SEW-Eurodrive IPOS plus User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Manual
IPOS
plus®
Positioning and Sequence Control System
Edition 11/2009 11645415 / EN

SEW-EURODRIVE—Driving the world

Manual – IPOSplus® 3
Contents
Contents
1 General Information .......................................................................................... 14
1.1 Structure of the safety notes ..................................................................... 14
1.2 Liability for defects .................................................................................... 15
1.3 Exclusion of liability................................................................................... 15
1.4 Copyright................................................................................................... 15
2 Safety Notes ...................................................................................................... 16
2.1 General information .................................................................................. 16
2.2 Designated use ......................................................................................... 17
2.3 Target group ............................................................................................. 17
2.4 Programming errors .................................................................................. 17
3 System Description........................................................................................... 18
3.1 Introduction ............................................................................................... 18
3.1.1 Scope of this documentation ..................................................... 18
3.1.2 Creating programs..................................................................... 19
3.2 IPOSplus® – features ................................................................................. 19
3.3 Controlling IPOSplus® units ....................................................................... 22
3.3.1 Active control signal source ....................................................... 22
3.4 Technology options / application modules ................................................ 22
3.4.1 Technology options.................................................................... 22
3.4.2 Application modules................................................................... 23
3.5 Technical data........................................................................................... 25
3.5.1 MOVIDRIVE®B ......................................................................... 25
3.5.2 MOVITRAC®B .......................................................................... 25
3.5.3 MQx ........................................................................................... 26
3.6 Reference documents............................................................................... 27
3.6.1 General manuals ....................................................................... 27
3.6.2 Manuals for serial interfaces/fieldbuses .................................... 27
3.6.3 Manuals for synchronized axis movements............................... 27
3.6.4 Manuals for application modules ............................................... 27
3.6.5 Manuals for the MQx fieldbus interfaces ................................... 27
4 IPOS Variables................................................................................................... 28
4.1 Introduction ............................................................................................... 28
4.2 Overview of the system variables ............................................................. 29
5 Task Management and Interrupts.................................................................... 40
5.1 Introduction ............................................................................................... 40
5.2 Task management for MOVIDRIVE®A and B.......................................... 40
5.3 Tasks for MOVIDRIVE®A......................................................................... 43
5.4 Tasks for MOVIDRIVE®B......................................................................... 43
5.4.1 Processing time for task 1 / task 2............................................. 43
5.4.2 Task 3........................................................................................ 44
5.4.3 Implementation information ....................................................... 44
5.4.4 Example..................................................................................... 45

Contents
4Manual – IPOSplus®
5.5 Interrupts................................................................................................... 45
5.5.1 Example..................................................................................... 46
5.6 Interrupts for MOVIDRIVE®A and B......................................................... 46
5.6.1 Interrupt activation ..................................................................... 46
5.6.2 Error interrupt............................................................................. 46
5.6.3 Touch probe DI02 interrupt........................................................ 47
5.6.4 Timer0 interrupt ......................................................................... 48
5.7 Variable interrupts with MOVIDRIVE®B................................................... 49
5.7.1 Calling up the variable interrupt................................................. 49
5.7.2 IPOS access to the internal interrupt control ............................. 50
6 Position Detection and Positioning................................................................. 53
6.1 Encoder evaluation ................................................................................... 53
6.2 Motor encoder (X15) ................................................................................. 54
6.3 Encoder combinations .............................................................................. 54
6.4 External encoder (X14) ............................................................................. 57
6.4.1 Positioning on external encoder (X14)....................................... 57
6.4.2 Slip compensation with external encoder .................................. 57
6.5 SSI absolute encoder (DIP) ...................................................................... 60
6.5.1 Startup ....................................................................................... 60
6.5.2 1. Select encoder type P950...................................................... 60
6.5.3 2. Set direction of rotation of the motor P35_ ............................ 61
6.5.4 3. Set counting direction P951 for the SSI absolute encoder .... 61
6.5.5 4. Set encoder scaling P955...................................................... 61
6.5.6 5. Set position offset P953......................................................... 61
6.5.7 6. Set Zero offset P954.............................................................. 62
6.5.8 7. Set encoder factors P942 and P943...................................... 62
6.5.9 8. Set P941 actual position source ............................................ 62
6.6 Referencing............................................................................................... 63
6.6.1 Type 0: Reference travel to zero pulse...................................... 67
6.6.2 Type 1: CCW end of the reference cam .................................... 67
6.6.3 Type 2: CW end of the reference cam....................................... 68
6.6.4 Type 3: CW limit switch ............................................................. 69
6.6.5 Type 4: CCW limit switch........................................................... 69
6.6.6 Type 5: No reference travel ....................................................... 70
6.6.7 Type 6: Reference cam flush with CW limit switch .................... 70
6.6.8 Type 7: Reference cam flush with CCW limit switch ................. 71
6.6.9 Type 8: Without enable.............................................................. 72
6.7 Modulo function......................................................................................... 73
6.7.1 Introduction ................................................................................ 73
6.7.2 Operating principle .................................................................... 74
6.7.3 Travel strategies ........................................................................ 77
6.7.4 Project planning......................................................................... 80
6.7.5 Project planning examples......................................................... 80
6.7.6 Frequently asked questions....................................................... 83

