QUICKSTART MANUAL - PHD's Online LitStorelitstore.phdinc.com/pdf.asp?filename=6441334.pdf · friendly and requires little time to learn and implement. ... servo drive itself requires

1

Internet Web Site: http://www.phdinc.com • E-Mail: [email protected]

®

100 8/99 4784

PHD Ltd. PHD GmbH7 Eden Way, Pages Industrial Park Arnold-Sommerfeld-Ring 2

Leighton Buzzard, Bedfordshire LU7 8TP U.K. D-52499 Baesweiler GERMANYPhone 01525 853488 • Fax 01525 378210 Phone 02401-805 230 • Fax 02401-805 232

PHD, Inc.9009 Clubridge Drive

P.O. Box 9070, Fort Wayne, Indiana 46899 U.S.A.Phone (219) 747-6151 • Fax (219) 747-6754

QUICKSTARTMANUALHardware & Setup Manual ForInterfacing the FSC-01 MotionController to the FSA-01 Servo Drive

NOTES

6441-334

FSC-01

FSA-01

2 39

NOTES

Table of Contents

Technical Overview of the PHD Servo System.............................................................................. 3How To Use The Quick Start Manual ............................................................................................ 6Getting Started ................................................................................................................................ 6Connecting the Step and Direction Outputs to the FSA-01 Inputs................................................. 7Connecting the FSA-01 Inputs and Outputs ................................................................................... 9Installing the Servo Motor Cable.................................................................................................. 10Installing the Servo Motor Feedback Cable ................................................................................. 10

The FSC-01 Motion ControllerGeneral Purpose Inputs, CW Jog, CCW Jog Inputs ..................................................................... 11CW and CCW Limit Switch Inputs .............................................................................................. 14Outputs.......................................................................................................................................... 16Installing the PHD Programmer Software .................................................................................... 17Configuring the FSC-01 Motion Controller for use with the PHD EC and EQ Series Actuators........................................................................ 17PHD EC Series Cantilever Actuator Configuration Examples ..................................................... 18PHD EQ Series Base Slide Actuator Configuration Examples .................................................... 19

The FSA-01 Servo DriveConfiguring the PHD FSA-01 Servo Drive.................................................................................. 22Configuring the FSA-01 Inputs .................................................................................................... 26Configuring the FSA-01 Outputs ................................................................................................. 28Saving the Drive Configuration Setup.......................................................................................... 30Configuring the FSA-01 Servo Drive for Operation .................................................................... 31

AppendixesAppendix A: Installing the PHD Programmer Software .............................................................. 33Appendix B: Installing the PowerTools Software ........................................................................ 34Appendix C: Wiring Diagram for the PHD 64722-010 I/O Cable ............................................... 35Appendix D: Serial Communications (RS-232) Cable Pinouts.................................................... 36Appendix E: Diagram for connecting PNP Inputs and Outputs to the FSA-01 Servo Drive Terminal Block J6 ................................................................................... 37Appendix F: Diagram Showing the Internal Connections Between the J5 Command Connector and J6 Terminal Strip .............................................................................................. 38

3

Technical Overview of the PHD Servo SystemThe PHD Servo System is comprised of two major components, a programmable motion control-ler and a servo drive with a corresponding servo motor. (Refer to Figure 1).

The FSC-01 Motion Controller is used to develop and run in a stand alone mode selected motionprofiles. It is programmed through a Personal Computer via an RS-232 connection using thesupplied PHD Programmer software. Once the unit is programmed, the on board non-volatilememory stores the program internally within the unit. Once the RS-232 cable is unplugged fromthe controller and subsequently powered down, the unit will automatically begin program execu-tion upon the next power-up cycle.

A total of eight opto isolated inputs are available on the motion controller for various functions.Two of the eight inputs are dedicated for limit sensors, which, when strategically placed on theelectric actuator, provide a margin of safety should the unit be inadvertently programmed orforced beyond its normal operating travel range. In the case the user decides not to utilize thesetwo inputs as limits, the software allows the opportunity to change these two inputs to generalpurpose type inputs.

Another two inputs are dedicated for clockwise and counterclockwise jog motions, however ifthe need should arise, one or both can be selected (through software) to function as generalpurpose inputs.

The last four inputs are general purpose inputs, fully programmable and accessible through theprogramming software. All inputs can be configured to accept either PNP Source or NPN Sinktype signals, allowing them to be interfaced to a wide range of PLC’s and other host controllersor devices.

Three outputs are also available, all opto isolated and like the general purpose inputs, fullyprogrammable and also readily accessible through the programming software. These too, can beconfigured to provide either PNP Source or NPN Sink type signals, again, allowing them to beinterfaced to a wide range of PLCs and other host controllers or devices.

The PHD Programmer software included with the FSC-01 Motion Controller is extremely userfriendly and requires little time to learn and implement. Because all commands are icon driven,all the user has to do is specify the information required to complete the desired action andarrange the various commands in a sequential manner. A total of 20 different program commandsare available within the programming software providing both the flexibility and capability tosolve most single axis point to point type motions.

Once the motion program is written and stored within the motion controller, the FSC-01 sendsvia 4 wires, step and direction pulses to the PHD FSA-01 Servo Drive. This closed loop servodrive receives the step and direction pulses and translates these signals to a level capable ofdriving the attached servo motor with integral encoder. Once the motor moves to its programmedposition, the encoder sends position information to the servo drive, thus confirming its actualposition. This feedback position is then compared to the original (programmed) position and ifany differences exist, the servo drive will take the required corrective measures to ensure both thecommanded programmed position and actual position are the same.

38

Appendix F

Diagram Showing the Internal Connections Betweenthe J5 Command Connector and J6 Terminal Strip

Drive Enable

J6 Terminal Strip

PHD Servo Drive P/N FSA-01

(Same as Emerson P/N EN 204)

Input 4

Input 3

Input 2

Input 1

Drive Enable

Output 3

Output 2

Output 1

I/O Supply +

I/O Common -

I/O Supply +

I/O Common -

4

3

2

1

16

17

18

19

31

32

33

34

VD

C10

-30

+-

Inp

uts

# 1

# 2

# 3

# 4

Ou

tpu

ts

# 1

# 2

# 3

2.8K

J5 Command Connector

Note: If a load is applied tothe same output signal onboth J5 and J6, the sumtotal current loading mustbe limited to 200 mA peroutput signal,

4

Interfacing the FSA-01 Servo Drive to the FSC-01 Motion Controller is straight forward. Theservo drive itself requires an initial one time setup which is accomplished through a PC via anRS-232 connection using the supplied software called PowerTools. Once the servo drive hasbeen configured to accept the step and direction signals from the motion controller, it simplyresides in the “background”, processing the signals sent from the motion controller. The servodrive requires three hardware inputs to function properly. Specifically, these inputs consist of the“Drive Enable”, a dedicated type input and two general purpose inputs programmed to functionas a “Stop” input and “Reset” input.

An interface I/O cable is available which connects directly to the servo drive via a DB 44 pinconnector. On the opposite end of this cable are the wire leads which allow direct access tovarious input and output type functions contained within the drive.The FSA-01 Servo Drive has a total of 5 inputs and 3 outputs, all opto isolated. One of the 5inputs is a dedicated input (e.g. Drive Enable) whereas, the remaining 4 inputs are generalpurpose type inputs and programmable. The 3 outputs are also general purpose type outputs andprogrammable as well. If desired, any one of the outputs can be programmed to report the statusof the drive through the “Drive OK” or “Fault” functions and may be monitored via a PLC oranother host controller or device as necessary.

An optional 24 VDC in-line brake is available for applications where a power failure could causeunwanted or unsafe motion of the actuator, particularly in vertical type applications. The brakeconveniently mounts between the actuator and servo motor. When a 24 VDC control signal (froma PLC or host controller) is applied to the brake, it releases for unobstructed motion. In the eventof a power failure, the absence of the 24 VDC control signal causes the brake to engage, prohib-iting any motion of the actuator.

To complete the system, an external 24 volt DC power source is required. This supply willprovide the necessary voltage to power the opto isolated I/O residing on both the motion control-ler and servo drive in addition to the limit and home switches and optional brake, if required.

37

Appendix E

Diagram For Connecting PNP Inputs and Outputsto the FSA-01 Servo Drive Terminal Block J6

VDC10-30

Drive E

nab

le

Inputs Outputs

+ - # 1 # 2 # 3 # 4 # 1 # 2 # 3

VDC Power Supply

+

-

Single PointPE Ground

*

*

J6 Terminal Strip



Sw1 Sw2

Out 2

Out 1

Note: All available connections at the terminal strip shown above can also be accessed through the PHD I/O Cable P/N 64722-010 (Emerson P/N CMDO-010)

Out 1 Programmable1 Drive OKOut 2 Programmable1 Fault

Output Output Type Program as:

Drive Enable Dedicated N/ASw 1 Programmable1 Reset FaultSw 2 Programmable1 Stop

Input Drive Input Type Program as:

Minimum Recommended HardwareFor Interfacing With Other ControlDevices Such as PLC�s.

Optional Output Hardware

1 Programmable through the initial setup and configuration software within the FSA-01 Servo Drive.

Load(PLC orIndicatorLamp)


A highspeed diode is requiredfor inductive loads such as a relay,solenoid or contactor. Omit if notrequired.(Use a 1N4000 Diode or equivalent)

*

24

5

Fig

ure

1 P

HD

Ser

vo S

yste

m O

verv

iew

F

SC

-01

PH

D M

otio

n C

ontr

olle

r

F

SA

-01

PH

D S

ervo

D

rive

Ste

p/D

irect

ion

Com

man

dsM

otor

Pos

ition

Fee

dbac

k

Ser

vo M

otor

Pow

er

RS

-232

PC

(F

or p

rogr

amm

ing

pur

pose

s)

PLC

or

Hos

tC

ompu

ter

Sig

nal I

nput

s

Sig

nal

Out

puts

Sig

nal

Out

puts

Hom

eS

witc

h

2

4 V

DC

Pow

er S

uppl

yE

nd o

f Lim

itS

witc

hes

Bra

ke P

ower

/C

ontr

ol L

ine

Opt

iona

lB

rake

Sig

nal

Inpu

ts

36

9 Pin Male D-SUB Connector

Pin # Function 2 RCV 3 XMT 5 COM

Pin # Function 3 XMT 2 RCV 5 COM

9 Pin Female D-SUB Connector

PC Servo Drive





PC Servo Drive

Schematic For 9 Pin PC Com Ports


Appendix D

Serial Communications Cable Pinout For Interfacing the PHD FSA-01Servo Drive To A Personal Computer

6

How To Use The Quick Start ManualThe intent of this manual is to guide the user through the necessary steps required to successfullyinterface the PHD FSC-01 Motion Controller to the FSA-01 Servo Drive.

Both of the above products have their own dedicated hardware manuals originally sent with each unit.Before placing these products into service, it is your responsibility to consult these hardware manualsand be familiar with the various requirements for installing and commissioning this equipment.

