Mitsubishi MELSEC-A series User manual

PROGRAMMABLE CONTROLLER
User '8 Manual
I
Positioning module
type AD71
CATALOG # UMPM
$ 15.00
A
MlTSUBlSHl
ELECTRIC

REVISIONS
%Themanualnumber is givenonthebottom left of the back cover.
Deletion ]
Section 8.1.4
“InstructionsforStrategic Materials” added
I
f

INTRODUCTION
Thankyouforchoosing the MitsubishiMELSEC-ASeries of GeneralPurposeProgrammable
Controllers.Pleasereadthismanualcarefully so thattheequipment is usedto its optimum.
A copy of this manual shouldbeforwardedto the end User.

CONTENTS
2. SYSTEMCONFIGURATION ............................................ 2-1 2-7
2.1 Introduction to the AD71 ................................................. 2.1
2.2 MELSEC-ASeries Equipment .............................................. 24
2.3 AD71ProgrammingEquipment ............................................. 2.7
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
GeneralSpecifications .................................................... 3.1
Performance Specifications and Functions ..................................... 3.2
3.2.1 AD71 performancespecifications. ..................................... 3.2
3.2.2 Functions ........................................................ 3-3
PositioningSystem Operation .............................................. 3.5
3.3.1 AD71 interfaces ................................................... 3.5
3.3.2AD71operation ................................................... 3.6
Format and Functionsof Operating Data ...................................... 3.8
3.4.1Parameters ....................................................... 3.8
3.4.2Zeroingdata ..................................................... 3-18
3.4.3Positioningdata .................................................. 3-22
BufferMemory ......................................................... 3.29
3.5.1Positioning start data .............................................. 3-31
3.5.2 Error reset(Address 201 ) ........................................... 3-43
3.5.3 OS data(Address512 to 767) ....................................... 3-43
3.5.4Positioningdata area
3.5.5Parameterarea
3.5.6Zeroingdataarea
1/0 Signals To and From PC CPU ........................................... 3-47
1/0 Interfacewith External Equipment ...................................... 3.53
3.7.1AD71electricalspecifications ....................................... 3-53
3.7.2 1/0 interface electricaldetails ........................................ 3-54
BatterySpecifications ................................................... 3.55
(X axis: address 3872 to 5871. Y axis: address 5872 to 7871 1 ............... 3-44
(X axis: address 7872 to 7887. Y axis: address 7892 to 7907) ............... 3-45
(X axis: address 791 2to 7918. Y axis: address 7922 to 7928) ............... 3-46
4 . HANDLING ......................................................... 4-1 -4-3
4.1 Handling Instructions ..................................................... 4-1
4.2Nomenclature ........................................................... 4-2
4.3.1 Batteryconnection ................................................. 4.3
4.3 Preparation ............................................................ -4-3
I6 fNA1 56101 C

......
5 . LOADING AND INSTALLATION ........................................ 5-1 %5-6
5.1 Installation Environments ................................................. 5.1
5.2SystemDesignPrecautions ................................................. 5-2
5.3 InstallationandRemoval .................................................. 5.3
5.4Wiring ................................................................. 5-5
5.4.1Wiringprecautions ................................................. 5.5
5.4.2Drive unit connector ............................................... 5-6
6 . PROGRAMMING .................................................... 6-1 5 6-54
6.1 Writing Programs ........................................................ 6.1
6.1.1 Program structure .................................................. 6.1
6.1.2Notes on programming .............................................. 6-3
6.2Notes on Use of the A6GPPand AD71TU ..................................... 6.5
6.3ACPUProgramming ...................................................... 6.6
6.3.1Data read and write precautions ....................................... 6-6
6.3.2Data communication with PC program .................................. 6.7
6.3.3 Start positioning .................................................. 6-15
6.3.4 Jog operationprogram ............................................. 6-23
6.3.5Inching ......................................................... 6.25
6.3.6 Positionaddressteaching ............................................ 6.29
6.3.7Zeroing ......................................................... 6-37
6.3.8Presentvaluechange ............................................... 6-39
6.3.9 Positioningstop .................................................. 6.41
6.4ACPURemote 1/0 Station Programming ..................................... 6.46
6.4.1Notes on programming ............................................. 6-46
6.4.2 Readingand writing data ........................................... 6-48
6.4.3Programexample ................................................. 6-51
7 . CHECK LISTS ....................................................... 7-1 z7-3
7.1 GeneralCheck List ....................................................... 7-1
7.2Testsand Adjustments ................................................... -7-2
7.2.1Sequencecheck ................................................... 7.2
7.2.2Checking positioningoperation ....................................... 7-3
IB INAI ffi101.A
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_ ...