Manual – IPOSplus® 5
Contents
6.8 Cam controllers......................................................................................... 84
6.8.1 Standard cam controller............................................................. 85
6.8.2 Expanded cam controller........................................................... 89
7 Position Detection via Binary Inputs............................................................... 96
7.1 Types of built-in encoders......................................................................... 96
7.2 Principle of the position detection ............................................................. 96
7.3 Position detection with MOVIDRIVE®B.................................................... 97
7.4 Position detection with MOVITRAC®B..................................................... 98
7.5 Position detection with MQx...................................................................... 99
7.5.1 Proximity sensor evaluation....................................................... 99
7.5.2 DI0 and DI1 terminal assignments............................................. 99
7.5.3 Position detection with built-in encoder ................................... 100
7.5.4 Encoder monitoring.................................................................. 100
7.5.5 Storing the actual position ....................................................... 100
7.5.6 Counter.................................................................................... 101
7.5.7 Connecting the built-in encoders ............................................. 101
8IPOS
plus® and Fieldbus ................................................................................... 102
8.1 Introduction ............................................................................................. 102
8.2 Binary inputs and outputs ....................................................................... 103
8.2.1 Fieldbus interface, DIO and DIP.............................................. 103
8.3 Cyclical process data .............................................................................. 103
8.3.1 Cyclical preset process data.................................................... 103
8.3.2 Cyclical user-specific process data.......................................... 104
8.4 Acyclical communication......................................................................... 105
8.5 Special features of communication via SBus.......................................... 105
8.6 Special features of communication via RS-485 ...................................... 106
8.7 Fieldbus control words and fieldbus status words .................................. 106
9IPOS
plus® and Synchronized Motion ............................................................. 107
9.1 Introduction ............................................................................................. 107
9.2 Speed synchronization via master/slave function ................................... 107
9.3 Synchronous operation with a DRS option card ..................................... 107
9.3.1 Activating and deactivating the free running function .............. 108
9.3.2 Setting the zero point for DRS11B........................................... 109
9.3.3 Activating and deactivating the offset function......................... 111
9.3.4 Switching between positioning and synchronous operation .... 113
9.4 Synchronous operation with technology option "Internal synchronous
operation"................................................................................................ 115
9.4.1 Requirements .......................................................................... 115
9.5 Synchronous operation with technology option "Cam" ........................... 116
9.5.1 Requirements .......................................................................... 117
10 IPOSplus® for MOVITRAC®B – Characteristics............................................. 118
10.1 Requirements.......................................................................................... 118
10.2 Functionality............................................................................................ 119
11 IPOSplus® for MQx – Characteristics.............................................................. 120
11.1 Introduction ............................................................................................. 120

