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Industrial Devices Corporation Impulse PCW-5181 User Manual Download Page 120

Industrial Devices Corporation

3925 Cypress Drive
Petaluma, CA  USA  94954
TEL: (800) 747-0064     •      FAX: (707) 789-0175    •    OUTSIDE THE U.S. CALL (707) 789-1000

E-mail: [email protected]       Web Site: www.idcmotion.com

Summary of Contents for Impulse PCW-5181

Page 1: ...ndustrial Devices Corporation User s Manual The Only Microstepping Drive with Open Loop Stall DetectTM OLSD Multi SteppingTM Dynamic SmoothingTM Xtreme SmoothnessTM Motion Node P N PCW 5181 Version 1...

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Page 3: ...d potential users of our products If you have any questions or concerns regarding this technical manual or the product it covers please contact Industrial Devices Corporation 3925 Cypress Drive Petalu...

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Page 5: ...IMPULSE DRIVE 3 10 Environmental and Installation Requirements 3 10 Mounting Arrangements 3 10 Impulse Dimensions 3 11 Inserting and Removing Mounting Brackets from the Impulse 3 12 Impulse DIN Rail...

Page 6: ...CHAPTER 6 HARDWARE REFERENCE 6 1 IMPULSE SPECIFICATIONS 6 1 REMOTE MOUNTING YOUR KEYPAD 6 2 EXTENDING THE CABLE LENGTH TO YOUR KEYPAD 6 2 KEYPAD MOUNTING TEMPLATE 6 3 IMPULSE I O SCHEMATICS 6 4 OPTIO...

Page 7: ...f microstepping Motion Node 7 simple moves can be stored in the Impulse and activated via inputs or serial port This feature is optional Xtreme SmoothingTM 6 component gain settings for low speed smoo...

Page 8: ...Chapter 1 Overview 1 2 This page intentionally left blank...

Page 9: ...ser s Manual 6 Remote cable for Keypad 7 Keypad mounting template 7 Keypad mounting gasket 8 IDCMotion Software 8 Keypad mounting template 9 Impulse Quick Setup Ref Guide 9 IDCMotion Software 10 Impul...

Page 10: ...Chapter 2 Shipping Contents 2 2 This page intentionally left blank...

Page 11: ...cation The Impulse drive easily interfaces with a PC PLC Step Direction Motion Controller or IDC keypad Block diagrams of several Impulse based applications are shown below Typical Impulse Application...

Page 12: ...erting tremendous force against an obstruc tion Always ensure that power to your system is OFF before performing any maintenance activity or making any connections or adjustments Do not insert objects...

Page 13: ...y noise pickup in cables 20 kHz switching Note This is a high impedance safety interlock circuit If the interlock wire breaks or the connector is removed the current to the motor is immediately stoppe...

Page 14: ...page 3 6 for more information If you will be using RS 485 communication the typical 5 wire interface connection to a host is shown below See Multi Dropping Impulse Drives with RS 485 on the next page...

Page 15: ...2 Do not duplicate unit addresses 3 Any loose RS 232C connections or miswiring along the daisy chain will cause communications to fail Please double check wiring if communication problems arise 4 Ple...

Page 16: ...M should be 0 to 0 5 VDC Consult factory if measured voltages are outside these ranges 5 For RS 232C only If any cable is more than 50 ft long you should use a line driver optical coupler or shield Sh...

Page 17: ...th the keypad FP220 Keypad Version 3 0 or higher Only FP220 Keypad versions 3 0 and higher will work with the Impulse drive To use an FP220 keypad with your Impulse you must set DIP switch 3 to the ON...

Page 18: ...ive detects and resolves fault conditions see table below Faults are signaled by either a steady red or a flashing red LED on the front panel A solid green LED indicates normal operation A slowly flas...

Page 19: ...p Dir and SD should not be connected Remember the drive common must be connected to the controller common 6 Activating the Shutdown input disables the drive amplifier and de energizes the motor When t...

Page 20: ...49 F Not intended for use in humidity above 95 non condensing or at altitudes greater than 3 048 meters 10 000 ft Heat Dissipation 4 A typical 32 Watts Leave 6 inches above and below drives for airflo...

