC to leave this menu.The outputs will return to their state prior to
entering the test mode.Please use caution when manually toggling outputs
connected to live devices.No software interlocks are observed during this test.
The OPTO position’s default configuration is as an input.Please see Configuring
Your System for information on changing these to Outputs.You will then be able
to toggle their state from this screen.
Where to go from here?
Successfully completing these steps confirms the basic operation of your system.At
this point, you may want to refer to the following sections for more information:
• Hardware connections p.134
• Configuring Your System p.19
• IDC Actuator Gear Ratios p.25
• Non-IDC’s motor operation p.21
• Drive mounting p.131
• Fan Kit and RPACK connections p.132
• I/O software configuration p.28
• I/O hardware schematics p.135
• Basic keypad operation p. 7
• Programming examples p.58
• RS232 connection and usage p.91

Chapter 3 - Keypad Operation
7
Keypad Operation
This chapter is meant to familiarize a first time user with the basics of IDC’s
keypad operation.IDC’s keypad functions fall into two categories. The keypad
functions first as a programming and troubleshooting tool.Secondly, it functions as
an operator interface.Operators can run programs,make menu choices,or be
prompted to enter data via the keypad number keys.
The first section of this chapter,Keypad Features , defines the basic function of
each button on the keypad.The second section, Menu Structur e, gives the
programmer a broad overview of how the keypad’s setup and programming menus
operate and fit together. Detailed information about each step parameter is
presented in Configuring Your Control .
Keypad Features
Display
Easy to read,2 line,40 character, back-lit supertwist display.
F1, F2, F3 Function Keys
Used as Menu selectors.Used with numeric keys to select commands in the editor.
Programmable as operator menu selections.See the FK command for information
on using the function keys within a program.