Mitsubishi MELSEC-K User manual

-_
t
i
MlTSUBlSHl
PROGRAMMABLE CON1
ROLLER
Instruction Manual
Positioning Unit Type KD7 I
Teaching Unit for KD7 I Type KD7 I TUE
I IB(NAl64492-B I
MlTSUBlSHl
ELECTRIC

0 '< '
CONTENTS
/
..
1. Introduction ......................................... 1
2. Composition
2-1 Component units
................................. 2
2-2 System composition
.............................. 3
3. Operation explanation
3-1 Principles of operation
......................... 4
3-2 Outline design of the positioning system ........ 6
Specifications
4-1 Performance specifications ...................... 7
4-2 General specifications
.......................... 8
4-3 Power unit capacity ............................. 9
Input/Output interface
40
5.
,
7
5-1 Signal names ................................... 10
5-2 Electrical specifications ...................... 12
5-3 Torque restriction ............................. 14
5-4 Interface for the KD71S1 ....................... 15
6. Pcsitioning nethod .................................. 19
6-1 Zero point return .............................. 20
6-2 Positioning .................................... 21
6-3 Positioning continuation
....................... 21
6-4 Speed and torque revisions ..................... 22
6-5 Speed revision during execution of positioning . 22
6-6 Positioning stop ................................ 22
6-7 Positioning start
.............................. 22

7.
Contents of preset data
7-1 Parameters ..................................... 25
7-2 Zero point return data ......................... 30
7-3 Positioning data ............................... 33
8. Hardware
8-1 Hardware composition and function of selector
switch
(SW2) ................................... 38
8-2
LED display contents ........................... 40
8-3 UNLOCK-LOCK switch ............................. 40
8-4
Use of selector switch (SW2) ................... 40
8-5
Programming settings data into ROM ............. 42
9. External connections
9-1 Example of connections to TGei Electric
VELCONIC ....................................... 43
9-2 Example of connections to Nikki Electric
DIGITAL S-PACK
................................. 45
9-3 Example of connections to Yasukawa Electric
POSITION PACK-1OA
.............................. 46
10. Operating the Teaching Unit
10-1 Connection with the Positioning Unit ........... 48
10-2 General operations ............................. 49
10-3
Operating modes ................................ 50
10-4
Write-in ....................................... 51
10-5 Readout ......................................... 54
- 10-6 Monitor ........................................ 56
10-7 Testing ........................................ 58
10-8
Special operations ............................. 62
7\

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11. Sequencer Program
11-1 1/0 signals and allocation ..................... 65
11-2 Signal exchange with sequencer
................. 66
11-3 Writing preset data ....................... 71
11-4 Readout
of preset data ....................... 77
11-5 Start
.......................................... 82
11-6
1 11-7
11-8
12. Trial
12-1
12-2
13. Error
13-1
13-2
Readout
of current value, torque, and status ... 85
Revision of current value ...................... 89
Speed revisions
................................ 89
run
Sequence checks
................................ 92
Check
of positioning operation ................. 94
code displays and their rectification
Error code display
............................. 95
Error code chart
............................... 96
14. Safety measures .............~........................ 103

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1, Introduction
The Positioning Unit KD71 (hereafter abbreviated as KD711, is
used for high-precision positioning control as one of the input/
output
peripherals of the MELSEC-K1, K2, KOJ.
The KD71 has a microprocessor, whose output is a positioning
pulse sequence, including acceleration and deceleration.
The output can be combined with various kinds
of servo
control drive units to perform positioning for
a wide range
c1
of industrial equipment.
Features :
1. Full digital control
0
The use of a high-speed microprocessor has made possible small
size and high performance, with high reliability.
2. One unit performs 2-axis control
With a single positioning unit, independent 2-axis control
or
simultaneous 2-axis control is possible.
3. Includes linear interpolation function.
0
A 2-axis linear interpolation function is included in the unit.
4, Includes backlash compensation function.
The backlash compensation function makes possible high-preci-
sion positioning possible.
I
5, Usable servo motors
Since the
KD71 operates with pulse-sequence output, it can be
used with DC servo motors, AC servo motors, stepping motors,
and other drive units.
-1-