The information contained within this manual is not intended to supersede or replace any informationcontained in either hardware manual. Therefore, in situations where technical issues might arisebetween this manual and the hardware manual(s), the information contained in the hardware manual(s)will take precedent.

Getting StartedTo set up your PHD Servo System, you will need the following:a) FSC-01 Motion Controller with supplied :

• PHD programmer software• Programming software manual• RS-232 programming cable• FSC-01 hardware manual• Quickstart manual

b) FSA-01 Servo Drive with supplied :• PowerTools setup software• E Series drives reference manual

c) Servo motor cable, p/n 64719-015d) Feedback cable, p/n 64720-015e) I/O cable, p/n 64722-010f) Servo motor, p/n 64715-001(Nema 23 size) or 64715-002 (Nema 34 size)g) Optional RS-232 PC cable, p/n 64723-010 (9 Pin) or 64724-010 (25 Pin)*h) IBM compatible 386 or higher CPU personal computer running Windows 3.1, Windows 95,

Windows 98 or Windows NT, 8 MB minimum memory, 12 MB available hard drive space,VGA or higher monitor.

i) PHD series EC or EQ electric actuatorj) For the EC actuator, the series 5580 or 18431 proximity switches, three total for:

• Home switch limit• CW (clockwise limit)• CCW (counterclockwise limit)

k) For the EQ actuator, the series 51422 or 6250 proximity switches, three total for:• Home switch limit• CW (clockwise limit)• CCW (counterclockwise limit)

k) 24 VDC regulated power supply

* Note: Instructions on how to construct an RS-232 cable (9 or 25 pin version) is illustrated in Appendix D. (This cable is used specifically to program the FSA-01 Servo Drive).

35

1 2 3 4 621 8 911121617181923242539274134323331373840261415434429282036

Pin #Red/Brown

Brown/Red

Black/Blue

Blue/Black

White/Orange

Orange/White

Purple/Blue

Blue/Purple

Red/Blue

Blue/Red

Black/Green

Green/Black

Black/Brown

Brown/Black

Purple/Orange

Orange/Purple

Black/Red

Red/Black

Purple/Green

Green/Purple

Yellow/Blue

Blue/Yellow

Yellow/Brown

Brown/Yellow

Purple/Brown

Brown/Purple

Purple/Gray

Gray/Purple

White/Blue

Blue/White

White/Green

Green/White

White/Red

Red/White

Yellow/Gray

Gray/Yellow

= Twisted Pair Wires

Do Not Connect

Do Not Connect

Input # 1

Input # 2

Input # 3

Input # 4

RS-485 +

RS-485 -

Encoder Output Channel A


Encoder Supply + 5 Volts

Encoder Common

Drive Enable Input

Output # 3

Output # 2

Output # 1

Encoder Output Channel B


Pulse Input Z

Pulse Input Z

Pulse Input A

Pulse Input A

I/O Supply +

I/O Common -

Encoder Output Channel Z


Pulse Input B

Pulse Input B

- Analog Command In

+ Analog Command In

Diagnostics Output Channel 1

I/O Supply +

I/O Common -


Diagnostics Output Common

Do Not Connect

Molded Male 44 PinDB Connector

FunctionWire Color Code Open End Wire Leads

Appendix C

Wiring Diagram For PHD P/N 64722-010 I/O Cable(Same as Emerson P/N CMDO-010 Cable)

Note: Unused wires must be kept electrically isolated from contactingother wires or voltages !

7

* (Same as Emerson P/N EN 204)

1Mates to J5 Connector on FSA-01 Servo Drive

Pin 27

Pin 41

Pin 26

Pin 40

PHD FSC-01Motion Controller

STEP +

STEP -

DIR +

DIR -

Pulse Input A

Pulse Input A

Pulse Input B

Pulse Input B

Purple/Green

Green/Purple

Gray/Purple

Purple/Gray

64722-010 I/O Cable(Emerson P/N CMDO-010) [Note: Diagram shows only the required wires necessary for interfacing to the FSC-01 Motion Controller.]

FunctionColor Code

Molded Male 44 PinDB Connector1

Female 44 PinDB Connector

J5

PHD FSA-01* Servo Drive

Connecting the Step and Direction Outputs To The FSA-01 Inputs Inputs=The step and direction output signals residing on the FSC-01 Motion Controller require connec-tion to the FSA-01 Servo Drive inputs for processing.

For this purpose the FSA-01 Servo Drive has a “J5 Command Connector” port dedicated forinput and output connections. This 44 pin connector is accessed through the I/O cable (PHD P/N64722-010) originally purchased with the drive. The I/O cable connects directly to the J5Command Connector port located on the front of FSA-01 drive via a molded male 44 DBconnector whereas the opposite end of the cable contains open wires color coded for identifica-tion purposes.

In this section, we need to interface the step and direction outputs from the FSC-01 MotionController to the inputs of the FSA-01 Servo Drive using the above cable. Please refer to Figure2 for more specific instructions.

Figure 2 Wiring Details for Interfacing the Step and Direction Outputs to Servo Drive Inputs

34

Appendix B

Installing PowerTools On Your PC

Hardware and Software RequirementsPowerTools software will run on any IBM based PC with Microsoft Windows version 3.1 or higher, atleast 4 MB of RAM, 6 MB of available hard disk space, I serial port (a second serial port is required ifyou are using one for a mouse) and a 3.5" floppy disk drive. It is recommended, but not necessary, to use amouse to navigate in PowerTools Software.

Installing the SoftwarePowerTools Software is delivered on 1.44 MB (3.5") diskettes. You should make an additional copy ofeach diskette before you install the PowerTools Software. You can use the backup diskettes to:

• Provide un-infected software if your computer becomes infected by a virus.

• Replace the original diskettes if they become damaged.

When you finish making copies, install the PowerTools Software from the backup diskettes. Store theoriginal diskettes in a safe place.

1. Close all applications you have open in Windows.

2. Insert disk 1 into drive A.

3. If you are using Windows 3.1, Choose the Run command from the File menu in Windows ProgramManager or File Manager. If you are using windows 95, select Run from the Start menu.

4. In the Run dialog, Type A:\setup (substitute the appropriate letter for your system), press enter.

The install program automatically:Creates a directory named C:\EMERSON\Ptools.Creates a new Windows group called “Emerson Motion Control”Loads PowerTools into the Emerson/Ptools directoryLoads the required DLL’s into your Windows System directory

Refer to the readme.txt file on the number one installation floppy for more information.

8

Fig

ure

3 W

irin

g Sc

hem

atic

Sho

win

g R

equi

red

Con

nect

ions

Bet

wee

n

the

FSC

-01

Mot

ion

Con

trol

ler

and

FSA

-01

Serv

o D

rive

L1

L2

L3

GN

D

Inpu

t J1

Mot

or P

ower R S T

Bla

ck

Blu

e

Bro

wn

Pin

#

Des

crip

tion

Com

man

d C

onne

ctor

J5

FS

A-0

1 S

ervo

Driv

e

FS

C-0

1 M

otio

n C

ontr

olle

r

24 V

DC

Pow

er S

uppl

y

+ -

Sw

1

Sw

2

No

Con

nect

ion

50 /

60 H

z90

- 2

64 V

AC

1 O

or

3 O

Hom

eS

witc

h

End

of L

imit

Sw

itche

s

Pul

se In

put A

Pul

se In

put A

Pul

se In

put B

Pul

se In

put B

I/O S

uppl

y +

I/O S

uppl

y -

Driv

e E

nabl

e In

put

Inpu

t # 1

(R

eset

Fau

lt)

Inpu

t # 2

(S

top)

Out

put #

1

27 41 26 40 34 32 16 1 2 19

Out

1 +

Out

1 -

Out

2 +

Out

2 -

Out

3 +

Out

3 -

In/J

og C

omIn

1In

2In

3In

4C

W J

og/In

5C

CW

Jog

/In 6

Lim

it C

omC

W L

imit

CC

W L

imit

Ste

p +

Ste

p -

Dir

+

Dir

-

Gre

en/Y

ello

w

Cab

le P

/N64

720-

015

Cab

le P

/N64

719-

015

Cab

le P

/N64

722-

010

Co

nn

ecto

r J7

Mo

tor

Fee

db

ack

Co

nn

ecto

r J8

AC

Po

wer

Hom

e an

d Li

mit

Sw

itch

Sig

nal W

ires

Load

33

Appendix A

Installing the PHD Programmer SoftwareThe PHD Programmer software comes on two 3.5" software diskettes. Before you can use the software,you must install it on your hard drive.

To run the PHD Programmer software, you must have a computer with the following requirements:* IBM compatible 386, 486, Pentium or better CPU. Pentium recommended for best performance.* Microsoft Windows 3.1, Windows 95, Windows 98, or Windows NT* At least 8 MB memory (16 MB or more will make the software run much faster)* 4 MB available hard drive space* VGA monitor, or better. 16 bit color setting recommended

(65,535 colors, sometimes called High Color)* Mouse or other input device* 3.5" floppy disk drive* A nine pin serial port must be available, preferably COM1.

The software installation is highly automated. Like most Windows programs the process is simple.

• Put Disk 1 in your 3.5" drive.

• From the Windows Program Manager, select Run from the File menu. (In Windows 95/98 and NT4.0,choose Run from the Start menu.)

• If your 3.5" drive is drive A, then enter the -command line A:\setup. If your drive is B, type B:\setup.

• The setup program will guide you through the rest of the installation.

If you encounter errors during installation, it is usually due to lack of memory or conflicts with otherprograms that are already running on your PC. If you experience an error while installing the program-ming software, quit all other Windows applications and try again. Holding down the ALT key and press-ing TAB will show you all the programs currently running on your PC. Laptop computers generallypresent the biggest challenge to installation, as they often come preloaded with programs that automati-cally execute on startup such as Microsoft Office and battery managers. Furthermore, laptops usuallyhave the least memory.

The programming software will install more easily and run much faster if you have more memory. Werecommend 8 megabytes of RAM on a Windows 3.1 system, and 16 megabytes with Windows 95.

Display SettingsThe PHD Programmer works well with any display resolution. At 640 x 480, the PHD Programmer willexactly fill your screen. At higher resolutions, like 800 x 600 or 1024 x 768, there will be room left overon the screen for other applications, or to expand the PHD Programmer window so you can see moreprogram lines. A 16 bit color setting is recommended (65,535 colors, sometimes called High Color)

Information in the program window will not display correctly if your display is set for “Large Fonts.”Please use the “Small Fonts” setting when running the PHD Programmer software. The display settingsare found under “Start ... Control Panels” in Windows 95, and in the “Main ... Control Panels” programgroup in Windows 3.1.

Programming Note: Always apply power to FSC-01 hardware after the PHD Programmer softwareis running on your PC.