8 . TROUBLESHOOTING ................................................ 8-1 'v 8-15
8.1 ErrorDetected by AD71 ................................................... 8.1
8.1.1Datarangeerrors ................................................... 8.2
8.1.3 Buffer memory write errors ........................................... 8-5
8.1.4 AD71 BUSY (positioning)stoperrors ................................... 8-6
8.2 Troubleshooting ......................................................... 8.7
8.2.1General troubleshooting ............................................. 8.7
8.2.2Driveinoperative ................................................... 8.8
8.2.3 Incorrectpositioning., ............................................. 8.10
8.2.4 Speed wrong ..................................................... 8.11
8.2.5 Corrupted positioningdata .......................................... 8.12
8.2.6Unrequested stop ................................................. 8.13
8.2.7 Zeroingfault ..................................................... 8.14
8.1.2 "HOLD" LED ..................................................... 8.5
9 . MAINTENANCE ...................................................... 91 9-4
9.1 Unit Storage ............................................................ 9.1
9.2 Battery Change .......................................................... 9.2
9.2.1 Batterychange frequency ............................................ 9.2
9.2.2Changing the battery ............................................... 9.4
APPENDICES .................................................... .AP P.l APP-24
APPENDIX 1 Format Sheets ............................................... .AP P.1
APPENDIX 2 AD71 Processing Times ........................................ .APP.6
APPENDIX 3 System Design Considerations ................................... .AP P.7
APPENDIX 4 Connectionwith Servo Motors ................................... .APP.9
4.1Connection with MitsubishiMELSERVO-A ................... .APP.10
4.2Connection with Oriental's Pulse Motor ...................... .AP P.l 1
4.3 Connection with ToeiElectric'sVELCONIC .................. .APP.13
4.4 Connectionwith Nikki Denso's DIGITALS-PACK NDS-300 ...... .APP.14
4.5 Connectionwith Yaskawa Electric'sPOSITION PACK-1OAand 10B.APP-15
APPENDIX 6 PositioningData Number and Buffer Memory Address ConversionTable . .APP.17
APPENDIX 5 Dimensions ................................................. .APP.16
t
INDEX
IB INAI E6101C

I. .
1. INTRODUCTION /MELSEC=A
1. INTRODUCTION
The AD71 is a position controller modulefor use with the MELSEC-A
series of programmable controllers. The operation of the position
controller may be adapted to suit the individual requirementsof the
system by using the extensiveMELSEC-Aseriessoftwarefeatures.
This manual covers both hardware and software and contains all the
information required to install and operate the unit to its optimum.
The manual is arranged as follows:
Chapter 2 System Configuration
ExplainstheAD71operating principles together with a
glossary of termsanddescribes theMELSEC-A series
system configurationssuitable for use with theAD71.
Chapter 3 Specifications
Gives the AD71 specifications, functions, a description of
thedatarequired for operation, 1/0 specifications with
external equipment, etc.
Chapter 4 Handling
AD7 1 nomenclature, etc.
Chapter 5 Loadingand Installation
Gives AD71 installation and wiring instructions, etc.
Chapter 6 Programming
Explainsthe PC programmingrequired to control the
AD71.
Chapter 7 Check Lists
Gives pre-start-up test procedures.
Chapter 8 Troubleshooting
Hardware and softwarefault finding
Chapter 9 Maintenance
Appendices
Gives AD71 dimensions, connection examples with
various servo motors, etc.
1-1
IS INA) M101-A