6. Positioning data settings
The setting of positioning data can be performed from the KD71
TU and- sequencer CPU.
-
Positioning
unit
..
KD71
2. Composition .
Teaching
unit
Connection
cable
2-1 Component parts
KD71TU
K70CBL
The component
parts used in conjunction with the positioning
-.- ~
unit are as listed below
Table 2: Positioning unit component parts
Name IModel
Battery
KGBAT
Memory
11 KROM
unit
I
Contents
Positioning unit main body (output sync type)
Positioning
data input/output unit
Cable for oor.necting the KD71 and KD71TU
(length 2m(78 inches) )
Memory backup battery for IC-RAM memory and
latch function.
EP-ROM (equivalent
to type- 2716, IC chip),
2K bytes.
Positioning unit main body
for use with
MELDAS-S1 (output source- type)
- I
L
- ._ . .
..
. I .
.. . ..
0
0
0
-2-

c,
2-2 System composition
Positioning unit
KD71
onnect
able
.70CBL
ion
Teaching unit
KD71TUE
Write-in of positioning
JUULPulse
..S e quen c e r
MELSEC-K
Sequence processing
Data processing
[+ Data link function 1
Positioning function
sequence output
w
data
Readout of positioning data
Control status display
Positioning test function Drive unit
AC/DC servo motor,
pulse motor,
stepping motor,
etc,
Fig. 2: System composition
-3-

3.
I
Operation explanation
I
3-1 Principles of operation
r
------------
pulse I
sequence
ULrLr
~S-peed r
A
command
>
M
Servo
Inverted; >Deviation- D'A conve r t e r
.Ir amp13 fier
pulse counter
sequence
J
*
I
I
I
I
I
I
Interface
PG
Feedback pulse sequence
,-LhnT
i
0
.-
-
vo motor speed
3
rn
tu
tu
a
Y
v) accumulation
Time
(t)
speed command.
0
Fig. 3: Block diagram of positioning system operation
The output of the KD71 is a pulse sequence. When a pulse
sequence is output, the pulses accumulate in the deviation
counter, and-this pulse accumulation
is converted to direct
current analog voltage by the
D/A converter, thus becoming the
_.
0

When the motor begins rotating as a result of the speed command,
pulses in proportion
to the amount of rotation are output from
the pulse genera.tor PG, and,decrease the accumulation in the
deviation counter.
I
The deviation counter preserves a fixed amount of accumulation,
continuing the
motor rotation, and when the command-pulse output
from the
KD71 is stopped, the accumulated pulses in the deviation
counter
are reduced and speed is lowered, and when the accumula-
*
ted pulses disappear, the motor stops. In other words, the ro-
tating speed of the motor is proportional to the frequency of
the command pulse, and the rotation angle of the motor is
0
proportional to the number of command pulses output.
-5-

3-2 Outline'design of the positioning system
\u A: Unit of
..
position detection (mm/PULSE)
I
Servo motor
Vs: Command pulse frequency [PULSE/sec]
n: Pulse generator slits [SLIT/rev]
(1) Unit Of position detection L: Feed screw lead [mm/revl
R: Deceleration rate *
V: Moving element speed [mm/sec]
N: Motor revolution [rpm]
K: Position loop gain [sec-ll
A=- (nn/PULSE)
Rxn
(2) Command pulse frequenc'y
0
7- 6 t Accumulated pulses in deviation counter [PULSE]
V
A
A&: Stopping accuracy [PULSE]
Vs = - ( PULSE/sec 1
(3) Pulse accumulation
of deviation counter
vs
K
E =-( PULSE)
The amount of movement of one pulse is shown in (l), the amount
of movement equaling the number
of output pulses x A. The com-
mand pulse frequency is computed in (2) from the moving element
speed and the unit of position detection.
The relation
of the command pulse frequency and the pulse ac-
cumulation in the deviation counter is shown in (3).
The KD71 sets the position of the moving element in absolute
value. When the zero point
is Po, and the amount of movement
from the zero point
is ,& ,
I?
P=Pot-
A
the following re'lation is obtained:

i
4. ,Specifications
4-1 Performance specifications
Item
No. of control
axes
'
Maximum command
value
Maximum speed
Speed setting
range
Automatic ac-
celeration/
deceleration time
Data capacity
Setting method
Zero point
return function
Setting data
RAM memory
backup
Specifications
.
Handles 32 points
No. of exclusive
I I/o points
2 axes (simul.
2-axis,
independent 2-axis)
999,999 pulses
6 digit decimals
100 KPPS
4 PPS s 100 KPPS, can be set in 4 PPS increments
Linear accel/decel
0.1 s 9.99 sec, setfable in 10 ms increments
400 data per axis
(0 s 399)
Can be input from teaching unit and sequencer CPU (KOJ, Kl,.K2)
Includes zero point shift function, zero point return direction, speed para-
meters settings
Parameter
Acceleration/deceleration
time 0.1 I, 9.99 sec.
Torque restriction 10 250%
Backlash 0-255 pulses
Speed restriction decimal-
6 digits
Upper stroke limit deci-
mal 4 digits
Upper stroke limit deci-
mal
6 digits
JOG speed decimal 4 digits
Zero point return data
Zero point return mode
Zero point address
decimal
6 digits
Creep speed decimal
6
digits
Torque restrictionl0s 250%
Dwell O.Ols9.99 sec.
Zero point return speed
decimal
6 digits
Positioning data
Data number
0 2, 399
Positioning pattern
Positioning address
decimal
6 digits ,
Speed decimal 6 digits
Torque restriction
10%
250%
Dwell O.Ols9.99 sec.
Condenser preservation
10 min. at 4OOC.
Lithium battery, overall preservation time in event
of power outage 300 days,
battery life 5 years.
s
-7-