9

Connecting the FSA-01 Inputs and OutputsThe same PHD cable P/N 64722-010 used in connecting the FSC-01 Motion Controller step anddirection outputs to the FSA-01 Servo Drive inputs has additional capacity for connecting tovarious other I/O functions residing within the servo drive. In this section, we need to connectthe I/O power supply, Inputs 1 and 2 and any (optional) Output(s). Refer to Figure 3 for wiringinstructions and Figure 4 for cable pinout information.

InputsIn order to utilize the servo drive for positioning type applications, a specific input scheme isrequired. These required inputs are: (1) the Drive Enable Input, (2) Reset Input and (3) StopInput .

The Drive Enable input enables (or disables) the power stage of the servo drive. For example,when 10 to 30 VDC is applied to this input, the power stage is enabled and the servo motor shaftwill produce torque as commanded by the drive. The absence of a voltage (less then 10 VDC) onthis same input will cause the power stage to be disabled or “off” thus inhibiting the ability toproduce torque at the servo motor shaft.

The Reset Input is used to reset drive faults which might occur. For example, in the case wherethe actuator might encounter an obstruction in its path preventing it from moving, in most casescauses a fault to occur. The fault can be cleared (remotely) through this input by supplying a 10to 30 VDC rising edge pulse. For our setup, Input # 1 was chosen to be configured as the Resetinput.

The Stop Input is used to rapidly decelerate the servo motor to a zero velocity, thus stopping it.When a 10 to 24 VDC is applied to this input, the drive will operate in a normal manner, how-ever, the absence of a voltage (less then 10 VDC) will cause the servo motor to immediatelystop. Once stopped, the servo motor position will be maintained as long as the Stop input func-tion remains active. For our setup, Input # 2 was chosen to be configured as the Stop input.

OutputsThe FSA-01 Servo Drive has a total of 3 programmable PNP (Sourcing) outputs. In some appli-cations, it may be desirable to monitor the servo drive status via a PLC or other host controller ordevice. In such instances, the following output functions may be of interest.

The Drive OK output is active whenever no fault conditions exist. In this case, if the drive isfunctioning correctly with no drive faults active, this output will be in the “on” state. If a faultwas detected, the output would go to a low or “off” state.[Note: Travel limits and Drive Enable inputs have no effect on this particular output].For more detailed information, please refer to the Emerson E Series Drives Reference Manual.

The Fault output is active whenever a drive fault condition exists. In this instance, if no drivefaults are present and if the Travel limits have not been exceded, the output will be in the “on”state.

The output will go low or “off” in the case a fault has occurred or either one of the Travel limitshas been exceded.

For more detailed information, please refer to the Emerson E Series Drives Reference Manual.

32

Figure 24 Instructions For Recovering From A Drive Fault.

Figure 25 Servo Drive Diagnostic Display Codes*

* Partial listing, please refer to the Emerson E Series Drives Reference Manual for a complete listing.

In the event of a drive fault dueto actuator over travel or obstruction,to clear the fault, momentarily energizeInput # 1 (e.g. Reset input). Alternativelythe drive can be reset through the DriveReset button.

Step 1

Step 2Servo drive is configured forpositioning mode and ready torun. (Ready to accept step anddirection pulses from FSC-01).

Your drive display shouldappear as follows:

Current Desired Action Required

Diagnostic Display

Description

Servo drive power stage is disabled

Servo drive configured for positioning mode

Following error fault(While in Position Mode)

Servo drive configured for positioning modeand ready to run.

Diagnostic Display Action Required

None

Apply 10 to 30 VDC to driveenable input.

NoneAwaiting step and direction pulsesfrom motion controller to start.

Reset drive by pressing the resetbutton or through the reset input.

Description






None




Ready to run. Apply 10 to 30 VDC to Stopinput.

10

1

2

3

4

16

17

18

19

26

27

31

32

33

34

40

41

Input 1

Input 2

Input 3

Input 4

Drive Enable

Output 3

Output 2

Output 1

I/O Supply +

Pulse Input A

Pulse Input B

I/O Common -

Pulse Input A

Pulse Input B

I/O Supply +

I/O Common -

Red/Brown

Brown/Red

Black/Blue

Blue/Black

Black/Green

Green/Black

Black/Brown

Brown/Black

Gray/Purple

Purple/Green

Brown/Yellow

Blue/Yellow

Yellow/Brown

Yellow/Blue

Purple/Gray

Green/Purple

PinFunction Wire Color Code

Figure 4 Partial Wiring Diagram For PHD P/N 64722-010 I/O Cable (Same as Emerson P/N CMDO-010 I/O Cable)

Refer to the following abbreviated schematic for detailed signal pinouts and wire color codeinformation. (A complete wiring schematic for the 64722-010 I/O Cable can be found inAppendix C).

Alternatively, the electrical connections for all inputs and outputs, the Drive Enable and the 10 to30 VDC power I/O supply inputs can also be accessed through the J6 terminal strip located onthe front side of the FSA-01 Servo Drive. If you decide to utilize the terminal strip in place of theI/O cable, refer to Appendix E and Appendix F for wiring information.

Installing the Servo Motor CableUsing the PHD 64719-015 Motor Cable, connect the end with the 4 wire leads to terminal blockJ8 located directly on the servo drive. (Refer to Figure 3 for more information). Connect theopposite end of the cable with the MS connector to the appropriate mating (8 pin) MS connectorlocated on the servo motor.

Installing the Servo Motor Feedback CableTo install the PHD 64720-015 feedback cable, connect the molded DB connector end of the cableto the motor feedback connector J7 located on the servo drive. Connect the opposite end of thecable with the MS connector to the mating (26 pin) MS connector located on the servo motor.

31

Configuring the FSA-01 Servo Drive for OperationOnce the required I/O has been connected and the drive has been configured through thePowerTools software, the next step is to actually place the drive into a “ready” mode. The readymode is the required state the drive must be set to in order to process the step and directionsignals generated from the motion controller. This is accomplished mainly through the inputstatus of both the Drive Enable input and the Stop input. Once these inputs are set, an onboarddiagnostic display located on the drive provides a convenient means of indicating the actual“state” or mode the drive is in. At this time, refer to Figure 23 below for the necessarysteps required to properly configure the drive.

En-204

Servo DriveDiagnosticDisplay Drive Fault

Reset Button

PHD FSA-01Servo Drive


Current Desired Action RequiredDiagnostic Display

Apply 10 to 30 VDC to Stopinput. (Input # 2)

Step 1

Step 2



Figure 23 Required Input Scheme for Drive “Ready” Configuration

11

PHD Switch Color Code Cross Reference Chart

The FSC-01 Motion Controller

General Purpose Inputs 1 through 4, CW jog and CCW jog InputsAll inputs are opto isolated and can be used with either Sinking (NPN) or Sourcing (PNP) typedevices with DC voltages ranging from 5 to 24 volts. When using other than mechanical switches orrelays, it is recommended that you use an external power source to supply power to the inputs.The FSC-01 motion controller has a total of 4 general purpose inputs available for use. However,this can be expanded to 8 inputs total if the user decides not to utilize the dedicated CW (clockwise)jog and CCW (counterclockwise) jog inputs or the limits inputs. The CW and CCW jog inputs can beconfigured to function as general purpose inputs through the programming software. (Consult thePHD Programmer Software manual for more information).

The following schematics will assist you in wiring various types of devices to the inputs of theFSC-01 Motion Controller.

In/Jog Com

INPUT24 VDCPowerSupply

-

+ PHD FSC-01Motion Controller

Output NPNProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3

Figure 5 FSC-01 Input Wiring Schematic For NPN (Sink) Devices

Switch Model Number Output Type Wire #1 Wire #2 Wire #3 18431-001-02 Ind. Prox NPN Brown Blue Black 51422-005-02 Ind. Prox NPN Brown Blue Black 55802 or 55822 Reed Switch NPN Blue Brown Black 55803 or 55823 Hall Switch NPN Brown Blue Black 62505 or 62515 Hall Switch NPN Brown Blue Black

30

Sending The Drive Configuration Setup To The Servo Drive

To send the completeddrive setup to the servodrive, depress the“Download” button asshown.

Saving The Drive Configuration SetupBefore downloading the drive setup information it is recommended you save the drive setup datato a file on your PC’s hard disk or floppy disk. To save a file, select Save from the file pull-downmenu or the save icon in the toolbar.

28

Enter your file name here.(Example: Setup.EN)

29Using the down arrow button,select the target drive where thefile will reside.

31

Note: After downloading the initial drive setup, the “Download” button will change to “Up-date”. Subsequently, any future changes in the program setup must be sent (e.g. downloaded)via the “Update” button.

30Once your selections havebeen made, click the “OK”button.

12


24 VDCPowerSupply

-

+


Output

COM

PNPProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3In/Jog Com

Figure 6 FSC-01 Input Wiring Schematic For PNP (Source) Devices

FSC-01MotionController

+24 VDC

IN

IN/JOG COM

24 VDC GND

Figure 7 FSC-01 Input Wiring Schematic For Normally Open or Normally Closed Switches

Switch Model Number Output Type Wire #1 Wire #2 Wire #3 18431-002-02 Ind. Prox PNP Brown Blue Black 51422-006-02 Ind. Prox PNP Brown Blue Black 55802 or 55822 Reed Switch PNP Brown Blue Black 55804 or 55824 Hall Switch PNP Brown Blue Black 62506 or 62516 Hall Switch PNP Brown Blue Black

29

The output menu will appear as shown below:

25

26

27

Using your cursor,select “Drive OK”.

Depress the radiobutton as shown toassign the “DriveOK” function toOutput # 1.

The following information should appearto indicate Output # 1 has been programmedto serve as the “Drive OK” function for the servodrive.

In the event you’d like to utilize other outputs as well, follow the same procedure as describedabove.

Note: When the active state of the output is “on”, the output will supply a voltage when theresult of the Or’ed output function(s) assigned to that output line is activated by the drive.

13

Figure 9 Typical Diagram For Interfacing PNP Sourcing PLC Outputs to FSC-01 Inputs

PLC with Sink(NPN) Outputs


+24 VDC

IN

IN/JOG COM

24 VDC GND

Output

Common

PLC withSource (PNP)Outputs


+24 VDC

IN

IN/JOG COM

24 VDC GND

Output

Common

Figure 8 Typical Diagram For Interfacing NPN Sinking PLC Outputs to FSC-01 Inputs

24 VDCPower Supply

+ -

28

21

22

Next, we will assign the second required input:

Using your cursor, select“Stop” as shown.

Depress the radio buttonas shown to assign the“Stop” function to Input# 2.

23The following information should appearto indicate Input 2 has been programmedto serve as the “Stop” function for theservo drive.

Configuring The FSA-01 Outputs (Optional)

24

Click on the “Outputs” tab

Note: When the active state of the input is “on”, the input will be active when 10 to 30 VDCis applied to the input line.

14

-


CW JOG

IN/JOG COM

CCW JOG

PowerSupply

24 VDC

Figure 10 Schematic For Interfacing Normally Open or Closed Switches to the FSC-01 Jog Inputs.

