LS Industrial Systems XGT Series User manual

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Programmable Logic Controller
XGB Positioning Module
User’s Manual
z Read this manual carefully before
installing, wiring, operating, servicing
or inspecting this equipment.
zKeep this manual within easy reach
for quick reference.
XGT Series
http://eng.lsis.biz
XBF-PD02
A

Safety Instruction
Before using the product …
For your safety and effective operation, please read the safety instructions thoroughly before using the product.
► Safety Instructions should always be observed in order to prevent accident or risk with the safe and
proper use the product.
► Instructions are divided into “Warning” and “Caution”, and the meaning of the terms is as follows.
This symbol indicates the possibility of serious injury or death if some applicable
instruction is violated
This symbol indicates the possibility of severe or slight injury, and property
damages if some applicable instruction is violated
Moreover, even classified events under its caution category may develop into serious accidents relying on
situations. Therefore we strongly advise users to observe all precautions properly just like warnings.
► The marks displayed on the product and in the user’s manual have the following meanings.
Be careful! Danger may be expected.
Be careful! Electric shock may occur.
► The user’s manual even after read shall be kept available and accessible to
any user of the product.
Warning
Caution

Safety Instruction
Safety Instructions for design process
 Please install a protection circuit on the exterior of PLC so that the whole system may
operate safely regardless of failures from external power or PLC. Any abnormal output or
operation from PLC may cause serious problems to safety in whole system.
- Install protection units on the exterior of PLC like an interlock circuit that deals with opposite
operations such as emergency stop, protection circuit, and forward/reverse rotation or install an
interlock circuit that deals with high/low limit under its position controls.
- If any system error (watch-dog timer error, module installation error, etc.) is detected during
CPU operation in PLC, all output signals are designed to be turned off and stopped for safety.
However, there are cases when output signals remain active due to device failures in Relay and
TR which can’t be detected. Thus, you are recommended to install an addition circuit to monitor
the output status for those critical outputs which may cause significant problems.
 Never overload more than rated current of output module nor allow to have a short circuit.
Over current for a long period time maycause a fire .
Never let the external power of the output circuit to be on earlier than PLC power, which may
cause accidents from abnormal output oroperation.
 Please install interlock circuits in the sequence program for safe operations in the system
when exchange data with PLC or modify operation modes using a computer or other
external equipments Read specific instructions thoroughly when conducting control operations
with PLC.
Warning

Safety Instruction
Safety Instructions for design process
Safety Instructions on installation process
 I/O signal or communication line shall be wired at least 100mm away from a high-voltage
cable or power line. Fail to follow this
Caution
 Use PLC only in the environment specified in PLC manual or general standard of data
sheet. If not, electric shock, fire, abnormal operation of the product may be caused.
Before install or remove the module, be sure PLC power is off. If not, electric shock or damage
on the product may be caused.
 Be sure that every module is securely attached after adding a module or an extension
connector. If the product is installed loosely or incorrectly, abnormal operation, error or dropping
may be caused. In addition, contact failures under poor cable installation will be causing
malfunctions as well.
Be sure that screws get tighten securely under vibrating environments. Fail to do so will put
the product under direct vibrations which will cause electric shock, fire and abnormal operation.
Do not come in contact with conducting parts in each module, which may cause electric
shock, malfunctions or abnormal operation.
Caution

Safety Instruction
Safety Instructions for wiring process
Prior to wiring works, make sure that every power is turned off. If not, electric shock or
damage on the product may be caused.
After wiring process is done, make sure that terminal covers are installed properly before
its use. Fail to install the cover may cause electric shocks.
Warning
 Check rated voltages and terminal arrangements in each product prior to its wiring
process. Applying incorrect voltages other than rated voltages and misarrangement among
terminals may cause fire or malfunctions.
Secure terminal screws tightly applying with specified torque. If the screws get loose, short
circuit, fire or abnormal operation may be caused. Securing screws too tightly will cause
damages to the module or malfunctions, short circuit, and dropping.
Be sure to earth to the ground using Class 3 wires for FG terminals which is exclusively
used for PLC. If the terminals not grounded correctly, abnormal operation or electric shock
may be caused.
Don’t let any foreign materials such as wiring waste inside the module while wiring,
which may cause fire, damage on the product or abnormal operation.
Make sure that pressed terminals get tighten following the specified torque. External
connector type shall be pressed or soldered using proper equipments.
Caution