4-2 General specifications
Item Specifications
Ambient
temperature
I
Ambient
(during storage)
Relative humidity
temperature
I 0 % 55oc
-10 'L 75OC
10 'L 90 %RH (non-condensing)
I
Shock protection
Noise protection
Voltage
protection
Insulation
resistance
Conforms to JIS C 0912 (10 g,
3 times in each direction X, Y, Z)
By noise limiter, noise voltage 1OOOV (P-P), noise width lps, noise frequency
25 2, 60Hz.
ACSOOV-1 min. Input/output terminals encased
Input/output terminals encased
With 500V insulation resist-
ance tester,
~MQ or more
10 % 90 %RH (non-condensing)
Conforms to JIS C 0911 'I1 83 type (16.7Hz compound amplitude 3 mm 2Hr)
Relative humidity
Vibration
protection
(during storage)
-8-

4-3 Power unit capacity
The capacity
of the power unit, and the load current of the KD71
and the’various 1/0 units is as shown below, The power unit
should
be selected by computing the total current consumed.
Power unit
K61PA62P
i
15V 4A I
Power unit
5V 15A
I5V lOAl
I
K2CPU
w/ peripheral unit
5V 2.2A
w/ KD71TUE
(w/oKD71
TU)
I
KJ71 L2, L4
I 0.1 A
If the system is run without a sufficient power capacity,
damage may result to the power unit, destruction of the sequenc
sequence
program, or malfunction of the CPU.

5. Input/Output interface
5-1 Signal names
U
a
2
Signal name
Drive unit
ready
READY
DOG
Zero-point
signal
PGO
Positioning stop
STOP
START
Deviation counter
clear
CLEAR
Direction sign
SIGN
Command puise
PULSE
Command pulse
for normal
direction
PULSE
F
Command pulse
for inverted
direction
PULSE R
Contents
(1) Set on LOW when servo drive unit is normal and ready to accept
(2) Before starting, the KD71 checks the drive unit ready signal, and
(3) Set to HIGH when drive unit is not capable of operation, e.g. when
feed pulses.
if not in a ready status, outputs a zero point return demand.
malfunction is found in control power or elsewhe-re.
(1) Used for near point detection during zero point return.
(2) When zero point return is performed by zero-point signal, the zero
Set on
LOW for near point detection.
point is the first grid point separated
from DOG following the
detection
of the near-point DOG.
(1) The zero-point signal is used during zero point return, and in
general, the zero-point grid signal
of thepulse encoder is
used. At zero-point set to
LOW.
(2) When zero point return method is by stopper,
and zero point return
completion
is input from external sources, this signal is also ysed.
(For details refer to section 7-2-1).
(1) LOW when positioning is stopped.
(2) When this signal is input, the KD71 stops execution of positioning,
and sets the start signal
(START) to OFF (HIGH).
(1) Low during execution 6,fpositioning.
(2) During output of feed pulse or during dwell, start signal becomes
ON (LOW). This signal is normally used as the brake release
signal for
mechanically-braked servos.
This is the pulse signal output before the execution of zero point
return operation, and it resets the accumulation pulses
of the servo
unit's deviation counter.
H
I-- -
Low during normal, HIGH during inverted.
Normal increase sthe current value, inverted decreases current
value.
Common feed pulse for normal and inverted.
Running direction
is determcined by direction sign (SIGN).
Feed pulse for normal (forward)'use.
Feed pulse for inverted (reverse) use.
0
0

The following outputs are used by selecting either A or B
output using the switch built into the unit. (Refer to Fig. 8)
Signal name
command
4J pulse
I PULSE F
A type (SW2-2 OFF)
Contents
Feed pulse
for normal (forward)
I PULSE R I
\
B type (SW2-2 ON)
Signal name
Direction sign
SIGN
Command pulse
PULSE
Contents
LOW during normal, HIGH during inverted.
((During normal,
current value increases;
during inverted,
current value decreases).
Feed pulse for use with both normal and
inverted. Running direction
is determined
by direction sign (SIGN) .
PULSE
uuuuu umuu
NOTES) 1. 1/0 signals are the same for X and Y axes.
2. For external connections and arrangement of connector
pins,
refer to section 9.
3. Selection of the output mode in Fig.8 is as follows:
when SW2-2 is OFF, the mode is A; when SW2-2 is ON, mode
is B (set to B by factory at time of shipping).
-11-

