Saia PCD2.H31x User manual

SAIAPCD
Process Control Devices
PCD2.H31x
Motion control modules
for servo drives
English edition 26/762 E2

SAIA-Burgess Electronics Ltd.
Bahnhofstrasse 18
CH-3280 Murten(Switzerland)
http;//www.saia-burgess.com
BA: Electronic Controllers Telephone 026 / 672 72 72
Telefax 026 /672 74 99
___________________________________________________________________________________________________________________________
SAIA-Burgess Companies
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g
ess Electronics B.V.
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___________________________________________________________________________________________________________________________
Issue : 22.11.2000
Subjetto change without notice

SAIA-Burgess Electronics Ltd.
SAIA® Process Control Devices
Motion control modules
for servo drives
PCD2.H31x
SAIA-Burgess Electronics Ltd. 1999. All rights reserved.
Edition 26/762 E2 - 11.99
Subject to technical changes

SAIA-Burgess Electronics Ltd.
Updates
Manual : PCD2.H31x - Motion control modules for servo drives - Edition E2
Date Chapter Page Description
12.05.2000 Appendix A A-36 divers corrections

PCD2.H31x Contents
26/762 E2 (2H3-00-E.DOC) SAIA-Burgess Electronics Ltd. Page 1
Contents
Page
1. Introduction
1.1 General 1-1
1.2 Function and application 1-2
1.3 Main characteristics 1-3
1.4 Typical areas of use 1-4
1.5 Programming 1-5
1.6 Operating modes 1-6
1.7 Commissioning 1-7
2. Technical data
2.1 Hardware technical data 2-1
2.2 Electrical specifications 2-3
2.3 Function-specific data 2-4
3. Presentation
4. Terminals and meaning of LEDs
5. Function description
5.1 Operating modes 5-1
5.2 Generator for the velocity profile 5-2
5.3 PID controller 5-4
5.4 Position decoder and input circuit 5-5
5.5 D/A converter 5-8
5.6 Complementary information: homing (FB Home) 5-9
6. Quick start
6.1 Getting started with IL programming 6-2
6.1.1 Entry-level example in IL with wait loop 6-3
6.1.2 Entry-level example in GRAFTEC 6-6
6.1.3 Simple commissioning program 6-11
6.2 Getting started with FUPLA programming 6-13

Contents PCD2.H31x
Page 2 SAIA-Burgess Electronics Ltd. (2H3-00-E.DOC) 26/762 E2
Page
7. Programming
7.1 Programming in IL with FBs 7-2
7.1.1 The IL package (installation of FB) 7-2
7.1.2 Individual FBs 7-5
7.2 Programming in FUPLA with FBoxes 7-9
7.3 Programming in GRAFTEC with FBoxes 7-10
8. Error handling and diagnosis
8.1 Definition error checked by assembler 8-1
8.2 Error handling in RUN 8-2
8.2.1 Incorrect parameters 8-2
8.2.2 Error during homing 8-3
9. Installation and commissioning
9.1 Introduction 9-1
9.2 Installation and wiring 9-2
9.3 Commissioning drive without motion control module 9-3
9.4 Drive with motion control module 9-4
9.4.1 Switching on the supply voltage 9-4
9.4.2 Preparing the user program 9-5
9.4.3 Determining machine data 9-6
9.4.4 Direction, path measurement (encoder) 9-8
9.4.5 PID controller 9-10
9.4.6 Effect of individual factors
on controller behaviour 9-14
9.4.7 Simple commissioning program 9-15
10. Commissioning tool
11. Security aspects
12. Application examples
12.1 Example: 1 axis with homing 12-1
12.2 Example: 1 axis with two velocities 12-9