Safety Instruction
Safety Instructions for test-operation and maintenance
 Don’t touch the terminal when powered. Electric shock or abnormal operation may occur.
Prior to cleaning or tightening the terminal screws, let all the external power off including
PLC power. If not, electric shock or abnormal operation may occur.
 Don’t let the battery recharged, disassembled, heated, short or soldered. Heat, explosion
or ignition may cause injuries or fire.
Warning
 Do not make modifications or disassemble each module. Fire, electric shock or abnormal
operation may occur.
 Prior to installing or disassembling the module, let all the external power off including
PLC power. If not, electric shock or abnormal operation may occur.
 Keep any wireless equipment such as walkie-talkie or cell phones at least 30cm away
from PLC. If not, abnormal operation may be caused.
 When making a modification on programs or using run to modify functions under PLC
operations, read and comprehend all contents in the manual fully. Mismanagement will
cause damages to products and accidents.
 Avoid any physical impact to the battery and prevent it from dropping as well. Damages
to battery may cause leakage from its fluid. When battery was dropped or exposed under strong
impact, never reuse the battery again. Moreover skilled workers are needed when exchanging
batteries.
Caution

Safety Instruction
Safety Instructions for waste disposal
 Product or battery waste shall be processed as industrial waste. The waste may discharge
toxic materials or explode itself.
Caution

RevisionHistory
Revision History
Version Date Remark Page
V 1.0 ’10. 1 First Edition -
The number of User’s manual is indicated right part of the back cover.※
ⓒLS Industrial Systems Co., Ltd 2010 All Rights Reserved.

About User’s Manual
About User’s Manual
Thank you for purchasing PLC of LS Industrial System Co.,Ltd.
Before use, make sure to carefully read and understand the User’s Manual about the functions, performances,
installation and programming of the product you purchased in order for correct use and importantly, let the end
user and maintenance administrator to be provided with the User’s Manual.
The User’s Manual describes the product. If necessary, you may refer to the following description and order
accordingly. In addition, you may connect our website (http://eng.lsis.biz/) and download the information as a PDF
file.
Relevant User’s Manuals
Title Description No. of User’s
Manual
XG5000 User’s Manual
(For XGI/XGR/XEC) 10310000821
XG5000 User’s Manual
(For XGK/XGB)
It describes how to use XG5000 software, especially
about online functions such as programming, printing,
monitoring and debugging by using XGB PLC. 10310000834
XGK/XGB
Instructions & Programming
User’s Manual
It is the user’s manual for programming to explain how
to use commands that are used in PLC system with
XGB main unit.
10310000833
XGI/XGR/XEC
Instructions & Programming
User’s Manual
It is the user’s manual for programming to explain how
to use commands that are used PLC system with XGB
IEC main unit.
10310000833
XGB Hardware
User’s Manual
It describes how to use the specification of power/input
/output/expansion modules, system configuration and
built-in High-speed counter for XGB main unit.
10310000926
XGB IEC Hardware
User’s Manual
It describes how to use the specification of power/input
/output/expansion modules, system configuration and
built-in High-speed counter for XGB IEC main unit.
10310000983