Page 21: ...g Your Impulse 3 11 Impulse Dimensions 5 599 6 365 6 000 1 779 1 779 5 599 1 779 6 365 TS 35 DIN RAIL Impulse with Screw type Mounting Bracket P N PCS 5110 Impulse with DIN rail Mounting Bracket P N P...

Page 22: ...nt position Do not attempt to remove the bracket by pulling it from the bottom of the bracket housing Both bracket and bracket housing could be permanently damaged Removal of Bracket DIN Rail Bracket...

Page 23: ...e drive to ensure it is securely fastened to the rail Removal of Impulse from the DIN Rail 1 Ensure power to the drive is OFF 2 Remove the motor connector 3 Insert tip of flat bladed screwdriver into...

Page 24: ...Chapter 3 Connecting and Installing Your Impulse 3 14 This page intentionally left blank...

Page 25: ...ace the IDC CD in your CD ROM drive and click on the Start button 2 Click on Run 3 Type the following in the Command Line box that appears replace x with your CD drive letter if different x App_Dev Se...

Page 26: ...modification troubleshooting etc See Upload Project on the next page for more information on using this option The Project Wizard is the best method for initial drive configuration and building a new...

Page 27: ...ick OK 3 Select the Port you will use to connect the Impulse 4 Select the Unit Number from 1 99 of the Impulse being configured 5 To test communication using the current setup click on Test Connection...

Page 28: ...ns to configure the Impulse see Fine Tuning Your Application Open an Existing Project If you want to open a project file which has been stored on disk not in the Impulse select Open an Existing Projec...

Page 29: ...the Motor setup window will appear The configuration procedure in Motor Setup differs slightly depending upon whether you are using IDC or Custom user defined motor see Appendix C to configure a custo...

Page 30: ...otor Only Load Inertia Enter Load Inertia in the text input box Move Unit Choose your move unit from the pulldown menu Mechanics window B below will appear if an IDC Mechanical System other than Motor...

Page 31: ...ve Units You cannot enter Distance Ratio if either steps or revs has been selected 4 Click Next and the Resolution setup window will appear Select your Step Resolution from the pulldown menu or enter...

Page 32: ...d the Accept window will appear This display allows you to review the settings made earlier or gives you an opportunity to return Back button to any parameter you may want to change When satisfied wit...

Page 33: ...Pressing this button tells the drive to execute an electronic probe of the motor to determine a host of proprietary internal settings for use in the anti resonance stall detect features Any time the d...

Page 34: ...ccess to the setup parameters and other features that will be covered in the remainder of this chapter Toolbar Buttons The Application Developer toolbar buttons allow quick access to most of the menus...

Page 35: ...lar electrical characteristic has not been con figured as part of the motor file To create or change a motor file see Edit Motor Mechanical These text input boxes display the mechanical characteristic...

Page 36: ...tem Units The text input box parameters in each available Setup Mechanical System window are dependent upon the selection you make from the Select Mechanical System list Examples of different mechanic...

Page 37: ...he Direction button to select Direction CW or Direction CCW Shutdown Polarity Toggle the Shutdown Polarity button to select Shutdown Active Low or Shutdown Active High Jog Input Configuration This opt...

Page 38: ...fault setting Note The keypad FP100 or FP220 only supports Standard decimal precision therefore project files intended to be used in conjunction with the keypad must be created using the Standard sett...

Page 39: ...the Advanced Motor Editor Verify that this value has been entered in the Test Speed display Run Test Stop Test Button Toggles between Run Test and Stop Test Restore Restores each X Smoothness to the p...

Page 40: ...est button 6 Move slider M1 to approximately 8 000 7 Move slider M2 left and right until the smoothest running condition is reached 8 Move slide M1 left and right until the smoothest running condition...

Page 41: ...Dynamic Smoothing Enabled by clicking on the check box and entering the recom mended gain in the input box Dynamic Smoothing is an IDC proprietary method of auto matically reducing jerk sudden change...

Page 42: ...ur Discrete Inputs and one Discrete Output from the pulldown menus Use the toggle buttons to right of the inputs to select between Active Low A L and Active High A H I O Descriptions Input Description...