CW and CCW Limit Switch InputsThe FSC-01 motion controller has two dedicated inputs labeled CW limit and CCW limit. By usingthe CW (clockwise) and CCW (counterclockwise) limits, one can safely operate the system withincertain predefined limits. If an overtravel condition is detected through either limit switch, the motioncontroller will stop all program execution and the green power LED located on the face of the control-ler will turn red and alternately flash on and off thus indicating a fault has occurred. To recover fromthe fault, remove AC power for a few seconds and re-establish AC power again. Alternatively, the unitcan be reset through the programming software as well, although not practical in some cases.

The opportunity exists if desired, to reconfigure these inputs as general purpose inputs through theprogramming software. However, PHD, Inc. strongly encourages the use of limits for all applica-tions for safety considerations.

The following schematics illustrate how to connect the various PHD switches to the limit inputs.

PowerSupply

-


Output

24 VDCCW LIMIT

LIMIT COM

NPNProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3

Figure 11 Wiring Diagram for Interfacing NPN (Sink) Proximity Switches to the FSC-01 Limit Inputs

PHD Switch Wire Color Code Cross Reference Chart


27

18

19

The input menu will appear as follows:

Using your cursor, select“Reset” as shown.

Depress the radio buttonas shown to assign the“Reset” function to Input# 1.

20The following information should appearto indicate Input # 1 has been programmedto serve as the “Reset” function for theservo drive.


15

CW LIMIT

LIMIT COM

-

+


OutputPowerSupply

24 VDC PNPProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3

Figure 12 Wiring Diagram for Interfacing PNP (Source) Proximity Switches to the FSC-01 Limit Inputs



Figure 13 Wiring Diagram for Interfacing 2 Wire Source Type Reed Switches to the FSC-01 Limit Inputs

26

14

15

Select the“Pulse/Direction”submode by clicking theappropriate radio button.

Select the “Differential”source by clicking onthe corresponding radiobutton.

16

17

The “EZ Setup” menu will expand as follows:

Verify the “Ratio:” is set to 1 revsand 8192 counts as shown.

Click on the “Inputs” tab

Configuring The FSA-01 InputsTo configure the FSA-01 inputs, click on the inputs tab to open the input configuration screen.Then refer to the step by step instructions located below.

LIMIT COM

CW LIMIT24 VDCPowerSupply

-


Wire # 1

Wire# 262507/62517

Reed Switch

2 Wire (Source) Schematic

PHD Switch Color Code Cross Reference ChartSwitch Model Number Wire # 1 Wire # 262507 or 62517 Reed Sw. Brown Blue

16

OutputsThe FSC-01 motion controller has a total of 3 programmable outputs for interfacing with other devices.The outputs can be configured for either Sourcing (PNP) or Sinking (NPN) modes. Because of theoptically isolated nature of the outputs, an external power source is required for operation.

When an output is programmed to a “low” state, it is actually closed and thus conducting current. Con-versely, when the output is set to its “high” state, it is open. At power-up, the FSC-01 sets all threeoutputs high (open circuit).

The maximum voltage between any pair of + and - output terminals is 24 volts DC. Never con-nect AC voltages to the output terminals. Maximum rated DC current per output is 100 mA.

The following diagrams below illustrate how to interface the FSC-01 outputs to a variety of devices.

(Note: Power supply may be built into PLC and internally wired to the common)

OUTPUT -

OUTPUT +

COMMON

INPUT

24 VDC Power Supply

+-


PLC WithNPN Input

Figure 15 Wiring Diagram for Interfacing FSC-01 Outputs to a NPN (Sink) Type PLC Input.

LIMIT COM


-


Wire # 1

Wire# 262507/62517

Reed Switch

Switch Model Number Wire # 1 Wire # 262507 or 62517 Reed Sw. Blue Brown


2 Wire (Sink) Schematic

Figure 14 Wiring Diagram for Interfacing 2 Wire Sink Type Reed Switches to the FSC-01 Limit Inputs

25

Drives: Part Number Cross ReferencePHD Part Number Emerson Part Number FSA-01 EN-204

Motors: Part Number Cross ReferencePHD Part Number Emerson Part Number 64715-001 MG-208 64715-002 MG-316

Figure A

Figure B

The following “EZ Setup” Screen will appear:

10

11

12

If desired, type in yourown name for your drive.

Using the Drive partnumber cross referenceinformation in Figure A,select the applicable drivetype by clicking on thedown arrow button.

Select the proper motor type byclicking on the down arrow button.Refer to Figure B for specific partnumber cross reference information.

13

Change the OperatingMode to “Pulse Mode”by depressing thecorresponding radiobutton.

17

OUTPUT -

OUTPUT +

COMMON

INPUT


+ 24 VDC

24 VDC GNDPLC WithPNP Input


Figure 16 Wiring Diagram for Interfacing FSC-01 Outputs to a PNP (Source) Type PLC Input.

Installing the PHD Programmer SoftwareTo install the PHD Programmer software, please refer to the software installation instructionslocated in Appendix A of this manual.

Configuring the FSC-01 Motion Controller for use with the PHD EC and EQ Series ActuatorsThe PHD Programmer software expects distances in steps and speeds in revolutions/sec. However,the software also gives you the option to both define and scale your own user units. Scaling yourown units will enable you to directly enter the required distance in any of the move command state-ments regardless of variations in lead or ball screw pitches and/or different gearing arrangements.For example, in the case of imperial units, once the software is initially configured with the propervalues, the user can program to move 3.125 inches by naturally specifying 3.125 in the appropriatemove instruction. In the case of Metric units, then 33.0 would equate to a 33 mm move.

The following illustrations and examples detail how to configure your motion controller to utilizeeven engineering units.

Figure 17 Resolution and Steps/Inch Parameters for Inline Series PHD EC Cantilever Slides

Denotes character field content not applicable

EC HB- x - R100 -

Slide Model Number Microstep Resolution Setting User Units Steps/Inch

Setting

EC HB- x - R101 -

EC HB- x - R102 -

EC HB- x - R104 -

8192

8192

8192

8192

Inch

Inch

Inch

Inch

40960

16384

8192

65536

ScrewLead

.200 In

.500 In

1.0 In

.125 In

Slide Model Number Microstep Resolution Setting User Units Steps/mm

SettingEC HB- x - R200 -

EC HB- x - R202 -

EC HB- x - R203 -

25400

25400

25400

mm

mm

mm

2540

1270

1016

ScrewLead

10 mm

25 mm

20 mm

24

8

9

After selecting the “New File” icon, your screen should display the following menu:

Using the mouse cursor,select ”Disabled”.

Depress the “OK”Button.

Using the mouse cursor,click on the “New File”icon.

7

18

Example # 1 :A machine builder intends to use the following PHD EC series slide: ECS6HB-3 x 250-R200and desires to program the actuator in metric units.Determine: (1) The drive resolution setting. (2) The required user unit setting.

Solution:(Note: The “H” in the model number designates an inline series slide)Locate the model number in Figure 17. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution Setting: 25400(2) Steps/Inch Setting: 2540Enter the respective settings per the procedure outlined in Figures 21 and 22.

Example # 2 :A machine builder has an EC series slide with the following model number: ECS2GB-3 x 3-R102and a 64696-03 Fold-back Pulley Kit and desires to program the actuator in imperial units.Determine: (1) The drive resolution setting (2) The required user unit setting

Solution:(Note: The “G” in the model number designates a Fold-back series slide)Locate the model number in Figure 18. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution Setting: 8192(2) Steps/Inch Setting: 16384Enter these new values using the same procedure set forth in Figures 21 and 22.

Example # 3 :A machine builder intends to use the following PHD EC series slide: ECS6HB-4 x 250-R202 anddesires to program the actuator in imperial units.Determine: (1) The drive resolution setting. (2) The required user unit setting

Figure 18 Resolution and Steps/Inch Parameters for Fold-back Series PHD EC Cantilever Slides

EC GB- x - R100 -

Slide Model Number

EC GB- x - R101 -

EC GB- x - R102 -

EC GB- x - R104 -

Foldback Pulley Kit Number

64695-XX Microstep Resolution Setting User Units Steps/Inch

Setting

8192

8192

8192

8192

25400

25400

25400

Inch

Inch

Inch

Inch

mm

mm

mm

40960

16384

8192

65536

2540

1270

1016

Steps/Inch Setting

81920

32768

16384

131072

5080

2540

2032

64696-XX


64695-XX 64696-XX

8192

8192

8192

8192

25400

25400

25400

Screw Lead

.200 In

.500 In

1.0 In

.125 In

10 mm

20 mm

25 mm


SettingSteps/mm Setting

Screw Lead

EC GB- x - R200 -

EC GB- x - R202 -

EC GB- x - R203 -

PHD EC Series Cantilever Slide Actuator Configuration Examples

23

Upon selecting the Configure Serial Port Option, the dialog box below will be displayed.

The following dialog box will appear:

2

Depress the Configure SerialPort button

3

4

5

6

Select the Com port youintend to use.

Select the applicable baudrate. (19200 is the defaultbaud rate and operatessatisfactory at this setting).

When finished with yourselections, depress theOK button

Depress the OK buttonto enable the newsettings.

19

Solution:(Note: The “H” designation in the model number denotes an inline series slide).Locate the model number in Figure 17. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution: 25400(2) Steps/Inch Setting: Calculate as follows.Because of the metric (20mm) lead screw and the machine builders desire to program in “inch”units, we must convert the 1270 steps/mm (also found in Figure 17) to “inch” units.

1270 steps/mm x 25.4 mm/inch = 32258 steps/inch

Enter these new values using the same procedure set forth in Figures 21 and 22.

Figure 20 Resolution and Steps/Inch Parameters for Fold-back SeriesEQ Base Slides

Figure 19 Resolution and Steps/Inch Parameters for PHD Inline Series EQ Base Slides


Setting8192

8192

8192

Inch

Inch

Inch

40960

16384

65536

ScrewLead

.200 In

.500 In

.125 In

EQ C - - R100 -

EQ C - - R101 -

EQ C - - R104 -

PHD EQ Series Base Slide Actuator Configuration Examples

(Applicable to all EQ series slides with 64417-xx motor mount kits)

Slide Model Number



Setting

8192

8192

8192

Inch

Inch

Inch

40960

16384

65536

Steps/Inch Setting

81920

32768

131072

64445-XX


64444-XX 64445-XX

8192

8192

8192

Screw Lead

.200 In

.500 In

.125 In

EQ C - - R100 -

EQ C - - R101 -

EQ C - - R104 -

22

a) Click on the Options pull-down menu.b) Select the Preferences/ Communications option.