◎Contents ◎
Chapter 1 Overview ............................................................................. 1-1~1-9
1.1 Characteristics......................................................................................................... 1-1
1.2 Purpose of Positioning Control................................................................................ 1-2
1.3
Signal Flow of Positioning Module........................................................................... 1-3
1.3.1 Operating sequence...................................................................................................1-3
1.3.2
Flow of position signal................................................................................................1-4
1.4 Function overview of positioning module.................................................................1-5
1.4.1 Position Control..........................................................................................................1-5
1.4.2 Interpolation Control...................................................................................................1-6
1.4.3 Speed Control.............................................................................................................1-9
Chapter 2 Specifications..........................................................................2-1~2-9
2.1 General Specifications............................................................................................. 2-1
2.2
Performance Specifications.....................................................................................2-2
2.2.1 Function Specifications...............................................................................................2-2
2.3 External I/O Interface Specifications........................................................................ 2-3
2.3.1 Input Specifications.....................................................................................................2-3
2.3.2
Output Specifications..................................................................................................2-4
2.3.3 Specifications on Interface with External Equipment.................................................2-5
2.4 The Name of Each Part........................................................................................... 2-8
2.4.1 The name of each part ...............................................................................................2-8
2.5 Connection to XGT Servo System........................................................................... 2-9
Chapter 3 Operation Order and Installation................................................ 3-14
3.1 Installation ............................................................................................................... 3-1
3.1.1 Installation Environment.............................................................................................3-1
3.1.2 Notices in Handling ....................................................................................................3-1
3.2 Notices in Wiring...................................................................................................... 3-2
3.2.1 Notices in Wiring ........................................................................................................3-2

3.2.2 Connection Example of Servo and Stepping Motor Drive Machine...........................3-3
3.2.3 Encoder Input (DC 5V Voltage Output) Wiring Example..........................................3-13
3.2.4 Encoder Input (5V Line Driver Output) Wiring Example ..........................................3-14
Chapter 4 Positioning Parameter & Operation Data............................4-1~4-24
4.1 Parameter & Operation data.................................................................................... 4-1
4.2 Basic Parameter......................................................................................................4-2
4.2.1 Basic parameter .........................................................................................................4-2
4.2.2 Basic parameter setting..............................................................................................4-3
4.3 Home/Manual parameter....................................................................................... 4-13
4.3.1 Contents of Home/Manual parameter......................................................................4-13
4.3.2 Home/Manual parameter setting..............................................................................4-13
4.4 Common Parameter............................................................................................... 4-16
4.4.1 Common parameter .................................................................................................4-16
4.4.2 Common Parameter Setting.....................................................................................4-16
4.5 I/O Signal Parameter............................................................................................. 4-19
4.5.1 I/O Signal Parameter................................................................................................4-19
4.5.2 Setting of I/O Signal Parameter................................................................................4-19
4.6 Operation Data ......................................................................................................4-20
4.6.1 Operation Data.........................................................................................................4-20
4.6.2 Operation Data Setting.............................................................................................4-20
Chapter 5 Program Configuration and Operation Method..................5-1~5-10
5.1 Internal Memory....................................................................................................... 5-1
5.1.1 Teaching Data ............................................................................................................5-1
5.1.2 State Information........................................................................................................5-3
5.2 I/O Signal................................................................................................................. 5-8
5.2.1 Contents of I/O Signal................................................................................................5-8
5.2.2 Use of I/O Signal........................................................................................................5-9
Chapter 6 Command..............................................................................6-1~6-39
6.1 Contents of General Command............................................................................... 6-1