Refer also to the following manuals:
SWO-AD71P Operating Manual
AGGPPUser's Manual
Al,A2, A3CPU User's Manual
Relevant drive unit instruction manual
In this manual, AD71 I/O numben assigned from the PC CPU
assume that the AD71 is loaded in slot 0 of themain base.
Packing list:
I Description I Quantity
AD71 positioning unit
1 40-pin connector for external wiring
1
1 -3

2. SYSTEM CONFIGURATKlN /MELSEC--
2. SYSTEM CONFIGURATION
2.1 Introduction to the AD71
The AD71 gives a pulsechain output. Thenumber of pulses deter-
mines the system position and the pulsefrequencydeterminesthe
positioning traverse speed. Positioning can consequently be specified
in a number of units (namely mm, inch, degrees orpulses) by spe-
cifying a feedrateperpulsewherethefeedrate is proportional to
the pulse frequency. A system schematic is shown below:
'C
ACPUl AI
PC
e
thing unit
'1
Drive unit Servo motor
~lsetrain, Speed command
r
-
DIA
Deviation converter
' - -1unter
AGGPP
>
Intelligent GPP
2
n
ln
it
'I I
t
Feedback pulse train !
1
i
i
I
I
otor rpwd
thecounterpulse
Time
T
The deviation counter in the drive unit integrates the incoming pulse
chain from the AD71 and converts the resultant value into an analog
voltage for use as a speedsignal.Thiscauses the motor to start
turning andthepulsegenerator to generatefeedbackpulses to the
deviationcounter. Thefeedbackpulsechain is compared with the
input pulse chain from the AD71 andan error valuegenerated until
theerror value is sufficient to maintainthe motor at the desired
sped. When the AD71 pulse output is switched off, thedeviation
countervaluedecreasesand the speeddecreases accordingly until
finally thedeviationcountervalue is zeroandthe motor stops.
Beforepositioning canbegin,thesystemmustbezeroed.This
involves driving themotor in a known direction to a known point
and loading a home position or zero address to the AD7l's position-
ingcounter. All subsequent positioning uses memory addresses
referred to this zeroaddress, either as an absoluteaddress (Le. each
point specified as an individual address) or as an incremental address
(i.e. a given distancefrom the previous address).
2-1
I8 (NAI 661014

2 SYSTEM CONFIGURATION /MELSEC-A
Thesystemcanbezeroed in one of three weys. All use a "zeroing
dog." The "zeroing dog" is a switch or actuator which provides one
of two conditionswhichdefine the home position. The second
condition depends on thezeroingmethod used, this will beone of
the following:
0 A zerophasesignal from the rotary encoder.
0 A mechanical stop followed by a timer timingout.
0 A mechanical stop followed by a torque feedback signal from the
drive unit.
The operating data for the AD71 is stored inthe buffermemory and
consists of parameters (defining system constants such as maximum
feedrates, etc.), zeroingdata (defining thezeroingprocess),posi-
tioning data (containing the individual addresses, speeds, etc.)and
start data (definingwhich position to start at, etc.).
Positioning data is referred to by a positioning data number,which is
defined by its location inthe buffer memory.
There are two methods for manual control of the AD71 pulse chain
output, theseare jogoperation andinching.During jog operation,
the outputpulse chain is maintained for as long as the jog signal from
the PC is onhowever during inching a definednumber of pulses is
output every time a manualpulsegenerator input signal is given.
(The manual pulse generator is also referred to as "manual pulser").
The inching function therefore requires the provision of an external
manualpulsegeneratorhardwired to the AD71 connector in order
tooperate effectively.
c