Contents
6Manual – IPOSplus®
11.2 Starting the programming tool................................................................. 121
11.3 Sequence control system........................................................................ 121
11.4 Digital inputs and outputs........................................................................ 121
11.5 Values of the DIAG11 variable for the error IPOS ILLOP ....................... 122
12 P9xx IPOS Parameters.................................................................................... 123
12.1 P90x IPOS reference travel .................................................................... 123
12.1.1 P900 Reference offset............................................................. 123
12.1.2 P901 Reference speed 1......................................................... 124
12.1.3 P902 Reference speed 2......................................................... 124
12.1.4 P903 Reference travel type ..................................................... 124
12.1.5 P904 Reference travel to zero pulse ....................................... 126
12.1.6 P905 Hiperface offset X15....................................................... 126
12.1.7 P906 Cam distance ................................................................. 126
12.2 P91x IPOSplus® parameters.................................................................... 127
12.2.1 P910 Gain X controller............................................................. 127
12.2.2 P911/912 Positioning ramp 1/2................................................ 127
12.2.3 P913/P914 Travel speed CW/CCW......................................... 127
12.2.4 P915 Velocity precontrol.......................................................... 127
12.2.5 P916 Ramp type ...................................................................... 128
12.2.6 P917 Ramp mode.................................................................... 130
12.2.7 P918 Bus setpoint source........................................................ 130
12.3 P92x IPOS monitoring ............................................................................ 131
12.3.1 P920/P921 SW limit switch CW/CCW ..................................... 131
12.3.2 P922 Position window.............................................................. 131
12.3.3 P923 Lag error window............................................................ 131
12.3.4 P924 Positioning interruption detection ................................... 131
12.4 P93x IPOSplus® special functions ........................................................... 132
12.4.1 P930 Override.......................................................................... 132
12.4.2 P931 IPOS CTRL.W Task 1 .................................................... 132
12.4.3 P932 IPOS CTRL.W Task 2 .................................................... 132
12.4.4 P933 Jerk time......................................................................... 132
12.4.5 P938 Speed task 1 .................................................................. 132
12.4.6 P939 Speed task 2 .................................................................. 133
12.5 P94x IPOSplus® encoder......................................................................... 134
12.5.1 P940 IPOS variable edit .......................................................... 134
12.5.2 P941 Actual position source .................................................... 134
12.5.3 P942/P943 Encoder factor numerator/denominator ................ 134
12.5.4 P944 Encoder scaling ext. encoder ......................................... 135
12.5.5 P945 Synchronous encoder type (X14)................................... 135
12.5.6 P945 Synchronous encoder counting direction (X14) ............. 136
12.5.7 P947 Hiperface offset X14....................................................... 136
12.5.8 P948 Automatic encoder replacement detection ..................... 137

Manual – IPOSplus® 7
Contents
12.6 P95x absolute encoder (SSI) .................................................................. 138
12.6.1 P950 Encoder type .................................................................. 138
12.6.2 P951 Counting direction .......................................................... 138
12.6.3 P952 Cycle frequency.............................................................. 139
12.6.4 P953 Position offset................................................................. 139
12.6.5 P954 Zero offset ...................................................................... 139
12.6.6 P955 Encoder scaling.............................................................. 139
12.6.7 P956 CAN encoder baud rate.................................................. 139
12.7 P96x IPOSplus® modulo function ............................................................ 140
12.7.1 P960 Modulo function.............................................................. 140
12.7.2 P961 Modulo numerator .......................................................... 140
12.7.3 P962 Modulo denominator....................................................... 140
12.7.4 P963 Modulo encoder resolution ............................................. 140
12.8 P97x IPOS synchronization .................................................................... 141
12.8.1 P970 DPRAM synchronization ................................................ 141
12.8.2 P971 Synchronization phase................................................... 141
13 Compiler – Editor ............................................................................................ 142
13.1 Technical features................................................................................... 142
13.2 First steps ............................................................................................... 143
13.2.1 Step 1: Starting IPOSplus® Compiler with MOVITOOLS®
MotionStudio............................................................................ 143
13.2.2 Step 2: Creating a new project ................................................ 145
13.2.3 Step 3: The first IPOSplus® program ........................................ 148
13.2.4 Step 4: Compiling and starting the IPOSplus® program ........... 151
13.3 Settings for the IPOSplus® Compiler ....................................................... 154
13.4 Search function ....................................................................................... 157
13.5 Creating a new project ............................................................................ 158
13.5.1 Project properties..................................................................... 158
13.5.2 Defining the program structure ................................................ 159
13.6 Saving a project ...................................................................................... 161
13.7 Setting up a project management structure ............................................ 162
13.8 Opening a project.................................................................................... 164
13.9 Handling projects with MOVIDRIVE®B .................................................. 164
13.9.1 Saving a project in the inverter ................................................ 164
13.9.2 Loading a project from the inverter.......................................... 165
13.9.3 Calling up a project from the inverter....................................... 165
13.10 Compiling a project ................................................................................. 166
13.11 Compiling and downloading.................................................................... 167
13.12 Starting a program .................................................................................. 167
13.13 Stopping a program ................................................................................ 167
13.14 Comparison with unit .............................................................................. 167
13.15 Debugger ................................................................................................ 168
13.16 Variable window...................................................................................... 169
13.17 Program information ............................................................................... 171
13.18 Entering instructions ............................................................................... 172
13.19 Comments............................................................................................... 173