Page 43: ...e allowing the binary representation of numbers 0 7 The Move Select configuration option is only available on inputs 1 3 with input 1 being the least significant bit LSB and input 3 being the most sig...

Page 44: ...as an active high sinking output Note The Brake output is not intended nor designed as a power source for a mechanical brake In Motion The In Motion output is activated upon receiving incoming step pu...

Page 45: ...nits The three move types are Incremental Absolute and Home each selectable by a radio button Incremental moves are indexed to the commanded position from the current position Absolute moves are index...

Page 46: ...carriage will be driven against mechanical end stop 2 carriage will end up homed outside the interval between the EOT switches Digital inputs are configurable as EOT Active High Active Low on the Set...

Page 47: ...ections under the File menu are generic to all Windows applications Edit Menu Stored Move and Motor File Editors both discussed previously can also be accessed from the menu bar Setup Menu I O Axis an...

Page 48: ...ss of each drive to be used on a daisy chain Each drive must have its own unique software address The unit number must be set before the units are connected in the daisy chain Press Query Address if t...

Page 49: ...ection inputs Binary inputs digital inputs 1 2 and 3 may be configured as Move Inputs Active High Active Low for triggering stored moves Setup I O Serial Commands A host system may trigger moves over...

Page 50: ...c Click Drive Info for a look at hardware and firmware versions In the unlikely event that the Impulse sustains an EEPROM Fault 7 red LED flashes the Restore Factory Settings button is used to clear t...

Page 51: ...www idcmotion com or directly from the factory 2 With a single Impulse drive connected select Communications Load FLASH Memory from Application Developer 3 Use the Open File dialog box to select the d...

Page 52: ...Chapter 4 Configuring Impulse with Application Developer 4 28 This page intentionally left blank...

Page 53: ...rives The FP100 RS485 and FP220 RS485 keypads may be used with an Impulse and RS 485 communication The keypad was designed to provide operators with a convenient way to configure an application and th...

Page 54: ...e included mounting gasket and 6 foot communication cable See Chapter 6 Hardware Reference for important information on mounting the keypad and extending cable length DIP Switch Settings DIP switch se...

Page 55: ...and I O status and fault history COPY Copies project files to and from a drive DEL Deletes project files or characters in a text entry editor DECIMAL POINT Used to enter fixed point numbers when the...

Page 56: ...shows the Menus which are accessible from the Main Display by pressing the RUN EDIT HELP COPY and DEL keys FP100 Main Menu and Sub Menus MOVE F1 Run a stored move FILE F1 Open Save or Rename a Projec...

Page 57: ...g and naming files General Rules for Using the Keypad Entering Characters with the ALPHA key The ALPHA key allows you to enter alphabet characters into a project file from the keypad The ALPHA key act...

Page 58: ...e LED diagnostic indicator Jog Motor JOG RUN JOG allows you to jog a properly configured motor The distance is displayed in the units selected under EDIT SETUP MECH UNITS and the default velocity is H...

Page 59: ...scrolling the filenames using the up or down arrow keys and pressing the ENTER key Once a project file is selected you will be prompted to enter a new name for the file Project file names may consist...

Page 60: ...up Parameter Description of Setup Parameter COMMAND Direction Positive or negative motor direction Shutdown Active Low or Active High polarity Drive Resolution Operating step resolution Stop Rate Dece...

Page 61: ...fault condition Press HISTRY for the following operating histories num ber of hours in operation number of power cycles and last eight drive faults Press HR_OP for the total number of hours the Impul...

Page 62: ...ted file is not saved to non volatile memory and must be saved under EDIT FILE SAVE if the data is to be stored Application Note Keypads do not provide the same decimal level precision as IDC s Applic...

Page 63: ...of Numeric Precision Axis Setup Command Numeric Precision Extended you will receive a precision error message when the file is loaded into a keypad Only the Standard level of numeric precision Axis S...

Page 64: ...ears on the bottom line 2 Press ESC to save your motor selection Probing the Motor A new drive setup must be instructed to probe itself after you have selected motor type on the keypad procedure on ne...

Page 65: ...following five parameters are configured in the COMMAND sub menu DIR Motor Direction POSITIVE CW or NEGATIVE CCW SHDWN Shutdown Polarity ACTIVE LOW or ACTIVE HIGH D RES Drive Resolution steps rev STPR...