1

The FSA-01 Servo Drive

Configuring The PHD FSA-01 Servo DriveThe PHD FSA-01 Servo Drive requires an initial (one time) setup in order to use it in conjunc-tion with the FSC-01 Motion Controller.In order to configure the servo drive, you will need the following items:(1) The Emerson PowerTools Software (Sold as PHD P/N 64511), and(2) An RS-232 PC Programming Cable * (Sold as PHD P/N 64723-010 or 64724-010)

(* Note: If you did not purchase an RS-232 PC cable and wish to make your own cable,refer to Appendix D for detailed information for constructing an RS-232 PC cable.)

At this time, install the Emerson PowerTools Software on your PC. (Detailed installationinstructions can be found in Appendix B of this manual.)

After installing the PowerTools software, connect the RS-232 cable between your PC and theFSA-01 Servo Drive, power up the servo drive and run the PowerTools software. Once on-line,follow the instructions below.

20

Example # 1 :A machine builder intends to use the following EQL1CF-25 x 38-R100 series base slide with a64417-xx series motor mount kit and desires to program the actuator in english units.Determine: (1) The drive resolution setting. (2) The required user unit setting.

Solution:Locate the model number in Figure 19. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution Setting: 8192(2) Steps/Inch Setting: 40960

Enter the respective settings per the procedure outlined in Figures 21 and 22.

Example # 2 :A machine builder has an EQ series base slide with the following model number: EQL5CF-40 x1500 R101 and a 64445-10 Fold-back Pulley Kit and desires to program the actuator in Enimperial unitsDetermine: (1) The drive resolution setting (2) The required user unit setting



Example # 3 :A machine builder intends to use the following PHD EQ series base slide: EQL1CF-25 x 12-R104 and a 64444-03 Fold-back Pulley Kit and desires to program the actuator in imperial units.Determine: (1) The drive resolution setting. (2) The required user unit setting

Solution:Locate the model number in Figure 20. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution: 8192(2) Steps/Inch Setting: 65536


21

Figure 21 Microstep Resolution Selection Menu

To Configure the User Units Menu:1) Enter a unit name in the text box. (Note: Maximum length: 4 characters)2) Enter the number of motor steps per unit of distance, as calculated.3) Check the User Units check box to enable the unit settings.

Figure 22 User Units Menu

Unit NameCheck Box

Motor Steps/Distance

Once the microstep resolution has beendetermined, using your cursor arrow, selectthe Custom setting by clicking once on theradio button located to the left. Then movingyour cursor to the text box, type in theresolution value. Depress the OK button toaccept the new setting.

20

Example # 1 :A machine builder intends to use the following EQL1CF-25 x 38-R100 series base slide with a64417-xx series motor mount kit and desires to program the actuator in english units.Determine: (1) The drive resolution setting. (2) The required user unit setting.


Enter the respective settings per the procedure outlined in Figures 21 and 22.

Example # 2 :A machine builder has an EQ series base slide with the following model number: EQL5CF-40 x1500 R101 and a 64445-10 Fold-back Pulley Kit and desires to program the actuator in Enimperial unitsDetermine: (1) The drive resolution setting (2) The required user unit setting



Example # 3 :A machine builder intends to use the following PHD EQ series base slide: EQL1CF-25 x 12-R104 and a 64444-03 Fold-back Pulley Kit and desires to program the actuator in imperial units.Determine: (1) The drive resolution setting. (2) The required user unit setting

Solution:Locate the model number in Figure 20. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution: 8192(2) Steps/Inch Setting: 65536


21

Figure 21 Microstep Resolution Selection Menu

To Configure the User Units Menu:1) Enter a unit name in the text box. (Note: Maximum length: 4 characters)2) Enter the number of motor steps per unit of distance, as calculated.3) Check the User Units check box to enable the unit settings.

Figure 22 User Units Menu

Unit NameCheck Box

Motor Steps/Distance

Once the microstep resolution has beendetermined, using your cursor arrow, selectthe Custom setting by clicking once on theradio button located to the left. Then movingyour cursor to the text box, type in theresolution value. Depress the OK button toaccept the new setting.

19

Solution:(Note: The “H” designation in the model number denotes an inline series slide).Locate the model number in Figure 17. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution: 25400(2) Steps/Inch Setting: Calculate as follows.Because of the metric (20mm) lead screw and the machine builders desire to program in “inch”units, we must convert the 1270 steps/mm (also found in Figure 17) to “inch” units.

1270 steps/mm x 25.4 mm/inch = 32258 steps/inch


Figure 20 Resolution and Steps/Inch Parameters for Fold-back SeriesEQ Base Slides

Figure 19 Resolution and Steps/Inch Parameters for PHD Inline Series EQ Base Slides


Setting8192

8192

8192

Inch

Inch

Inch

40960

16384

65536

ScrewLead

.200 In

.500 In

.125 In

EQ C - - R100 -

EQ C - - R101 -

EQ C - - R104 -

PHD EQ Series Base Slide Actuator Configuration Examples

(Applicable to all EQ series slides with 64417-xx motor mount kits)

Slide Model Number



Setting

8192

8192

8192

Inch

Inch

Inch

40960

16384

65536

Steps/Inch Setting

81920

32768

131072

64445-XX


64444-XX 64445-XX

8192

8192

8192

Screw Lead

.200 In

.500 In

.125 In

EQ C - - R100 -

EQ C - - R101 -

EQ C - - R104 -

22

a) Click on the Options pull-down menu.b) Select the Preferences/ Communications option.

1

The FSA-01 Servo Drive

Configuring The PHD FSA-01 Servo DriveThe PHD FSA-01 Servo Drive requires an initial (one time) setup in order to use it in conjunc-tion with the FSC-01 Motion Controller.In order to configure the servo drive, you will need the following items:(1) The Emerson PowerTools Software (Sold as PHD P/N 64511), and(2) An RS-232 PC Programming Cable * (Sold as PHD P/N 64723-010 or 64724-010)

(* Note: If you did not purchase an RS-232 PC cable and wish to make your own cable,refer to Appendix D for detailed information for constructing an RS-232 PC cable.)

At this time, install the Emerson PowerTools Software on your PC. (Detailed installationinstructions can be found in Appendix B of this manual.)

After installing the PowerTools software, connect the RS-232 cable between your PC and theFSA-01 Servo Drive, power up the servo drive and run the PowerTools software. Once on-line,follow the instructions below.

18

Example # 1 :A machine builder intends to use the following PHD EC series slide: ECS6HB-3 x 250-R200and desires to program the actuator in metric units.Determine: (1) The drive resolution setting. (2) The required user unit setting.

Solution:(Note: The “H” in the model number designates an inline series slide)Locate the model number in Figure 17. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution Setting: 25400(2) Steps/Inch Setting: 2540Enter the respective settings per the procedure outlined in Figures 21 and 22.

Example # 2 :A machine builder has an EC series slide with the following model number: ECS2GB-3 x 3-R102and a 64696-03 Fold-back Pulley Kit and desires to program the actuator in imperial units.Determine: (1) The drive resolution setting (2) The required user unit setting

Solution:(Note: The “G” in the model number designates a Fold-back series slide)Locate the model number in Figure 18. For this particular slide, the table shows the followingvalues.(1) Microstep Resolution Setting: 8192(2) Steps/Inch Setting: 16384Enter these new values using the same procedure set forth in Figures 21 and 22.

Example # 3 :A machine builder intends to use the following PHD EC series slide: ECS6HB-4 x 250-R202 anddesires to program the actuator in imperial units.Determine: (1) The drive resolution setting. (2) The required user unit setting

Figure 18 Resolution and Steps/Inch Parameters for Fold-back Series PHD EC Cantilever Slides

EC GB- x - R100 -

Slide Model Number

EC GB- x - R101 -

EC GB- x - R102 -

EC GB- x - R104 -



Setting

8192

8192

8192

8192

25400

25400

25400

Inch

Inch

Inch

Inch

mm

mm

mm

40960

16384

8192

65536

2540

1270

1016

Steps/Inch Setting

81920

32768

16384

131072

5080

2540

2032

64696-XX


64695-XX 64696-XX

8192

8192

8192

8192

25400

25400

25400

Screw Lead

.200 In

.500 In

1.0 In

.125 In

10 mm

20 mm

25 mm


SettingSteps/mm Setting

Screw Lead

EC GB- x - R200 -

EC GB- x - R202 -

EC GB- x - R203 -

PHD EC Series Cantilever Slide Actuator Configuration Examples

23

Upon selecting the Configure Serial Port Option, the dialog box below will be displayed.

The following dialog box will appear:

2

Depress the Configure SerialPort button

3

4

5

6

Select the Com port youintend to use.

Select the applicable baudrate. (19200 is the defaultbaud rate and operatessatisfactory at this setting).

When finished with yourselections, depress theOK button

Depress the OK buttonto enable the newsettings.

17

OUTPUT -

OUTPUT +

COMMON

INPUT


+ 24 VDC

24 VDC GNDPLC WithPNP Input


Figure 16 Wiring Diagram for Interfacing FSC-01 Outputs to a PNP (Source) Type PLC Input.

Installing the PHD Programmer SoftwareTo install the PHD Programmer software, please refer to the software installation instructionslocated in Appendix A of this manual.

Configuring the FSC-01 Motion Controller for use with the PHD EC and EQ Series ActuatorsThe PHD Programmer software expects distances in steps and speeds in revolutions/sec. However,the software also gives you the option to both define and scale your own user units. Scaling yourown units will enable you to directly enter the required distance in any of the move command state-ments regardless of variations in lead or ball screw pitches and/or different gearing arrangements.For example, in the case of imperial units, once the software is initially configured with the propervalues, the user can program to move 3.125 inches by naturally specifying 3.125 in the appropriatemove instruction. In the case of Metric units, then 33.0 would equate to a 33 mm move.

The following illustrations and examples detail how to configure your motion controller to utilizeeven engineering units.

Figure 17 Resolution and Steps/Inch Parameters for Inline Series PHD EC Cantilever Slides

Denotes character field content not applicable

EC HB- x - R100 -


Setting

EC HB- x - R101 -

EC HB- x - R102 -

EC HB- x - R104 -

8192

8192

8192

8192

Inch

Inch

Inch

Inch

40960

16384

8192

65536

ScrewLead

.200 In

.500 In

1.0 In

.125 In


SettingEC HB- x - R200 -

EC HB- x - R202 -

EC HB- x - R203 -

25400

25400

25400

mm

mm

mm

2540

1270

1016

ScrewLead

10 mm

25 mm

20 mm

24

8

9

After selecting the “New File” icon, your screen should display the following menu:

Using the mouse cursor,select ”Disabled”.

Depress the “OK”Button.

Using the mouse cursor,click on the “New File”icon.

7

16

OutputsThe FSC-01 motion controller has a total of 3 programmable outputs for interfacing with other devices.The outputs can be configured for either Sourcing (PNP) or Sinking (NPN) modes. Because of theoptically isolated nature of the outputs, an external power source is required for operation.

When an output is programmed to a “low” state, it is actually closed and thus conducting current. Con-versely, when the output is set to its “high” state, it is open. At power-up, the FSC-01 sets all threeoutputs high (open circuit).