Contents
8Manual – IPOSplus®
13.20 Overview of the icons.............................................................................. 174
14 Compiler – Programming ............................................................................... 175
14.1 Preprocessor........................................................................................... 176
14.2 Preprocessor statements ........................................................................ 176
14.3 #include................................................................................................... 178
14.4 Include folders......................................................................................... 179
14.5 #define .................................................................................................... 179
14.6 #undef ..................................................................................................... 180
14.7 #declare .................................................................................................. 181
14.8 SEW standard structures ........................................................................ 182
14.9 User-defined structures........................................................................... 184
14.10 long ......................................................................................................... 186
14.11 initial long ................................................................................................ 186
14.12 #pragma.................................................................................................. 187
14.13 Explanation of const.h and io.h / constb.h and iob.h .............................. 188
14.14 Identifiers ................................................................................................ 190
14.15 Constants................................................................................................ 190
14.16 IPOSplus® variables in the compiler ........................................................ 191
14.16.1 Example................................................................................... 191
14.17 Declaration of global variables................................................................ 191
14.18 Indirect addressing – pointer................................................................... 192
14.19 numof().................................................................................................... 193
15 Compiler – Operators ..................................................................................... 194
15.1 Order of priority of operators................................................................... 194
15.2 Unary operators ...................................................................................... 195
15.3 Binary operators...................................................................................... 196
15.3.1 Example................................................................................... 196
15.4 Ternary operators ................................................................................... 196
15.4.1 Example................................................................................... 196
16 Compiler – Constructions .............................................................................. 197
16.1 if...else..................................................................................................... 197
16.1.1 Syntax...................................................................................... 197
16.2 for............................................................................................................ 198
16.2.1 Syntax...................................................................................... 198
16.3 while........................................................................................................ 199
16.3.1 Syntax...................................................................................... 199
16.4 do...while................................................................................................. 200
16.4.1 Syntax...................................................................................... 200
16.5 switch...case...default.............................................................................. 202
16.5.1 Syntax...................................................................................... 202
16.6 return....................................................................................................... 203