_, . . .. . .
General designof positioningsystem
Pulse generator (PGI
Servo motor
W
P
A : Positiondetectionincrement (mm/p)
Vs : Command pulse frequency (p/s)
n
: Number of pulsegeneratorslits(slitshev)
L : Feed screw lead (mm/rev)
R : Reduction ratio
V : Moving part speed (mm/s)
N : Motor speed (rpm)
K : Position loop gain (sec-' 1
E : Deviationcounterpulse value
PO : Zero point (pulse)
P
: Address (pulse)
(1 ) Positiondetection increment
(2) Command pulse frequency
(3) Deviation counterpulse value
E = - (pulse)
VS
K
Expression (1) indicatesthetravel perpulse, i.e. thenumber of
output pulses x A. Usingexpression (2). calculatethecommand
pulsefrequency from the work speedand position detection incre-
ment.Expression (3) indicates the relation between the command
pulse frequency and deviation counter pulse value.
Any of the four positioning units, (mm),(inch), (degree),and
(PULSE),may be selected individually for the X and Y axes.

2, SYSTEM CONFIGURATION /MELSEC-A
2.2 MELSEC-ASeries Equipment
Fig. 2.1 shows a schematicdiagram of the MELSEC-A series equip-
ment for use with theAD71.
I-
Battery
(AGBAT)
1
I
J
Positioning module
(AD71)
I
iL
Note I: For use of the positioning unit in the data link system, refer to Section
2.2.
i
Fig. 2.1 Overall Configuration
b
2-4
18 INAI 66101C

2. SYSTEM CONFIGURATION /MELSEC-A
Building block type CPU
U
I I
Main base unit (A3::B)
I I
Extension cable (AC:;::B)
'
n I
V I I
-lml&
I
Extension bare unit
(A6;:B)
--I
1 L
L
-
Printer
Tesching unit
(AD71Tl.J)
r- ___---
1
Intelligent 4qArnI GPP 3.5inchfloppy disk
(A6GPP)(SWOGP.AD71 P)
r--=====----- - -7
Servo motor
Pulse motor
Stepping motor
Etc.
d I Driveunit I Pulse motor
u "
il
I
L"
I8 INAl €6101 C

.2 SYSTEM CONFlGURATlON /MELSEC-A
The AD71 can be used with thefollowingindependent CPUs:
Applicablemodel A1(EICPU
A2(E)CPU
A3(E)CPU
Do not use the AD71 on any extension base which does not include
a power supply (i.e. A5C:B).
The following CPU types are required for a data link system.
A1 (E)CPU P21/R21
A2(E)CPU P21/R21
A3(E)CPU P21/R21
c."
IB INA) 66101.A

_. .. . ... . ,
2. SYSTEM CONFIGURATION ..
2.3 AD71 Programming Equipment
The following tableindicates the equipmentavailable for program-
ming the AD71.
hit Division Description Remarks
SWOGP-AD71
P
AD7 1 /AD72 software package
0 Consists of the following:
1 AGGPP 1
OProgrammingunit withCRT
OEquipped with
ROM writer, FDD and printer
interface functions.
Intelligent
GPP AGGPP-SET SWLI-GPPA
K series system disk
SWL2-GPPK
A series system disk
I WO-GPPU I User disk (3.5 inch, formatted)
I AC30R4 I Cable for connecting AD71 andAGGPP.
0 Consists of the following:
TYW Remarks I
'rogramming
unit OProgrammingunit withplasma display
AGPHP OEquipped with FDD, printer interface and
memory
cassette functions.
SWXP-GPPA A series system disk
Plasma handy
programmer AGPHP-SET
ISW:lGP-GPPKI K seriessystem disk
I
I Sk-GPPU 1 User disk (3.5 inch, formatted)
~ ~~
1 AC30R4 I
Cable for connecting AD71 and AGPHP.
3m (9.84
ft) length.
1 I 1
Floppy disk for storing user programs (3.5 inch, formatted)
SWO-GPPU
AC30R4
User disk
RS-422cable
~~~~ ~~
Cable for connecting CPU and AGGPP. 3m (9.84ft) length.
Cable for connecting GPPscreen monitor display. lm (3.28 ft)
length.
Composite
video cable AClOMD
Cleaningdisk SWO-FDC Floppy disk for cleaning floppy disk drive.
Cable for connecting CPU and AGGPP. 30m (98.4 ft) length.
For print out ofprogram ladder diagrams and lists.
Cable for connecting AGGPP and printer (KGPR, K7PR,general-
purpose printer with RS-232C interface). 3m (9.84 ft) length.
Paper for KGPR printer.
9 inch. Available in units of 2000 pcs.
Cable RS-422cable
Printer
AC300R4
KGPR
K7PR
AC30R2
RS232C
cable
Printer
Printer paper KGPR-Y
KGPR ink
ribbon KGPR-R Replacement ink ribbon for KGPR.
I
AD7 1/AD72 teach box.
~~~~~~~
Teaching unit
Table 2.1 AD71 Programming Equipment
L.
'B INAi 66101 C