6.1.1 Internal Memory Read................................................................................................6-1
6.1.2
Internal Memory Write................................................................................................6-2
6.2 Dedicated Commands............................................................................................. 6-3
6.3
Use of Dedicated Command ...................................................................................6-4
6.3.1 Homing start...............................................................................................................6-4
6.3.2 Floating origin setting (Command : FLT)....................................................................6-5
6.3.3
Direct start (Command : DST)....................................................................................6-6
6.3.4
Indirect start (Command : IST) ........................................................................................6-7
6.3.5 Linear Interpolation (Command: LIN).........................................................................6-8
6.3.6 Circular Interpolation (Command: CIN)......................................................................6-9
6.3.7
Simultaneous Start (Command : SST).....................................................................6-10
6.3.8
Speed/Position Switching Control (Command : VTP)..............................................6-11
6.3.9
Position/Speed Switching Control (Command : PTV)..............................................6-12
6.3.10
Deceleration Stop (Command : STP).....................................................................6-13
6.3.11
Synchronous Start by Position (Command : SSP).................................................6-14
6.3.12
Synchronous Start by Speed (Command : SSS)...................................................6-15
6.3.13
Position Override (Command : POR).....................................................................6-16
6.3.14
Speed Override (Command : SOR).......................................................................6-17
6.3.15
Position Assigned Speed Override (Command : PSO)..........................................6-18
6.3.16
Inching Operation (Command : INCH)...................................................................6-19
6.3.17
Start Step No. Change (Command : SNS).............................................................6-20
6.3.18
Repeat Step No. Change (Command : SRS) ........................................................6-21
6.3.19
M code Release (Command : MOF)......................................................................6-22
6.3.20
Current Position Preset (Command : PRS) ...........................................................6-23
6.3.21
Encoder Preset (Command : EPRS) .....................................................................6-24
6.3.22 Single Teaching (Command: TEA).........................................................................6-25
6.3.23
Teaching Array(Command : TEAA) .............................................................................6-26
6.3.24
Teaching Array Data Setting (Command: TWR)....................................................6-27
6.3.25
Basic Parameter Teaching (Command : TBP).......................................................6-29
6.3.26
Homing/Manual Parameter Teaching (Command : THP) ......................................6-31
6.3.27
I/O Signal Parameter Teaching (Command : TSP)................................................6-33
6.3.28
Common Parameter Teaching (Command : TCP).................................................6-34
6.3.29
Operation Data Teaching (Command: TMD) .........................................................6-35
6.3.30
Parameter/Operation Data Save (Command : WRT) ............................................6-37
6.3.31
Emergency Stop (Command : EMG) .....................................................................6-38
6.3.32
Error Reset (Command : CLR) ..............................................................................6-38

6.3.33 Operation State Reading (Command: SRD)..........................................................6-39
Chapter 7 Function Block......................................................................7-1~7-37
7.1 Common Issues of Function Block.......................................................................... 7-1
7.2 Function Block of Positioning Module .....................................................................7-2
7.3 Function Block related to Module Information Read................................................7-3
7.3.1 Operation Information Read (APM_CRD) .................................................................7-3
7.3.2 Operation State Bit Information Read (APM_SRD)...................................................7-4
7.3.3 Encoder Value Read (APM_ENCRD)........................................................................7-6
7.4 Parameter/Operation Data Teaching Function Block .............................................. 7-7
7.4.1 Basic Parameter Teaching (APM_SBP) ...................................................................7-7
7.4.2 Homing/Manual Parameter Teaching (APM_SHP)....................................................7-8
7.4.3 I/O Signal Parameter Teaching (APM_SIP)...............................................................7-9
7.4.4 Common Parameter Teaching (APM_SCP) ............................................................7-10
7.4.5 Operation Data Teaching (APM_SMD)....................................................................7-11
7.4.6 Single Teaching (APM_TEA)...................................................................................7-12
7.4.7 Teaching Array (APM_ATEA)...................................................................................7-13
7.4.8 Saving Parameter/Operation Data (APM_WRT).....................................................7-14
7.5 Start/Stop Function Block....................................................................................... 7-15
7.5.1 Homing Start (APM_ORG).......................................................................................7-15
7.5.2 Direct Start (APM_DST)...........................................................................................7-16
7.5.3 Indirect Start (APM_IST)..........................................................................................7-17
7.5.4 Linear Interpolation (APM_LIN) ...............................................................................7-18
7.5.5 Circular interpolation (APM_CIN).............................................................................7-19
7.5.6 Simultaneous Start (APM_SST)...............................................................................7-20
7.5.7 Deceleration Stop (APM_STP) ................................................................................7-21
7.5.8 Emergency Stop (APM_EMG).................................................................................7-22
7.6 Manual Operation Function Block ......................................................................... 7-23
7.6.1 Inching Operation (APM_INC).................................................................................7-23
7.7 Synchronization Start Function Blocks.................................................................. 7-24
7.7.1 Position Synchronization (APM_SSP).....................................................................7-24
7.7.2 Speed Synchronization (APM_SSS)........................................................................7-25
7.8 Modification Function Block................................................................................... 7-26
7.8.1 Position Override (APM_POR) ................................................................................7-26
7.8.2 Speed Override (APM_SOR)...................................................................................7-27