PCD2.H31x Contents
26/762 E2 (2H3-00-E.DOC) SAIA-Burgess Electronics Ltd. Page 3
Page
Appendix A: Summary of all function blocks (FB)
Init: Initialization FB A-1
Home: Home position FB A-3
Exec: Execution FB A-5
StartMot Start motion A-7
StopUrg Stop motion in urgency A-8
Stop Stop motion A-9
MotOff Motor regulation off A-10
RdActPos Read Actual Position A-11
RdActVel Read Actual Velocity A-12
RdIntSum Read Integration Sum A-13
RdIndexRg Read Index Register A-14
RdStatRg Read Status Register A-15
RdTargPos Read Target Position A-16
RdTargVel Read Target Velocity A-17
GoForw Go Forwards A-18
GoBackw Go Backwards A-19
SgStpFor Single Step Forwards A-20
SgStpBak Single Step Backwards A-21
LdDestAbs Load Destination Absolute A-22
LdDestRel Load Destination Relative A-23
LdVelAbs Load Velocity Absolute A-24
LdVelRel Load Velocity Relative A-25
LdAccAbs Load Acceleration Absolute A-26
LdAccRel Load Acceleration Relative A-27
LdPropG Load Proportional Gain A-28
LdIntG Load Integrative Gain A-29
LdDerG Load Derivative Gain A-30
LdSampInt Load derivative Sampling interval A-31
LdIntLim Load Interactive Limit A-32
ActRegFact Activate Regulation Factors A-33
LdBrkPtAbs Load Breakpoint Absolute A-34
LdBrkPtRel Load Breakpoint Relative A-35
ResStatRg Reset Status Register A-36
SetIdxPos Set Index Position A-37
SetZero Set Home position A-38
MotConf Motion Configuration A-39
SetPosTol Set Position Tolerance A-40
Appendix B: Summary of all function boxes (FBox)

Contents PCD2.H31x
Page 4 SAIA-Burgess Electronics Ltd. (2H3-00-E.DOC) 26/762 E2
Notes

PCD2.H31x Contents
26/762 E2 (2H3-00-E.DOC) SAIA-Burgess Electronics Ltd. Page 5
Important note:
Many detailed manuals have been created to ensure perfect operation of
the SAIAPCD. These are for use by technically qualified staff, who
may also have successfully completed our workshops.
The diverse performance features of the SAIAPCD best become appa-
rent only by following closely all the information and guidelines con-
tained in these manuals regarding assembly, wiring, programming and
commissioning.
Doing this will enable you to join the large group of enthusiastic SAIA
PCD users.
Summary
Hardware
PCD4 Hardware
PCD6
PCD4.H1..
PCD4.H2..
PCD4.H3..
Reference
Guide
(PG3)
PCD8.P1..
PCD7.D1..
PCA2.D1..
PCD7.D2..
Installation
Components
for RS 485-
Networks
FUPLA/
KOPLA
function
families
PCD1/2 series PCD4 series PCD6 series
General
Manuals
*)
*)
*)
*) Adapter module 4'717'4828'0
allows H modules to be used
with the PCD6.
User's
Guide
- PG4
- Modem
-S-Bus
- PROFIBUS
-Remote I/O
PCD4.H4..
Hardware
PCD1
PCD2
Serie xx7
PCD2.M220
PCD2.H110
PCD2.H150
PCD2.H210
PCD2.H31x

Contents PCD2.H31x
Page 6 SAIA-Burgess Electronics Ltd. (2H3-00-E.DOC) 26/762 E2
Reliability and safety of electronic controllers
SAIA-Burgess Electronics Ltd. is a company which devotes the greatest
care to the design, development and manufacture of its products:
•state-of-the-art technology
•compliance with standards
•ISO 9001 certification
•international approvals: e.g. Germanischer Lloyd, UL,
Det Norske Veritas, CE mark ...
•choice of high-quality componentry
•quality control checks at various stages of production
•in-circuit tests
•run-in (burn-in at 85°C for 48h)
Despite every care, the excellent quality which results from this does
have its limits. It is therefore necessary, for example, to reckon with the
natural failure of components. For this reason SAIA-Burgess Electronics
Ltd. provides a guarantee according to the "General terms and conditions
of supply".
The plant engineer must in turn also contribute his share to the reliable
operation of an installation. He is therefore responsible for ensuring that
controller use conforms to the technical data and that no excessive stres-
ses are placed on it, e.g. with regard to temperature ranges, overvoltages
and noise fields or mechanical stresses.
In addition, the plant engineer is also responsible for ensuring that a
faulty product in no case leads to personal injury or even death, nor to
the damage or destruction of property. The relevant safety regulations
should always be observed. Dangerous faults must be recognized by ad-
ditional measures and any consequences prevented. For example, outputs
which are important for safety should lead back to inputs and be monito-
red from software. Consistent use should be made of the diagnostic ele-
ments of the PCD, such as the watchdog, exception organization blocks
(XOB) and test or diagnostic instructions.
If all these points are taken into consideration, the SAIAPCD will pro-
vide you with a modern, safe programmable controller to control, regu-
late and monitor your installation with reliability for many years.