3. SPECIFICATIONS /MELSEC-A
3. SPECIFICATIONS
3.1 General Specifications
I 1-m I
I temperature
I
Operating amblent
0 to 55O c
I
Storage ambient
-20 to 758c
I
Operating ambient
hurnidlty 10 to
90%RH, noncondensing
Storage ambient
humidity 10 to
90%RH, non-condensing
~ ~~
-
Frequency Sweep Count Amplitude
Acceleration
Conforms
resistance
JIscosll
to
10 to 55Hz
0 075mrn
-
10 0031nchl 10 tarn&
55 to 150Hz
Noise durability
Conforms to JIS C 0912 (109
x 3 times in 3 directions)Shock resinance
lg
-
'(1 octaveIminuteJ
IN noise width and25 to MHz noise frequency
By noise simulator of 15OOVpp noise voltage,
I wit~~~~~~tqeI SOOV AC for 1 rnlnute acrossDC external terrnlnals andground
I
~ ~~~ ~ ~~~
Insulation
resistance 5MR or larger by
500V DC lnsulatlon resostance tester across
AC external terrnlnels and ground
Operating
ambience Free of corrosive gases. Dust should be rnlnimal.
Cooling method Self-cooling
Table 3.1 General Specifications
One Octave marked indicates a change from the initial frequency
to double
orhalffrequency.For example, any
of the changes fromlOHzto20H2,from
20Hzto 40Hz, from40Hzto20H2, and 20HztolOHz are referred to as
one
octave.
3-1
I8 iNAl 66101E

3. SfEClflCAllONS /MELSEC-A
3.2 Performance Specificationsand Functions
3.2.1 AD71 performancespecifications
ltrm
Podormanerr and Specifications
32
Number of
1/0 points
Number of controlaxes 2 (simultaneous or independent)
Interpolation Linear interpolation (for 2
axes)
~~ ~
400 pointsper axis
Input from A6GPP or seguence program
15 minutes without battery 125OC)
total of 300days.
Lithum battew guarantees power failure backup for
a
Battery guaranteed for five years.
RAMmemory backup
-
Posi-
,ionin
Method Absolute and/or incremental method.
Max.162 Im)
Max. 16200 (inch)
Max. 16200 (degree)
1to 16,252,928 (PULSE)
(commandunit: 0.1 to 10um/PLS)
(command unit:
1 x lo-' to 0.001 inch/PLS)
(commandunit: 1
x lo-' to 0.001 degreelPLS)
10 to 12oooO Immlmin) (commandunit: 10mm/min)
10 to 200000 (PLS/sec) (command unit: 10 PLS/sec)
1to12000(inch/minl(commandunit:1inch/minl
1to12000 (degree/min)
(commandunit: 1 degreelmin)
Positioning units
Positioning speed
and deceleration
Acceleration Automatic trapezoidal accelerationand deceleration
Acceleration and
deceleration times
Backlashcompensation
64 to 4999(msec)
0 to 65535 x position command unit
(0 to 255 pulses if unit is PULSE)
Error compensation The AD71 may
be "calibrated" to allow for mechani-
cal errors.
With zero eddrerc change function.
Zeroing directionand speed depand on setting.
Jog operation by jog start signal input.
Zeroing
Jog operation function
Inching function Operation using manual pulse generator.
M function
Internal current consumption
M code output
5V
DC, 1.5A
External supplyvoltage, current 4.75 to 26.4V, max. 50mA
Size mm (inch)
Weight kg (Ib) 0.63 (1.93)
Table 3.2 PerformanceSpecifications
3-2
IS (NAI 66101C