Page 66: ...its selected in EDIT SETUP MECH UNITS User Units 2 Press ESC Configuring Jog Parameters This option allows you to modify the jog parameters which are used by the Jog inputs JOG JOG JOG SPEED and in th...

Page 67: ...atio This option allows you to enter the desired units scaling ratio for distance velocity and acceleration The ratio is motor revolution per user unit Note If user units REVS or STEPS has been select...

Page 68: ...enter the test speed 3 Press ESC FINE Fine Adjustments This option allows fine adjustment of values L1 and L2 of X SM1 When this menu is entered the motor will run at the test speed configured in the...

Page 69: ...N2 setting 1 Press GAIN1 F1 2 Using numeric keys enter a gain of between 0 and 32 767 3 Press ESC GAIN2 required only if GAIN1 was configured This option allows you to configure the anti resonance gai...

Page 70: ...selected the Dynamic Smoothing Gain will be fixed 1 Press GAIN F1 2 Using numeric keys enter a gain 0 to 2621 3 Press ESC Configuring Stop Mode Current Reduction Timeout I STOP This option allows you...

Page 71: ...T has expired The valid range for percentage of reduction is 0 to100 The Idle Mode reduction percentage takes precedence over the Stop Mode 25 reduction if both modes have been enabled TIMEOUT 1 Press...

Page 72: ...the up or down arrow key select the desired input function 4 Press ESC SETUP I O EDIT I O SETUP INPUT OUTPUT POLAR Configurable Inputs Input Description UNDEFINED The input position currently has no f...

Page 73: ...must be grounded to be asserted The inputs and output are selected by using the left and right arrow keys The polarity is selected by toggling between ACTIVE LOW and ACTIVE HIGH using the up and down...

Page 74: ...ance from the current position Absolute moves are indexed to the commanded position Home moves provide a built in routine to automatically find an exact position to reference all moves from i e to fin...

Page 75: ...Move Selection Input Scan Time This option allows you to set the move selection input scan time in milliseconds The scan time serves as a timeout for which the move selection inputs must be held in a...

Page 76: ...s or RS485 buses The valid range for unit numbers is 1 99 1 Using the numeric keys enter the desired unit number for the drive Very Important Send the File to the Drive When all setup parameters have...

Page 77: ...OW 5 V min to 2 V max Input Current any terminal 0 V to Gnd 1 mA to 15 mA Digital Inputs Input Voltage HIGH 3 V min to 24 V max LOW 0 V min to 1 5 V max Input Current 0 V 2 5 mA inputs 1 2 3 8 mA inpu...

Page 78: ...tances your keypad may require a separate regulated 5 VDC 500mA power supply as shown in the illustration below Consult IDC Applications Engineering if you have questions about this procedure Warning...

Page 79: ...with your keypad and may also be found at http www idcmotion com support index html KEYPAD MOUNTING TEMPLATE E M B CUT THESE HOLES FOR 6 32 CAPTIVE MOUNTING 3 16 CLEARANCE HOLES 4 CUT THESE HOLES FOR...

Page 80: ...COMMON COM AM26LS32 IN1_BUF COM IN1 IN2 5V Inputs 1 2 Inputs 3 4 external external Impulse internal Impulse internal 5V 1K CMPD914 4 02k COM IN3 IN4 COM LIMIT SWITCH external Impulse internal ANA OUT...

Page 81: ...and the Shutdown signal to SD Step Dir and SD should not be connected Remember to connect commons 2 Activating the Shutdown input logic low disables the drive amplifier and de energizes the motor Whe...

Page 82: ...leaves two 2 inputs for move selects which allows for the selection of three 3 stored moves The PSR 2 position sensor contains a series diode and cannot be used in series as is the RPS 2 sensor shown...

Page 83: ...See page next page for connection information SS IO SS IO 6 25 pin D Shell I O cable that connects Impulse to other devices or PLC SS IO is 2 ft SS IO 6 is 6 ft See the next page for wire color codes...