Manual – IPOSplus® 9
Contents
17 Compiler – Functions ..................................................................................... 204
17.1 User-defined functions ............................................................................ 204
17.2 Overview of commands for standard functions....................................... 205
17.2.1 Standard bit functions.............................................................. 205
17.2.2 Standard communication functions.......................................... 206
17.2.3 Standard positioning functions................................................. 206
17.2.4 Standard program functions .................................................... 206
17.2.5 Standard setting functions ....................................................... 207
17.2.6 Special standard unit functions................................................ 207
17.3 Standard functions .................................................................................. 208
17.3.1 _AxisStop................................................................................. 208
17.3.2 _BitClear.................................................................................. 209
17.3.3 _BitMove.................................................................................. 209
17.3.4 _BitMoveNeg ........................................................................... 209
17.3.5 _BitSet ..................................................................................... 210
17.3.6 _Copy ...................................................................................... 210
17.3.7 _FaultReaction......................................................................... 210
17.3.8 _GetSys................................................................................... 211
17.3.9 _Go0........................................................................................ 217
17.3.10 _GoAbs.................................................................................... 218
17.3.11 _GoRel..................................................................................... 219
17.3.12 _InputCall................................................................................. 220
17.3.13 _Memorize............................................................................... 221
17.3.14 _MoviLink................................................................................. 222
17.3.15 _MovCommDef ....................................................................... 227
17.3.16 _MovCommOn......................................................................... 229
17.3.17 _Nop ........................................................................................ 229
17.3.18 _SBusCommDef...................................................................... 230
17.3.19 _SBusCommOn....................................................................... 234
17.3.20 _SBusCommState ................................................................... 234
17.3.21 _SetInterrupt............................................................................ 235
17.3.22 _SetSys ................................................................................... 236
17.3.23 _SetTask.................................................................................. 238
17.3.24 _SetTask2................................................................................ 239
17.3.25 _SetVarInterrupt ...................................................................... 240
17.3.26 _SystemCall............................................................................. 241
17.3.27 _TouchProbe ........................................................................... 242
17.3.28 _Wait........................................................................................ 243
17.3.29 _WaitInput................................................................................ 243
17.3.30 _WaitSystem............................................................................ 244
17.3.31 _WdOff..................................................................................... 244
17.3.32 _WdOn..................................................................................... 245
18 Compiler – Examples...................................................................................... 246
18.1 Setting bits and output terminals............................................................. 246
18.2 Clearing bits and output terminals .......................................................... 247

Contents
10 Manual – IPOSplus®
18.3 Querying bits and input terminals ........................................................... 248
18.3.1 Testing single bits.................................................................... 248
18.3.2 Testing several bits.................................................................. 248
18.4 Querying an edge ................................................................................... 249
18.4.1 Example 1................................................................................ 249
18.4.2 Example 2................................................................................ 251
18.5 Value of a number................................................................................... 252
18.6 MoviLink command ................................................................................. 253
18.6.1 Reading an internal unit parameter ......................................... 253
18.6.2 Writing a variable via SBus ..................................................... 254
18.6.3 Reading a parameter via SBus................................................ 255
18.7 SCOM communication ............................................................................ 256
18.7.1 Receiver................................................................................... 256
18.7.2 Sender ..................................................................................... 257
18.8 Touch probe interrupt processing ........................................................... 258
18.9 State machine, fieldbus control with emergency mode........................... 261
18.9.1 Mode 0..................................................................................... 265
18.9.2 Mode 1..................................................................................... 265
18.9.3 Mode 2..................................................................................... 265
18.9.4 Mode 3..................................................................................... 265
18.10 Compiler programming frame ................................................................. 266
19 Compiler – Error Messages............................................................................ 275
20 Assembler – Introduction............................................................................... 276
20.1 Setting the user travel units .................................................................... 276
20.1.1 Travel distance factors NUMERATOR/DENOMINATOR ........ 276
20.1.2 UNIT ........................................................................................ 278
20.2 First steps ............................................................................................... 279
20.2.1 Starting the IPOSplus® Assembler ........................................... 279
20.2.2 Creating a new program .......................................................... 280
20.2.3 Compiling and starting the program......................................... 281
21 Assembler – Editor ......................................................................................... 282
21.1 Example .................................................................................................. 283
21.2 Creating programs .................................................................................. 283
21.2.1 Inserting command lines.......................................................... 283
21.3 Compiling and downloading.................................................................... 284
21.4 Starting/stopping programs..................................................................... 285
21.4.1 Variable window....................................................................... 285
21.5 File/unit comparison................................................................................ 285
21.6 Debugger ................................................................................................ 285
21.6.1 Execute to cursor..................................................................... 286
21.6.2 Single step............................................................................... 286
21.7 Loading the program from the inverter.................................................... 287
21.8 Overview of the icons.............................................................................. 287