7.8.3 Position Assigned Speed Override (APM_PSO)......................................................7-28
7.8.4 Position/Speed Switching Control (APM_PTV)........................................................7-29
7.8.5 Speed/Position Switching Control (APM_VTP)........................................................7-30
7.8.6 Start Step Number Change (APM_SNS).................................................................7-31
7.8.7 Repeat Step No. Change (APM_SRS)....................................................................7-32
7.8.8 Current Position Change (APM_PRS).....................................................................7-33
7.8.9 Encoder Value Preset (APM_EPRE).......................................................................7-34
7.9 Error Function blocks ............................................................................................7-35
7.9.1 Error Reset (APM_RST)..........................................................................................7-35
7.10 Other Function Blocks......................................................................................... 7-36
7.10.1 Floating Origin Setting (APM_FLT)........................................................................7-36
7.10.2 M code Release (APM_MOF)................................................................................7-37
Chapter 8 Program.................................................................................8-1~8-91
8.1 Example of XBC Programming ............................................................................... 8-1
8.1.1 General description....................................................................................................8-1
8.1.2 Current State Read....................................................................................................8-1
8.1.3
Operation Test............................................................................................................8-3
8.1.4
Parameter and Operation Data Setting......................................................................8-7
8.1.5
Positioning Operation...............................................................................................8-15
8.1.6
Operation Setting Change while Operating .............................................................8-26
8.1.7
Error .........................................................................................................................8-35
8.2 Example of IEC type Programming....................................................................... 8-36
8.2.1 General description..................................................................................................8-36
8.2.2 Current State Read..................................................................................................8-36
8.2.3
Operation Test..........................................................................................................8-41
8.2.4
Parameter and Operation Data Setting....................................................................8-47
8.2.5
Positioning Operation...............................................................................................8-56
8.2.6
Operation Setting Change while Operating .............................................................8-73
8.2.7
Error .........................................................................................................................8-90
Chapter 9 Functions ..............................................................................9-1~9-99
9.1 Homing .................................................................................................................... 9-1

9.1.1 Homing method..........................................................................................................9-1
9.1.2 Parameters for Homing..............................................................................................9-1
9.1.3 Origin Detection after DOG Off..................................................................................9-2
9.1.4 Origin Detection after Deceleration when DOG On...................................................9-4
9.1.5 Origin Detection by DOG...........................................................................................9-5
9.1.6 Origin Detection by Origin and Upper/Lower Limit ....................................................9-6
9.1.7 Origin Detection by Upper/Lower Limit......................................................................9-7
9.2 Positioning Control ..................................................................................................9-8
9.2.1 Operation Data for Positioning Control......................................................................9-9
9.2.2 Operation mode of Positioning Control....................................................................9-10
9.2.3 Positioning Control...................................................................................................9-17
9.2.4 Speed Control ..........................................................................................................9-19
9.2.5 Linear Interpolation Control......................................................................................9-21
9.2.6 Designate Midpoint of Circular Interpolation............................................................9-26
9.2.7 Circular interpolation control of designating Center point........................................9-33
9.2.8 Circular interpolation control with designated radius...............................................9-41
9.2.9 Speed/Position Switching Control............................................................................9-49
9.2.10 Position/Speed Switching Control..........................................................................9-51
9.2.11 Start of Positioning .................................................................................................9-53
9.2.12 Positioning stop......................................................................................................9-55
9.3 Manual Operation Control ..................................................................................... 9-61
9.3.1 Jog Operation ..........................................................................................................9-61
9.3.2 Inching Operation.....................................................................................................9-65
9.4 Synchronous Control............................................................................................. 9-67
9.4.1 Speed Synchronous Control....................................................................................9-67
9.4.2 Position synchronous control...................................................................................9-72
9.5 Modification Function of Control............................................................................9-76
9.5.1 Floating Origin Setting .............................................................................................9-76
9.5.2 Position Override .....................................................................................................9-77
9.5.3 Speed Override........................................................................................................9-80
9.5.4 Positioning Speed Override .....................................................................................9-82
9.5.5 Current Position Preset............................................................................................9-85
9.5.6 Encoder Preset ........................................................................................................9-86
9.5.7 Start Step no. Change..............................................................................................9-87
9.5.8 Repeat Operation Step no. Change.........................................................................9-88
9.6 Auxiliary Function of Control .................................................................................9-90