Page 84: ...ire Color Pin Impulse Signal Wire Color 1 STEP Brown 10 COM Gray 19 COM Black White 2 STEP Red 11 COM White 20 Reserved Red Black 3 DIR Orange 12 Reserved Black 21 Reserved Orange Black 4 DIR Pink 13...

Page 85: ...5 52 Inductance mH 8 8 Max Winding Temperature F C 212 100 Mechanical Specs S12T Rotor Inertia oz in s2 kg m2 5 1x10 4 Axial Shaft Load lbs N 10 45 Radial Shaft Load 0 5 inches lbs N 5 22 Motor Weigh...

Page 86: ...22T S22V S23T S23V Rotor Inertia oz in s2 kg m2 1 66x10 3 1 17x10 5 3 31x10 3 2 34x10 5 4 97x10 3 3 51x10 5 Axial Shaft Load lbs N 25 111 25 111 25 111 Radial Shaft Load 0 5 inches lbs N 5 6 25 5 6 25...

Page 87: ...22 50 222 Radial Shaft Load 0 5 inches lbs N 14 5 64 4 14 5 64 4 Motor Weight lbs kg 5 1 2 3 8 3 3 8 Step Angle full step degrees 1 8 1 8 Notes T Series V Parallel Parallel V wiring 50 duty cycle max...

Page 88: ...1 2 205 MAX Note Specs apply to parallel 120 VAC connections Electrical Specs P21V P22V Continuous Stall Torque oz in N m 100 200 Recommended Current Phase Amps 1 3 2 0 Winding Resistance Ambient Ohms...

Page 89: ...Brown NC Electrical Specs P31V P32V P33V Continuous Stall Torque oz in N m 450 3 2 920 6 5 1260 8 9 Recommended Current Phase Amps 2 9 3 3 4 0 Inductance mH 14 30 25 Max Winding Temperature F C 212 1...

Page 90: ...Chapter 6 Hardware Reference 6 14 This page intentionally left blank...

Page 91: ...settings Control and drive resolutions don t match Check Speed Torque requirements of move Decrease acceleration Motor stalls 1 LED flash Acceleration and or velocity are too high Reduce acceleration...

Page 92: ...IDC for assistance 2 LED flashes Undervoltage Fault Indicates that the high voltage pow er supply has fallen below 110 VDC for more than 3 seconds This pre vents the drive from trying to operate a mo...

Page 93: ...hecksum Fault At power up the drive tests the in tegrity of its non volatile memory by computing a checksum This fault indicates an abnormal or defective condition in the drive An error occured during...

Page 94: ...Chapter 7 Troubleshooting Your Impulse 7 4 This page intentionally left blank...

Page 95: ...esent on site customer seminars determine custom product needs or respond to high volume requirements Toll Free Technical Support Industrial Devices employs a large staff of mechanical and electrical...

Page 96: ...ll returned packages must be accompanied by an RMA Return Material Authorization number To obtain return authorization contact your local IDC distributor or IDC Please note the following procedure 1 O...

Page 97: ...e logic common COM of the IDC control to earth ground on your machine or to the GND terminal on the control drive Separating earth ground from logic common min imizes the potential for ground loops Us...

Page 98: ...Appendix A Recommended Wiring Practices A 2...

Page 99: ...s called the transmission frame The structure of the transmission frame is as follows Unit Address This byte specifies the address of the unit for which this transmission frame is intended The valid r...

Page 100: ...s Read Queries The following example illustrates a read request of parameter index 113 Commanded Position from unit 2 Bytes are shown in hexadecimal format After sending the read request the host syst...

Page 101: ...g the transmission status is covered in the next topic Interpreting the Transmission Status Response Whenever an error occurs during a transmission received by the drive the drive reports the error in...

Page 102: ...Jog Velocity Upper Word 0 0h SerJogV_L Serial Jog Velocity Lower Word 0 0h Parameter Formula SerJogV_H SerJogV_H INT VelocityRPS 50x10 6 StepResolution 65535 SerJogV_L SerJogV_L INT FRAC VelocityRPS 5...

Page 103: ...51h JogAcel_L Jog Acceleration Rate Lower Word 60210 EB32h Parameter Formula JogAcel_H JogAcel_H INT AccelRPS2 50x10 6 2 StepResolution 65535 JogAcel_L JogAcel_L INT FRAC AccelRPS2 50x10 6 2 StepReso...