5-2 EleCtfical specifications
(1). Input
Signal name
Supplied
power
STOP
DOQ
READY
PQO
(2) output
Signal name
START
CLEAR
S I QN
PULSE
PULSE
F
PULSE R
Contents
DC5-24V (4.75d25V stabilized current)
1 5 0 mA(max))
At HIGH level supplied power voltage
-lV or more
(Input current 0.3mA or less)
At LOW level supplied power voltage
(Inputcurrent 2.5mA or more)
-3V or less
-At HIGH leuel supplied power voltage
-1~ or more
(Inputcurrent 0.3mA or less)
At LOW level supplied power voltage
(Inputcurrent 2.5mA or more)
-3V 0-r less
Pulse width: 2 0 PS Or more
Pulse fall time: 3 psor le-ss
Con tents
Output type: Open
collector
Load voltage-.: 4.75 d 25VDC
,Load current:
lOmA (max)
Output voltage
at ON: 0.6V or less
Current leakage at(OFF-state): O.lmA or less
Output type: open collector
Load voltage: 4.75 d25VDC
Load current: lOmA (max)
Use with range of 2mANlOm
When
ised
with less than 2mA, add a dummy resistor.
Pulse rise time and fall time:
Both3 p s or less'
0
-1 2-

-1
KD7 1
~~
Pin number
..
I
Signal name
X axisY axis Type A
2A 2B
9B
7B
STOP
-
- 8A 10A DOG
- 7A 9A READY
- 1B 3B -
PGO
- 8B
1 OB
1 kQ
Type B
STOP
'
DOG
READY
Pa0
1A
4A
I
I
I I
3A (+) power: supply
5B (-9 supply)*
DC 5m24V (outside
F
-
13B
14A
-- 12A
5A
11A 15B START
k
18A
18B
16B
.Same as
6 B above.
PULSE F
I
'I
-
--
SIGN
14B 19A
15A 19B
12B 17A
Same as
13A 17B above*
- PULSE R
Same as
.above
-
PULSE
CLEAR
4B 6A
Same as
above
CLEAR
START
Fig. 5.1 KD71 1/0 circuits.
-1 3-

5-3 Torque restriction
The KD71 includes
a function for controlling torque. When per-
forming torque restriction, the
KD7l's torque restriction value
is readout by the KCPU sequence program, converted to analog
by the D/A converter unit w63A,and output to the drive unit.
For reading the troque restriction value, refer to section
I 1-6.
Sequencer
KCPU
Torque
:est ri c t ion
ralue
:e adou t
Drive unit
Pulse
sequence
res
t r i c t.i o n
(analog volume)
Fig,
5.2 Block diagram of torque restriction function
-14-

5-4 Interface for the KD71S1
The positioning unit KD71S1 is connected to, and used with the
Mitsubishi
servo unit MELDAS-Sl._ The differences between
the servo unit and the
KD71 are the mode of input/output
signals and the pin numbers only. Other functions, operat-
ions., and specifications are identical to ,the KD7l. Select
positioning functions, data transmission finctions, and
memory protect
ON-OFF ‘selector switches in accordance with
Fig. 8.
0
-1 5-

5-4-1 1/0 interface
Signal name
Drive unit ready
READY
Near point signal
DOG
Zero-point signal
Positioning stop
STOP
Start
START
Clear signal
CLEAR
Direction sign
SIGN
Pulse sequence
output
PULSE
:1) Set to HIGH when the MELDAS-S1 is normal and ready to
accept feed pulses.
:2) Before starting, the KD71S1 checks the drive unit ready
signal, and if not in a ready status, outputs a zero
point return demand
(1) Used for near-point detection during zero point return.
HIGH at near-point detection.
(2) The zero point is the first grid point separated from
the
DOG following thedetection of the near-point DOG.
(1) Zero point signal for zero point return, uses MELDAS-Sl's
grid
ON signal (resolver phase angle 0).
(2) When zero point return method is by stopper, and zero
point return completion is input from external sources,
this
signal is also used.
(1) HIGH when positioning is stopped.
(2) When this signal is present, the KD71S1 stops execution of
positioning, and sets the start signal (START) to OFF
(Low) .
During output of feed pulse, or during dwell, start signal
is ON (HIGH). This signal is normally used as the brake
release signal for
mechanically-braked servos.
For MELDAS-S1 alarm reset, this is the pulse signal output
before execution of zero point return operation.
1 0-5 Oms
I I
Used as the direction sign for pulse sequence commands.
Differential output.
This is the pulse sequence command, and is output
differentially.
nrulnnn n
I I I
PULSE
1
I
SIGN