PCD2.H31x Introduction
26/762 E2 (2H3-01-E.DOC) SAIA-Burgess Electronics Ltd. Page 1-1
1. Introduction
1.1 General
The PCD2.H3.. motion control module is an intelligent I/O module from
the PCD2 series. This module is used for positioning an independent axis
with a variable speed control drive (servomotor). The servomotor can be
any adjustable DC or AC motor having a power stage and incremental
shaft encoder for the registration of position and speed.
PCD1/2-BUS
PROCESSOR PCD1/2
BUS
INTERFACE
M
+
–
POWER
AMPLIFIER
INCREM.
INPUTS
DIGITAL
INPUTS
ANALOG
DIGITAL
POSITION
DECODER
PID
REGULATOR
24V or 5V
±
10V
24 V
SET-
POINT
PCD2.H3..
Block diagram of a servo drive for 1 axis
v1
v2
v
s
1
s
2
s
Destination position
Position control operation with constant acceleration, delay and slow ad-
vance to approach destination position
Y
X
Coordinated, quasi-synchronous operation of 2 axes

Introduction PCD2.H31x
Page 1-2 SAIA-Burgess Electronics Ltd. (2H3-01-E.DOC) 26/762 E2
1.2 Function and application
The ..H3.. module is used to position a single axis with variable speed
control DC or AC servomotors. This requires the drive unit to have a
power stage and incremental shaft encoder for capturing position or
speed. In a PCD1 system up to 4 motion control modules (4 axes) and in
a PCD2 up to 8 ..H3.. modules (8 axes) can be plugged anywhere on the
I/O bus and operated together with all base units.
The motion control module contains a single-chip processor that inde-
pendently directs and PID controls every movement according to pa-
rameters supplied by the user program (velocity, acceleration and desti-
nation position). This enables each axis to be controlled independently. It
is possible to program the linkage of several axes (point-to-point) in co-
ordinated, quasi-synchronous mode. Linear motion is thereby achieved
with cartesian axes.
PCD2.H31x motion control modules should be plugged into the
PCD2.M1xx base unit and not the PCD2.C1xx expansion unit. This is to
take account of the relatively high current consumption.

PCD2.H31x Introduction
26/762 E2 (2H3-01-E.DOC) SAIA-Burgess Electronics Ltd. Page 1-3
1.3 Main characteristics
•Ideal for compact or economical machines
•PID controlled regulation of servomotor position and speed
•Velocity, destination position and PID parameters can be modified,
even during motion
•Analogue ±10Voutput with 12 bits inc. sign bit for triggering the
motor power stage
•Digital input for reference switch with the .. H310
•Encoder signal inputs of 24 VDC (source operation) or
5 V/RS 422 (antivalent line driver)
•Other axis-specific inputs and outputs (such as the limit switches, the
reference switch for the PCD2.H311 module, ENABLE for the driver)
must be monitored or controlled with a standard I/O module (e.g.
PCD2.B100, PCD2.E110/E111 or PCD2.A410).

Introduction PCD2.H31x
Page 1-4 SAIA-Burgess Electronics Ltd. (2H3-01-E.DOC) 26/762 E2
1.4 Typical areas of use
•Handling robots
•Automatic placement and assembly machines
•Automatic palletizers
•Packing machines
•Sheet metal working machines
•Automatic drilling machines
•etc.

PCD2.H31x Introduction
26/762 E2 (2H3-01-E.DOC) SAIA-Burgess Electronics Ltd. Page 1-5
1.5 Programming
The availability of practical function blocks (FBs and FBoxes) means that
only the desired parameters need to be entered for the various motion
and travel functions. The present detailed manual contains descriptions of
each function block, complemented with practical application examples.
Programming is via the standard PG4 programming tool from version
V2.0.70, either in IL (Instruction List) or graphically (FUPLA).
Initialization instruction
INIT FB. When it is called, 11 parameters are given with it.
See section 7.1.2 and appendix A, pages A1/2
Execution instruction
EXEC FB, always including 3 parameters. Over 30 different in-
structions can be executed.
See section 7.1.2 and appendix A, pages A5/40
Home instruction
HOME FB for automatically seeking the reference switch. This
FB has 7 parameters.
See section 7.1.2 and appendix A, pages A3/4
Diagnostics and error handling
Recognition of incorrect FB parameters (diagnostic register)
Timeout monitoring for FB 'Home'.
See chapter 8.