Page 104: ...olution 65535 StMvAlncL StMvAlncL INT FRAC AccelRPS2 50x10 6 2 StepResolution 65535 65535 StMvVlncH StMvVlncH INT VelocityRPS 50x10 6 StepResolution StMvVlncL StMvVlncL INT FRAC VelocityRPS 50x10 6 St...

Page 105: ...eleration Distance Lower Word 0 0h Parameter Formula Incremental Moves StMvMT 0 Homing Moves StMvMT 1 Absolute Moves All Moves StMvMDx Move Distance Steps 1 0 5 32767 RPS Decel RPS Accel RPS Decel INT...

Page 106: ...tored moves 1 7 Parameter Parameter Description Default Value SerMvSel Stored Move Selection 0 0h Parameter Formula SerMvSel SerMvSel Stored Move Number Index Parameter Description 75 SerMvSel Transmi...

Page 107: ...based on the input step frequency Parameter Parameter Description Default Value CmdVel Commanded Velocity N A Parameter Formula CmdVel VelocityRPS CmdVel 0 0064 25600 Index Parameter Description 104 C...

Page 108: ...dest Fault in MS Nibble N A Index Parameter Description 105 StoredFlt1 StoredFlt2 Transmission Frame Unit Address 105 StoredFlt1 LSB StoredFlt1 MSB StoredFlt2 LSB StoredFlt2 MSB CkSum LSB CkSum MSB Fo...

Page 109: ...cle or system reset Parameter Parameter Description Default Value EE_Enable EEPROM Enable Value 1 1h Index Parameter Description 115 EE_Enable Transmission Frame Unit Address 115 EE_Enable LSB EE_Enab...

Page 110: ...kSum LSB CkSum MSB Formulas Index Parameters Defaults Bits 3 0 Status Value Drive Status Bit 0 Input 1 Status Bit 1 Input 2 Status Bit 2 Input 3 Status Bit 3 Input 4 Status Bits 7 4 Bit 4 Output 1 Sta...

Page 111: ...5 communications Parameter Parameter Description Default Value UnitAddr Unit Address Number 1 1h Map Index Parameter Description 118 UnitAddr Transmission Frame Unit Address 118 UnitAddr LSB UnitAddr...

Page 112: ...utDwn Shutdown Override 0 0h Index Parameter Description 119 ShutDwn Transmission Frame Unit Address 119 ShutDwn LSB ShutDwn MSB CkSum LSB CkSum MSB Formulas Index Parameters Defaults Parameter Formul...

Page 113: ...ollowing guidelines 1 2 phase hybrid permanent magnet step motor 2 4 6 or 8 lead motor 3 Series or parallel inductance rating between 2 80 mH Higher inductance motors will not damage the drive but the...

Page 114: ...ent has been pre configured under labo ratory conditions for IDC motors but cannot be accurately determined in the field for cus tom motors If an incorrect Saturation Current is entered the Open Loop...

Page 115: ...ors will benefit from the advanced features of the Impulse drive i e X Smoothness Dynamic Smoothing Click the Advanced button and the Advanced tuning window will appear as shown Test Speeds 1 2 3 Ente...

Page 116: ...s present you may leave it as is or enter a value according to the table Note Both Damping Gains 1 and 2 must be configured Click OK and you will return to the Motor Editor Click OK or Save in the Mot...

Page 117: ...Encoderless Stall Detection keypad 5 19 environmental requirements 3 10 EOT End of Travel limit switches 6 6 F factory authorized distributors 8 1 fault history 4 26 fault indications LED 3 8 faults 1...

Page 118: ...6 4 digital output 6 4 fault output 6 5 limit switch connections 6 6 step direction shutdown 6 5 Send All project file parameters 4 10 sending files from the keypad 5 10 serial communication advanced...

Page 119: ...Do Not Print This Page Inserted as Placeholder...

Page 120: ...Industrial Devices Corporation 3925 Cypress Drive Petaluma CA USA 94954 TEL 800 747 0064 FAX 707 789 0175 OUTSIDE THE U S CALL 707 789 1000 E mail info idcmotion com Web Site www idcmotion com...

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