9.6.1 Upper/Lower limit.....................................................................................................9-90
9.6.2 M code .....................................................................................................................9-92
9.7 Data Modification Function.................................................................................... 9-94
9.7.1 Teaching Array .........................................................................................................9-94
9.7.2 Parameter Change from Program ...........................................................................9-95
9.7.3 Data Change from Program.....................................................................................9-99
Chapter 10 Positioning Monitoring Package ...................................10-1~10-10
10.1 Positioning Monitoring Package.......................................................................... 10-1
10.1.1 Introduction of Positioning Monitoring Package.....................................................10-1
10.2 Menus and Functions of Positioning Monitoring.................................................. 10-3
10.2.1 Monitoring and Command......................................................................................10-3
10.3 Parameter/Operation Data Setting Using Monitoring Package...........................10-9
10.3.1 Changing the Position Parameter..........................................................................10-9
10.3.2 Change of Position Operation Data.....................................................................10-10
Appendix 1 Positioning Error Information & Solutions.......App. 1-1~App.1-8

Chapter1Overview
1-1
Chapter 1 Overview
This user’s manual describes the standard of positioning module, installation method, the method to use each positioning function,
programming and the wiring with external equipment.
1.1 Characteristics
The characteristics of positioning module are as follows.
(1) The positioning module is available for XGB Series. (It can’t be used with XBM-Dx-xxS.)
(2) Various positioning control function
It has various functions needed for positioning system such as positioning control, speed control etc.
(a) Up to 150 operation data including positioning address and operation method, operation pattern is available to set for each axis.
With this operation data, positioning for each axis is carried out
(b) Various operations are available.
1) Position Control
2) Speed Control
3) Synchronous Control
4) Linear Interpolation
5) Circular Interpolation
(c) Switching Control in operation is available.
1) Position/Speed Control Switching
2) Speed/Position Control Switching.
(d) Various Homing Control Function.
1) 5 methods are available for Homing
a) The origin detection after DOG Off
b)The origin detection after deceleration in case of DOG On
c) The origin detection by DOG
d) The origin detection by DOG and upper-lower limit
e) The origin detection by upper-lower limit
2) Available to execute the positioning control (floating origin setting) from random position to the origin of machine
(3) Easy maintenance
Various data such as positioning data, parameter etc. are saved on flash memory in module. Therefore, data will be saved
forever (The frequency of writing is limited to 100,000)
(4) The number of positioning module using in one basic unit is not limited
(But, it is available to use within the range satisfied with the capacity of 5V source supply current of basic unit.)
(5) Self-diagnosis, monitoring, test by strong positioning software package is available.
(a) Monitoring (Module & External Input/output Signal) Function
(b) Reading and Saving Module Parameter/Operation Data
(c) Operation data edition of each axis is available in Excel program
(6) Applicable XGB basic unit and XG5000 version for positioning module
XGB basic unit Version
XBC – Dx-xxH V1.8 or upper
XEC – Dx-xxH V1.2 or upper
XG5000 V3.1 or upper

Chapter 1 Overview
1-2
1.2 Purpose of Positioning Control
The purpose of positioning module is to transfer the moving objects (unprocessed items, tools etc.) with setting speed
from the current position and stop them on the setting position correctly. And it also controls the position of high
precision by positioning pulse string signal as it is connected to various servo driving devices or stepping motor
control driving devices. In application, it can be used widely with engineering machine, semiconductor assembly
machine, grinder, small machine center, lifter etc.
<XGB positioning function general >
<Positioning system inner block diagram >

Chapter1Overview
1-3
1.3 Signal Flow of Positioning Module
1.3.1 Operating sequence
The flow of PLC system using the positioning module is as follows.

Chapter 1 Overview
1-4
1.3.2 Flow of position signal
Flow of position signal is as follows.
< XGB Positioning signal flow >