3. SPECIFKAT1ONS ~/MELSEC-A
3.2.2 Functions
The AD71 can drive two axes independently or with linear inter-
polation, either:
(1) Using theAGGPP or teaching unit, or
(2) From thePCsequence program
For use of the AGGPP, refer to the SWOGP-AD71P Operating Man-
ual. For use of the AD71TU, refer to the AD71TU Operating Man-
ual. Positioningcontrol functions are shown below.
~~
Squmce Progrm or ABOPP
Function
Trm-axir indopmndmt
omntion Two-axir intorpolation
omration
Error detection
~~
An error code is provided by the AD71 ifa data setting or
positioning control erroroccurs.
(For details oftheerror codes, refer to Chapter
8.)
I
st date and write
data) can be read and written.
AD71 set data (parameters, zeroing data, positioning
and
speed read
Present value Presentvalue data and
speed data can be read from the
AD71.
(Presentvaluecan
be reed and monitoredduring posi.
tioning.)
~~~ ~~
Teaching
(positioningdata mite) position data.
After manual positioning, presentvaluecan be written as
The drive for thegiven axis
is advanced by a pre-
Inching operation defined number
of pulses
each time a manual pulse Unavailable
is received. The manual
pulse
is providedby a
manual pulsegenerator.
Jog operation The drive for thegiven axis
is operated for a~ long as
Unavailable
the
jog input is on.
1 Returnsthedrive to a I
Zeroing
I
defined start position and
refers the zeroaddress to
I Unavailable
that position.
point
position to the set position
position to the set position
positioning
Moves fromthe current
Moves from the current
at
set speed.
at interDolated speed.
tioning
Posi- Continuous
positioning
positionlng with
Continuous
(Patternchange)
speed change series of positions
at dif-
ferent
speeds after recetv-
Ing a singlestartslgnal.
Unavailable
TaMe 3.3 Positioning Control Functions
.
3 -3
I8 INAI 66101-C

3. SPECIFICATIONS
I. /MELSEC-A
Note 1: Errorcompensationandbacklash compenmtion functions are valid
for all the functions shown in Table
3.3.
2: An indexedcode may be used as adigital signal for thecontrol of
amciated processes during positioning. This
is known asan "M"
code.
3: The A071 present value can be rewritten before positioning is s?a,-ted
using the sequence programor AGGPP.
4: Positioning may be executed continuously for upto 20 points by
writing positioning start data to the buffer memory
(X axis: 0 to
39, Y axis: 300 to 339).
3-4
IB INAJ 66101-A

3. SPECWICATIONS /MELSEC-A
3.3 Positioning System Operation
3.3.1 AD71 interfacesFig,3.2indicatesthesignalcommunicationsbetween the AD71 and
external devices.
o Communicationbetween PC CPUand AD71
Control signalsanddatacommunications via base unit, they
consist of:
I
Control signals. . , .I/O signalsgiven in Section 3.6 (page 348).
Data ... . . . . . .. .Written to and read from the buffer memory
by the PC CPU. Detailed in Section3.4
(page 3-81.
0 Communicationbetween A6GPP (orAD71TU) and AD71
Data write, AD71 test, AD71monitor, etc.via the AD7l's
RS422 connector.
o Communicationsbetween drive unit and AD71
Control signal communication to and from thedrive unit and
pulse train output from theAD71. (For the 1/0 interface,refer
to Section 3.7 (page 3-54).]
PC CPU
Data writelread
I
II-
-1
Fig. 3.2 AD71 Function BlockDiagram
3-5
IB INAl €6101-C
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