The maximum voltage between any pair of + and - output terminals is 24 volts DC. Never con-nect AC voltages to the output terminals. Maximum rated DC current per output is 100 mA.

The following diagrams below illustrate how to interface the FSC-01 outputs to a variety of devices.


OUTPUT -

OUTPUT +

COMMON

INPUT

24 VDC Power Supply

+-


PLC WithNPN Input

Figure 15 Wiring Diagram for Interfacing FSC-01 Outputs to a NPN (Sink) Type PLC Input.

LIMIT COM


-


Wire # 1

Wire# 262507/62517

Reed Switch

Switch Model Number Wire # 1 Wire # 262507 or 62517 Reed Sw. Blue Brown


2 Wire (Sink) Schematic

Figure 14 Wiring Diagram for Interfacing 2 Wire Sink Type Reed Switches to the FSC-01 Limit Inputs

25

Drives: Part Number Cross ReferencePHD Part Number Emerson Part Number FSA-01 EN-204

Motors: Part Number Cross ReferencePHD Part Number Emerson Part Number 64715-001 MG-208 64715-002 MG-316

Figure A

Figure B

The following “EZ Setup” Screen will appear:

10

11

12

If desired, type in yourown name for your drive.

Using the Drive partnumber cross referenceinformation in Figure A,select the applicable drivetype by clicking on thedown arrow button.

Select the proper motor type byclicking on the down arrow button.Refer to Figure B for specific partnumber cross reference information.

13

Change the OperatingMode to “Pulse Mode”by depressing thecorresponding radiobutton.

15

CW LIMIT

LIMIT COM

-

+


OutputPowerSupply

24 VDC PNPProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3

Figure 12 Wiring Diagram for Interfacing PNP (Source) Proximity Switches to the FSC-01 Limit Inputs



Figure 13 Wiring Diagram for Interfacing 2 Wire Source Type Reed Switches to the FSC-01 Limit Inputs

26

14

15

Select the“Pulse/Direction”submode by clicking theappropriate radio button.

Select the “Differential”source by clicking onthe corresponding radiobutton.

16

17

The “EZ Setup” menu will expand as follows:

Verify the “Ratio:” is set to 1 revsand 8192 counts as shown.

Click on the “Inputs” tab

Configuring The FSA-01 InputsTo configure the FSA-01 inputs, click on the inputs tab to open the input configuration screen.Then refer to the step by step instructions located below.

LIMIT COM


-


Wire # 1

Wire# 262507/62517

Reed Switch

2 Wire (Source) Schematic

PHD Switch Color Code Cross Reference ChartSwitch Model Number Wire # 1 Wire # 262507 or 62517 Reed Sw. Brown Blue

14

-


CW JOG

IN/JOG COM

CCW JOG

PowerSupply

24 VDC

Figure 10 Schematic For Interfacing Normally Open or Closed Switches to the FSC-01 Jog Inputs.

CW and CCW Limit Switch InputsThe FSC-01 motion controller has two dedicated inputs labeled CW limit and CCW limit. By usingthe CW (clockwise) and CCW (counterclockwise) limits, one can safely operate the system withincertain predefined limits. If an overtravel condition is detected through either limit switch, the motioncontroller will stop all program execution and the green power LED located on the face of the control-ler will turn red and alternately flash on and off thus indicating a fault has occurred. To recover fromthe fault, remove AC power for a few seconds and re-establish AC power again. Alternatively, the unitcan be reset through the programming software as well, although not practical in some cases.

The opportunity exists if desired, to reconfigure these inputs as general purpose inputs through theprogramming software. However, PHD, Inc. strongly encourages the use of limits for all applica-tions for safety considerations.

The following schematics illustrate how to connect the various PHD switches to the limit inputs.

PowerSupply

-


Output

24 VDCCW LIMIT

LIMIT COM

NPNProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3

Figure 11 Wiring Diagram for Interfacing NPN (Sink) Proximity Switches to the FSC-01 Limit Inputs



27

18

19

The input menu will appear as follows:

Using your cursor, select“Reset” as shown.

Depress the radio buttonas shown to assign the“Reset” function to Input# 1.

20The following information should appearto indicate Input # 1 has been programmedto serve as the “Reset” function for theservo drive.


13

Figure 9 Typical Diagram For Interfacing PNP Sourcing PLC Outputs to FSC-01 Inputs

PLC with Sink(NPN) Outputs


+24 VDC

IN

IN/JOG COM

24 VDC GND

Output

Common

PLC withSource (PNP)Outputs


+24 VDC

IN

IN/JOG COM

24 VDC GND

Output

Common

Figure 8 Typical Diagram For Interfacing NPN Sinking PLC Outputs to FSC-01 Inputs

24 VDCPower Supply

+ -

28

21

22

Next, we will assign the second required input:

Using your cursor, select“Stop” as shown.

Depress the radio buttonas shown to assign the“Stop” function to Input# 2.

23The following information should appearto indicate Input 2 has been programmedto serve as the “Stop” function for theservo drive.

Configuring The FSA-01 Outputs (Optional)

24

Click on the “Outputs” tab


12


24 VDCPowerSupply

-

+


Output

COM

PNPProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3In/Jog Com

Figure 6 FSC-01 Input Wiring Schematic For PNP (Source) Devices


+24 VDC

IN

IN/JOG COM

24 VDC GND

Figure 7 FSC-01 Input Wiring Schematic For Normally Open or Normally Closed Switches


29

The output menu will appear as shown below:

25

26

27

Using your cursor,select “Drive OK”.

Depress the radiobutton as shown toassign the “DriveOK” function toOutput # 1.

The following information should appearto indicate Output # 1 has been programmedto serve as the “Drive OK” function for the servodrive.

In the event you’d like to utilize other outputs as well, follow the same procedure as describedabove.

Note: When the active state of the output is “on”, the output will supply a voltage when theresult of the Or’ed output function(s) assigned to that output line is activated by the drive.

11


The FSC-01 Motion Controller

General Purpose Inputs 1 through 4, CW jog and CCW jog InputsAll inputs are opto isolated and can be used with either Sinking (NPN) or Sourcing (PNP) typedevices with DC voltages ranging from 5 to 24 volts. When using other than mechanical switches orrelays, it is recommended that you use an external power source to supply power to the inputs.The FSC-01 motion controller has a total of 4 general purpose inputs available for use. However,this can be expanded to 8 inputs total if the user decides not to utilize the dedicated CW (clockwise)jog and CCW (counterclockwise) jog inputs or the limits inputs. The CW and CCW jog inputs can beconfigured to function as general purpose inputs through the programming software. (Consult thePHD Programmer Software manual for more information).

The following schematics will assist you in wiring various types of devices to the inputs of theFSC-01 Motion Controller.

In/Jog Com

INPUT24 VDCPowerSupply

-


Output NPNProximity Sensor

-

+

Wire # 1

Wire# 2

Wire # 3

Figure 5 FSC-01 Input Wiring Schematic For NPN (Sink) Devices


30

Sending The Drive Configuration Setup To The Servo Drive

To send the completeddrive setup to the servodrive, depress the“Download” button asshown.

Saving The Drive Configuration SetupBefore downloading the drive setup information it is recommended you save the drive setup datato a file on your PC’s hard disk or floppy disk. To save a file, select Save from the file pull-downmenu or the save icon in the toolbar.

28

Enter your file name here.(Example: Setup.EN)

29Using the down arrow button,select the target drive where thefile will reside.

31

Note: After downloading the initial drive setup, the “Download” button will change to “Up-date”. Subsequently, any future changes in the program setup must be sent (e.g. downloaded)via the “Update” button.

30Once your selections havebeen made, click the “OK”button.

10

1

2

3

4

16

17

18

19

26

27

31

32

33

34

40

41

Input 1

Input 2

Input 3

Input 4

Drive Enable

Output 3

Output 2

Output 1

I/O Supply +

Pulse Input A

Pulse Input B

I/O Common -

Pulse Input A

Pulse Input B

I/O Supply +

I/O Common -

Red/Brown

Brown/Red

Black/Blue

Blue/Black

Black/Green

Green/Black

Black/Brown

Brown/Black

Gray/Purple

Purple/Green

Brown/Yellow

Blue/Yellow

Yellow/Brown

Yellow/Blue

Purple/Gray

Green/Purple

PinFunction Wire Color Code

Figure 4 Partial Wiring Diagram For PHD P/N 64722-010 I/O Cable (Same as Emerson P/N CMDO-010 I/O Cable)

Refer to the following abbreviated schematic for detailed signal pinouts and wire color codeinformation. (A complete wiring schematic for the 64722-010 I/O Cable can be found inAppendix C).

Alternatively, the electrical connections for all inputs and outputs, the Drive Enable and the 10 to30 VDC power I/O supply inputs can also be accessed through the J6 terminal strip located onthe front side of the FSA-01 Servo Drive. If you decide to utilize the terminal strip in place of theI/O cable, refer to Appendix E and Appendix F for wiring information.

Installing the Servo Motor CableUsing the PHD 64719-015 Motor Cable, connect the end with the 4 wire leads to terminal blockJ8 located directly on the servo drive. (Refer to Figure 3 for more information). Connect theopposite end of the cable with the MS connector to the appropriate mating (8 pin) MS connectorlocated on the servo motor.

Installing the Servo Motor Feedback CableTo install the PHD 64720-015 feedback cable, connect the molded DB connector end of the cableto the motor feedback connector J7 located on the servo drive. Connect the opposite end of thecable with the MS connector to the mating (26 pin) MS connector located on the servo motor.

31

Configuring the FSA-01 Servo Drive for OperationOnce the required I/O has been connected and the drive has been configured through thePowerTools software, the next step is to actually place the drive into a “ready” mode. The readymode is the required state the drive must be set to in order to process the step and directionsignals generated from the motion controller. This is accomplished mainly through the inputstatus of both the Drive Enable input and the Stop input. Once these inputs are set, an onboarddiagnostic display located on the drive provides a convenient means of indicating the actual“state” or mode the drive is in. At this time, refer to Figure 23 below for the necessarysteps required to properly configure the drive.

En-204

Servo DriveDiagnosticDisplay Drive Fault

Reset Button

PHD FSA-01Servo Drive


Current Desired Action RequiredDiagnostic Display

Apply 10 to 30 VDC to Stopinput. (Input # 2)

Step 1

Step 2



Figure 23 Required Input Scheme for Drive “Ready” Configuration

9

Connecting the FSA-01 Inputs and OutputsThe same PHD cable P/N 64722-010 used in connecting the FSC-01 Motion Controller step anddirection outputs to the FSA-01 Servo Drive inputs has additional capacity for connecting tovarious other I/O functions residing within the servo drive. In this section, we need to connectthe I/O power supply, Inputs 1 and 2 and any (optional) Output(s). Refer to Figure 3 for wiringinstructions and Figure 4 for cable pinout information.

InputsIn order to utilize the servo drive for positioning type applications, a specific input scheme isrequired. These required inputs are: (1) the Drive Enable Input, (2) Reset Input and (3) StopInput .