Introduction PCD2.H31x
Page 1-6 SAIA-Burgess Electronics Ltd. (2H3-01-E.DOC) 26/762 E2
1.6 Operating modes
When solving motion control tasks with a servo drive, two different oper-
ating modes are fundamentally available:
•position control mode
•speed control mode
In position control mode various parameters are entered (PID factors, ac-
celeration, velocity, etc.) after which a preset destination position is ap-
proached in a controlled manner
In speed control mode the desired velocity is attained with a preset rate
of acceleration. Travel continues at this velocity in a controlled manner
until there is a stop instruction. The desired velocity can be changed even
during motion.
v1
v2
v
s
1
s
2
s
Destination position
Position control mode with constant acceleration and delay, plus reduced
speed on approach to destination position

PCD2.H31x Introduction
26/762 E2 (2H3-01-E.DOC) SAIA-Burgess Electronics Ltd. Page 1-7
1.7 Commissioning
Convenient commissioning software is available in the form of a FUPLA
program. This tool offers a simple method whereby all tests and adjust-
ments required during commissioning can be carried out or checked on-
line.
This commissioning tool is available on diskette, order reference:
PCD8.H31.
See chapter 10 for more details.

Introduction PCD2.H31x
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Notes

PCD2.H31x Technical data
26/762 E2 (2H3-02-E.DOC) SAIA-Burgess Electronics Ltd. Page 2-1
2. Technical data
2.1 Hardware technical data
Digital inputs of the PCD2.H310 module
Number of inputs: 1 encoder A, B, IN
1 reference input
Input voltage: typically 24 V
"Low" range: 0 ... +4 V
"High" range: +15 ... +30 V
Source operation only (pos. logic)
Input current at 24 VDC: 6 mA (typical)
Circuit type electronically connected
Reaction time 30 µs
Digital inputs of the PCD2.H311 module
Number of inputs: 1 encoder A, /A, B, /B, IN, /IN
(no reference input)
Input voltage: typically 5 V
Signal level: Antivalent inputs according to RS 422
Hysteresis: max. 200 mV
Line termination resistance: 150 Ω
Analogue output for the PCD2.H310/311 modules
Analogue controller output 12 bit resolution (with sign bit)
Short-circuit protection yes
Electrical isolation no
Output voltage *) ±10 V, accuracy of adjustment ±5 mV
Logic positive (positive switching)
Minimum load impedance 3 kΩ
5 V supply of 5 V encoder for the PCD2.H311 module
5 V output 5 V supply of encoder
Short-circuit protection yes
Electrical isolation no
Output voltage 5 V
Max. load current 300 mA
Short-circuit current 400 mA
(This current additionally loads the 5 V bus of the PCD1/2)
*) Balancing output voltage is carried out in the factory. You are there-
fore strongly advised not to adjust the tuning potentiometer.

Technical data PCD2.H31x
Page 2-2 SAIA-Burgess Electronics Ltd. (2H3-02-E.DOC) 26/762 E2
Operating conditions
Ambient temperature Operation: 0 ...+50°C without forced ven-
tilation
Storage: -20 ... +85°C
Noise immunity CE mark, compliant with EN 50081-1 and
EN 50082-2
LED displays and possibilities for querying fromsoftware
Total 5
LED "A" Status of encoder input "A"
LED "B" Status of encoder input "B"
LED "IN" Status of index input
LED "Ref" Status of reference switch (H310)
LED "Pw 5V" Encoder 5 V supply (H311)
LED "Power" ±15 V supply
Querying from software
Input Power (addr. 08) Enables software monitoring of supplies
Input Ref (addr. 11) Enables the logic status of the reference
switch to be queried (H310)
Input Pw5V (addr. 11) Enables software monitoring of the 5 V
supply (H311)
Input Version (addr. 12) Enables module type to be queried H310
or H311 (H = H310, L = H311)
General
Processor LM 628
Programming Based on PCD user program (PG4) and
supported by a library of FBs and FBoxes.
Ordering details
PCD2.H310 1 axis for encoder 24 VDC
PCD2.H311 1 axis for encoder 5 V/RS 422
PCD9.H31E Software library with function blocks (FBs)
for programming in IL.
PCD8.H31 Commissioning tool in FUPLA