The Drive Enable input enables (or disables) the power stage of the servo drive. For example,when 10 to 30 VDC is applied to this input, the power stage is enabled and the servo motor shaftwill produce torque as commanded by the drive. The absence of a voltage (less then 10 VDC) onthis same input will cause the power stage to be disabled or “off” thus inhibiting the ability toproduce torque at the servo motor shaft.

The Reset Input is used to reset drive faults which might occur. For example, in the case wherethe actuator might encounter an obstruction in its path preventing it from moving, in most casescauses a fault to occur. The fault can be cleared (remotely) through this input by supplying a 10to 30 VDC rising edge pulse. For our setup, Input # 1 was chosen to be configured as the Resetinput.

The Stop Input is used to rapidly decelerate the servo motor to a zero velocity, thus stopping it.When a 10 to 24 VDC is applied to this input, the drive will operate in a normal manner, how-ever, the absence of a voltage (less then 10 VDC) will cause the servo motor to immediatelystop. Once stopped, the servo motor position will be maintained as long as the Stop input func-tion remains active. For our setup, Input # 2 was chosen to be configured as the Stop input.

OutputsThe FSA-01 Servo Drive has a total of 3 programmable PNP (Sourcing) outputs. In some appli-cations, it may be desirable to monitor the servo drive status via a PLC or other host controller ordevice. In such instances, the following output functions may be of interest.

The Drive OK output is active whenever no fault conditions exist. In this case, if the drive isfunctioning correctly with no drive faults active, this output will be in the “on” state. If a faultwas detected, the output would go to a low or “off” state.[Note: Travel limits and Drive Enable inputs have no effect on this particular output].For more detailed information, please refer to the Emerson E Series Drives Reference Manual.

The Fault output is active whenever a drive fault condition exists. In this instance, if no drivefaults are present and if the Travel limits have not been exceded, the output will be in the “on”state.

The output will go low or “off” in the case a fault has occurred or either one of the Travel limitshas been exceded.

For more detailed information, please refer to the Emerson E Series Drives Reference Manual.

32

Figure 24 Instructions For Recovering From A Drive Fault.

Figure 25 Servo Drive Diagnostic Display Codes*

* Partial listing, please refer to the Emerson E Series Drives Reference Manual for a complete listing.

In the event of a drive fault dueto actuator over travel or obstruction,to clear the fault, momentarily energizeInput # 1 (e.g. Reset input). Alternativelythe drive can be reset through the DriveReset button.

Step 1



Current Desired Action Required

Diagnostic Display

Description






None




Description






None




Ready to run. Apply 10 to 30 VDC to Stopinput.

8

Fig

ure

3 W

irin

g Sc

hem

atic

Sho

win

g R

equi

red

Con

nect

ions

Bet

wee

n

the

FSC

-01

Mot

ion

Con

trol

ler

and

FSA

-01

Serv

o D

rive

L1

L2

L3

GN

D

Inpu

t J1

Mot

or P

ower R S T

Bla

ck

Blu

e

Bro

wn

Pin

#

Des

crip

tion

Com

man

d C

onne

ctor

J5

FS

A-0

1 S

ervo

Driv

e

FS

C-0

1 M

otio

n C

ontr

olle

r

24 V

DC

Pow

er S

uppl

y

+ -

Sw

1

Sw

2

No

Con

nect

ion

50 /

60 H

z90

- 2

64 V

AC

1 O

or

3 O

Hom

eS

witc

h

End

of L

imit

Sw

itche

s

Pul

se In

put A

Pul

se In

put A

Pul

se In

put B

Pul

se In

put B

I/O S

uppl

y +

I/O S

uppl

y -

Driv

e E

nabl

e In

put

Inpu

t # 1

(R

eset

Fau

lt)

Inpu

t # 2

(S

top)

Out

put #

1

27 41 26 40 34 32 16 1 2 19

Out

1 +

Out

1 -

Out

2 +

Out

2 -

Out

3 +

Out

3 -

In/J

og C

omIn

1In

2In

3In

4C

W J

og/In

5C

CW

Jog

/In 6

Lim

it C

omC

W L

imit

CC

W L

imit

Ste

p +

Ste

p -

Dir

+

Dir

-

Gre

en/Y

ello

w

Cab

le P

/N64

720-

015

Cab

le P

/N64

719-

015

Cab

le P

/N64

722-

010

Co

nn

ecto

r J7

Mo

tor

Fee

db

ack

Co

nn

ecto

r J8

AC

Po

wer

Hom

e an

d Li

mit

Sw

itch

Sig

nal W

ires

Load

33

Appendix A

Installing the PHD Programmer SoftwareThe PHD Programmer software comes on two 3.5" software diskettes. Before you can use the software,you must install it on your hard drive.

To run the PHD Programmer software, you must have a computer with the following requirements:* IBM compatible 386, 486, Pentium or better CPU. Pentium recommended for best performance.* Microsoft Windows 3.1, Windows 95, Windows 98, or Windows NT* At least 8 MB memory (16 MB or more will make the software run much faster)* 4 MB available hard drive space* VGA monitor, or better. 16 bit color setting recommended

(65,535 colors, sometimes called High Color)* Mouse or other input device* 3.5" floppy disk drive* A nine pin serial port must be available, preferably COM1.

The software installation is highly automated. Like most Windows programs the process is simple.

• Put Disk 1 in your 3.5" drive.

• From the Windows Program Manager, select Run from the File menu. (In Windows 95/98 and NT4.0,choose Run from the Start menu.)

• If your 3.5" drive is drive A, then enter the -command line A:\setup. If your drive is B, type B:\setup.

• The setup program will guide you through the rest of the installation.

If you encounter errors during installation, it is usually due to lack of memory or conflicts with otherprograms that are already running on your PC. If you experience an error while installing the program-ming software, quit all other Windows applications and try again. Holding down the ALT key and press-ing TAB will show you all the programs currently running on your PC. Laptop computers generallypresent the biggest challenge to installation, as they often come preloaded with programs that automati-cally execute on startup such as Microsoft Office and battery managers. Furthermore, laptops usuallyhave the least memory.

The programming software will install more easily and run much faster if you have more memory. Werecommend 8 megabytes of RAM on a Windows 3.1 system, and 16 megabytes with Windows 95.

Display SettingsThe PHD Programmer works well with any display resolution. At 640 x 480, the PHD Programmer willexactly fill your screen. At higher resolutions, like 800 x 600 or 1024 x 768, there will be room left overon the screen for other applications, or to expand the PHD Programmer window so you can see moreprogram lines. A 16 bit color setting is recommended (65,535 colors, sometimes called High Color)

Information in the program window will not display correctly if your display is set for “Large Fonts.”Please use the “Small Fonts” setting when running the PHD Programmer software. The display settingsare found under “Start ... Control Panels” in Windows 95, and in the “Main ... Control Panels” programgroup in Windows 3.1.

Programming Note: Always apply power to FSC-01 hardware after the PHD Programmer softwareis running on your PC.

7

* (Same as Emerson P/N EN 204)

1Mates to J5 Connector on FSA-01 Servo Drive

Pin 27

Pin 41

Pin 26

Pin 40


STEP +

STEP -

DIR +

DIR -

Pulse Input A

Pulse Input A

Pulse Input B

Pulse Input B

Purple/Green

Green/Purple

Gray/Purple

Purple/Gray

64722-010 I/O Cable(Emerson P/N CMDO-010) [Note: Diagram shows only the required wires necessary for interfacing to the FSC-01 Motion Controller.]

FunctionColor Code

Molded Male 44 PinDB Connector1

Female 44 PinDB Connector

J5

PHD FSA-01* Servo Drive

Connecting the Step and Direction Outputs To The FSA-01 Inputs Inputs=The step and direction output signals residing on the FSC-01 Motion Controller require connec-tion to the FSA-01 Servo Drive inputs for processing.

For this purpose the FSA-01 Servo Drive has a “J5 Command Connector” port dedicated forinput and output connections. This 44 pin connector is accessed through the I/O cable (PHD P/N64722-010) originally purchased with the drive. The I/O cable connects directly to the J5Command Connector port located on the front of FSA-01 drive via a molded male 44 DBconnector whereas the opposite end of the cable contains open wires color coded for identifica-tion purposes.

In this section, we need to interface the step and direction outputs from the FSC-01 MotionController to the inputs of the FSA-01 Servo Drive using the above cable. Please refer to Figure2 for more specific instructions.

Figure 2 Wiring Details for Interfacing the Step and Direction Outputs to Servo Drive Inputs

34

Appendix B

Installing PowerTools On Your PC

Hardware and Software RequirementsPowerTools software will run on any IBM based PC with Microsoft Windows version 3.1 or higher, atleast 4 MB of RAM, 6 MB of available hard disk space, I serial port (a second serial port is required ifyou are using one for a mouse) and a 3.5" floppy disk drive. It is recommended, but not necessary, to use amouse to navigate in PowerTools Software.

Installing the SoftwarePowerTools Software is delivered on 1.44 MB (3.5") diskettes. You should make an additional copy ofeach diskette before you install the PowerTools Software. You can use the backup diskettes to:

• Provide un-infected software if your computer becomes infected by a virus.

• Replace the original diskettes if they become damaged.

When you finish making copies, install the PowerTools Software from the backup diskettes. Store theoriginal diskettes in a safe place.

1. Close all applications you have open in Windows.

2. Insert disk 1 into drive A.

3. If you are using Windows 3.1, Choose the Run command from the File menu in Windows ProgramManager or File Manager. If you are using windows 95, select Run from the Start menu.

4. In the Run dialog, Type A:\setup (substitute the appropriate letter for your system), press enter.

The install program automatically:Creates a directory named C:\EMERSON\Ptools.Creates a new Windows group called “Emerson Motion Control”Loads PowerTools into the Emerson/Ptools directoryLoads the required DLL’s into your Windows System directory

Refer to the readme.txt file on the number one installation floppy for more information.

6

How To Use The Quick Start ManualThe intent of this manual is to guide the user through the necessary steps required to successfullyinterface the PHD FSC-01 Motion Controller to the FSA-01 Servo Drive.

Both of the above products have their own dedicated hardware manuals originally sent with each unit.Before placing these products into service, it is your responsibility to consult these hardware manualsand be familiar with the various requirements for installing and commissioning this equipment.

The information contained within this manual is not intended to supersede or replace any informationcontained in either hardware manual. Therefore, in situations where technical issues might arisebetween this manual and the hardware manual(s), the information contained in the hardware manual(s)will take precedent.

Getting StartedTo set up your PHD Servo System, you will need the following:a) FSC-01 Motion Controller with supplied :

• PHD programmer software• Programming software manual• RS-232 programming cable• FSC-01 hardware manual• Quickstart manual

b) FSA-01 Servo Drive with supplied :• PowerTools setup software• E Series drives reference manual

c) Servo motor cable, p/n 64719-015d) Feedback cable, p/n 64720-015e) I/O cable, p/n 64722-010f) Servo motor, p/n 64715-001(Nema 23 size) or 64715-002 (Nema 34 size)g) Optional RS-232 PC cable, p/n 64723-010 (9 Pin) or 64724-010 (25 Pin)*h) IBM compatible 386 or higher CPU personal computer running Windows 3.1, Windows 95,

Windows 98 or Windows NT, 8 MB minimum memory, 12 MB available hard drive space,VGA or higher monitor.

i) PHD series EC or EQ electric actuatorj) For the EC actuator, the series 5580 or 18431 proximity switches, three total for:

• Home switch limit• CW (clockwise limit)• CCW (counterclockwise limit)

k) For the EQ actuator, the series 51422 or 6250 proximity switches, three total for:• Home switch limit• CW (clockwise limit)• CCW (counterclockwise limit)

k) 24 VDC regulated power supply

* Note: Instructions on how to construct an RS-232 cable (9 or 25 pin version) is illustrated in Appendix D. (This cable is used specifically to program the FSA-01 Servo Drive).

35

1 2 3 4 621 8 911121617181923242539274134323331373840261415434429282036

Pin #Red/Brown

Brown/Red

Black/Blue

Blue/Black

White/Orange

Orange/White

Purple/Blue

Blue/Purple

Red/Blue

Blue/Red

Black/Green

Green/Black

Black/Brown

Brown/Black

Purple/Orange

Orange/Purple

Black/Red

Red/Black

Purple/Green

Green/Purple

Yellow/Blue

Blue/Yellow

Yellow/Brown

Brown/Yellow

Purple/Brown

Brown/Purple

Purple/Gray

Gray/Purple

White/Blue

Blue/White

White/Green

Green/White

White/Red

Red/White

Yellow/Gray

Gray/Yellow

= Twisted Pair Wires

Do Not Connect

Do Not Connect

Input # 1

Input # 2

Input # 3

Input # 4

RS-485 +

RS-485 -



Encoder Supply + 5 Volts

Encoder Common

Drive Enable Input

Output # 3

Output # 2

Output # 1



Pulse Input Z

Pulse Input Z

Pulse Input A

Pulse Input A

I/O Supply +

I/O Common -



Pulse Input B

Pulse Input B

- Analog Command In

+ Analog Command In


I/O Supply +

I/O Common -


Diagnostics Output Common

Do Not Connect

Molded Male 44 PinDB Connector

FunctionWire Color Code Open End Wire Leads

Appendix C

Wiring Diagram For PHD P/N 64722-010 I/O Cable(Same as Emerson P/N CMDO-010 Cable)

Note: Unused wires must be kept electrically isolated from contactingother wires or voltages !

5

Fig

ure

1 P

HD

Ser

vo S

yste

m O

verv

iew

F

SC

-01

PH

D M

otio

n C

ontr

olle

r

F

SA

-01

PH

D S

ervo

D

rive

Ste

p/D

irect

ion

Com

man

dsM

otor

Pos

ition

Fee

dbac

k

Ser

vo M

otor

Pow

er

RS

-232

PC

(F

or p

rogr

amm

ing

pur

pose

s)

PLC

or

Hos

tC

ompu

ter

Sig

nal I

nput

s

Sig

nal

Out

puts

Sig

nal

Out

puts

Hom

eS

witc

h

2

4 V

DC

Pow

er S

uppl

yE

nd o

f Lim

itS

witc

hes

Bra

ke P

ower

/C

ontr

ol L

ine

Opt

iona

lB

rake

Sig

nal

Inpu

ts

36





PC Servo Drive





PC Servo Drive



Appendix D

Serial Communications Cable Pinout For Interfacing the PHD FSA-01Servo Drive To A Personal Computer

4

Interfacing the FSA-01 Servo Drive to the FSC-01 Motion Controller is straight forward. Theservo drive itself requires an initial one time setup which is accomplished through a PC via anRS-232 connection using the supplied software called PowerTools. Once the servo drive hasbeen configured to accept the step and direction signals from the motion controller, it simplyresides in the “background”, processing the signals sent from the motion controller. The servodrive requires three hardware inputs to function properly. Specifically, these inputs consist of the“Drive Enable”, a dedicated type input and two general purpose inputs programmed to functionas a “Stop” input and “Reset” input.

An interface I/O cable is available which connects directly to the servo drive via a DB 44 pinconnector. On the opposite end of this cable are the wire leads which allow direct access tovarious input and output type functions contained within the drive.The FSA-01 Servo Drive has a total of 5 inputs and 3 outputs, all opto isolated. One of the 5inputs is a dedicated input (e.g. Drive Enable) whereas, the remaining 4 inputs are generalpurpose type inputs and programmable. The 3 outputs are also general purpose type outputs andprogrammable as well. If desired, any one of the outputs can be programmed to report the statusof the drive through the “Drive OK” or “Fault” functions and may be monitored via a PLC oranother host controller or device as necessary.

An optional 24 VDC in-line brake is available for applications where a power failure could causeunwanted or unsafe motion of the actuator, particularly in vertical type applications. The brakeconveniently mounts between the actuator and servo motor. When a 24 VDC control signal (froma PLC or host controller) is applied to the brake, it releases for unobstructed motion. In the eventof a power failure, the absence of the 24 VDC control signal causes the brake to engage, prohib-iting any motion of the actuator.

To complete the system, an external 24 volt DC power source is required. This supply willprovide the necessary voltage to power the opto isolated I/O residing on both the motion control-ler and servo drive in addition to the limit and home switches and optional brake, if required.

37

Appendix E

Diagram For Connecting PNP Inputs and Outputsto the FSA-01 Servo Drive Terminal Block J6

VDC10-30

Drive E

nab

le

Inputs Outputs

+ - # 1 # 2 # 3 # 4 # 1 # 2 # 3

VDC Power Supply

+

-

Single PointPE Ground

*

*

J6 Terminal Strip



Sw1 Sw2

Out 2

Out 1

Note: All available connections at the terminal strip shown above can also be accessed through the PHD I/O Cable P/N 64722-010 (Emerson P/N CMDO-010)

Out 1 Programmable1 Drive OKOut 2 Programmable1 Fault

Output Output Type Program as:

Drive Enable Dedicated N/ASw 1 Programmable1 Reset FaultSw 2 Programmable1 Stop

Input Drive Input Type Program as:

Minimum Recommended HardwareFor Interfacing With Other ControlDevices Such as PLC�s.

Optional Output Hardware

1 Programmable through the initial setup and configuration software within the FSA-01 Servo Drive.



A highspeed diode is requiredfor inductive loads such as a relay,solenoid or contactor. Omit if notrequired.(Use a 1N4000 Diode or equivalent)

*

24

3

Technical Overview of the PHD Servo SystemThe PHD Servo System is comprised of two major components, a programmable motion control-ler and a servo drive with a corresponding servo motor. (Refer to Figure 1).

The FSC-01 Motion Controller is used to develop and run in a stand alone mode selected motionprofiles. It is programmed through a Personal Computer via an RS-232 connection using thesupplied PHD Programmer software. Once the unit is programmed, the on board non-volatilememory stores the program internally within the unit. Once the RS-232 cable is unplugged fromthe controller and subsequently powered down, the unit will automatically begin program execu-tion upon the next power-up cycle.

A total of eight opto isolated inputs are available on the motion controller for various functions.Two of the eight inputs are dedicated for limit sensors, which, when strategically placed on theelectric actuator, provide a margin of safety should the unit be inadvertently programmed orforced beyond its normal operating travel range. In the case the user decides not to utilize thesetwo inputs as limits, the software allows the opportunity to change these two inputs to generalpurpose type inputs.

Another two inputs are dedicated for clockwise and counterclockwise jog motions, however ifthe need should arise, one or both can be selected (through software) to function as generalpurpose inputs.

The last four inputs are general purpose inputs, fully programmable and accessible through theprogramming software. All inputs can be configured to accept either PNP Source or NPN Sinktype signals, allowing them to be interfaced to a wide range of PLC’s and other host controllersor devices.

Three outputs are also available, all opto isolated and like the general purpose inputs, fullyprogrammable and also readily accessible through the programming software. These too, can beconfigured to provide either PNP Source or NPN Sink type signals, again, allowing them to beinterfaced to a wide range of PLCs and other host controllers or devices.

The PHD Programmer software included with the FSC-01 Motion Controller is extremely userfriendly and requires little time to learn and implement. Because all commands are icon driven,all the user has to do is specify the information required to complete the desired action andarrange the various commands in a sequential manner. A total of 20 different program commandsare available within the programming software providing both the flexibility and capability tosolve most single axis point to point type motions.

Once the motion program is written and stored within the motion controller, the FSC-01 sendsvia 4 wires, step and direction pulses to the PHD FSA-01 Servo Drive. This closed loop servodrive receives the step and direction pulses and translates these signals to a level capable ofdriving the attached servo motor with integral encoder. Once the motor moves to its programmedposition, the encoder sends position information to the servo drive, thus confirming its actualposition. This feedback position is then compared to the original (programmed) position and ifany differences exist, the servo drive will take the required corrective measures to ensure both thecommanded programmed position and actual position are the same.

38

Appendix F

Diagram Showing the Internal Connections Betweenthe J5 Command Connector and J6 Terminal Strip

Drive Enable

J6 Terminal Strip



Input 4

Input 3

Input 2

Input 1

Drive Enable

Output 3

Output 2

Output 1

I/O Supply +

I/O Common -

I/O Supply +

I/O Common -

4

3

2

1

16

17

18

19

31

32

33

34

VD

C10

-30

+-

Inp

uts

# 1

# 2

# 3

# 4

Ou

tpu

ts

# 1

# 2

# 3

2.8K

J5 Command Connector

Note: If a load is applied tothe same output signal onboth J5 and J6, the sumtotal current loading mustbe limited to 200 mA peroutput signal,

1

Internet Web Site: http://www.phdinc.com • E-Mail: [email protected]

®

100 8/99 4784

PHD Ltd. PHD GmbH7 Eden Way, Pages Industrial Park Arnold-Sommerfeld-Ring 2

Leighton Buzzard, Bedfordshire LU7 8TP U.K. D-52499 Baesweiler GERMANYPhone 01525 853488 • Fax 01525 378210 Phone 02401-805 230 • Fax 02401-805 232

PHD, Inc.9009 Clubridge Drive

P.O. Box 9070, Fort Wayne, Indiana 46899 U.S.A.Phone (260) 747-6151 • Fax (260) 747-6754

QUICKSTARTMANUALHardware & Setup Manual ForInterfacing the FSC-01 MotionController to the FSA-01 Servo Drive

NOTES

6441-334

FSC-01

FSA-01

Documents

QUICKSTART MANUAL - PHD's Online LitStorelitstore.phdinc.com/pdf.asp?filename=6441334.pdf · friendly and requires little time to learn and implement. ... servo drive itself requires