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Emerson PCM-22 Operator's Manual

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Over 100 years cumulative experience
24 hour rush turnaround / technical support service
Established in 1993
The leading independent repairer of servo motors and drives in North America.
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Canada: 1 (905) 829 -2505
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  • Page 1 Over 100 years cumulative experience 24 hour rush turnaround / technical support service Established in 1993 The leading independent repairer of servo motors and drives in North America. Visit us on the web: www.servo-repair.com www.servorepair.ca www.ferrocontrol.com www.sandvikrepair.com www.accuelectric.com Scroll down to view your document! For 24/7 repair services : USA: 1 (888) 932 - 9183 Canada: 1 (905) 829 -2505...
  • Page 2 Information furnished by EMERSON EMC is believed to be accurate and reliable. However, no responsibility is assumed by EMERSON EMC for its use. EMERSON EMC reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice.

  • Page 3: Training Services (612)-474-1116

    Our engineers offer you a broad base of experience and knowledge of electronic motion control applications. EMERSON BBS (612) 474-8835. PCX Software updates can be obtained from the Emerson BBS. 300 - 9600 Baud, N, 8, 1.

  • Page 4: Table Of Contents

    Installing Your PCM Module ............6 Input Wiring....................6 Output Wiring ..................... 7 ....................7 ENSOR ETUP Follower Sensor ................... 7 Master Sensor....................7 Programming The PCM-22 ............. 8 ................ 11 ASTER ESCRIPTION Master Axis Setup ..................12 ..................16 ASTER YCLES Master Cycle Number ................

  • Page 6: Overview

    PCM module eliminating the need to replace EPROM's on the FX amplifier. Features Not all of the features available with the PCM-22 will be used in every application. For example, there are 15 programming functions available with the PCM-22, however, a typical rotary knife program will use only a few of them.

  • Page 7: Theory Of Operation

    PCXWin Software Theory Of Operation The PCM-22 allows an FX Drive to monitor a product's position (with respect to its motor position) and produce uniformly spaced cuts or perforations on the product. The object of Rotary Knife Control is to...

  • Page 8: Pcm-22 Terminology

    Usually this ratio is close to 1:1. The "working segment" is a length during which the Working Ratio is applied. Figure 2 shows a typical motion profile for a PCM-22 Rotary Knife System. Figure 2 PCM-22 Motion Profile Example •...
  • Page 9 PCXWin Software operation using inputs. The working ratio can also be adjusted using PCX software or with serial commands.
  • Page 10 PCXWin Operators Manual When any of these parameters are changed, the PCM-22 calculates and completes the profiles necessary to accommodate the new parameters. Any changes made before the center of the working segment will take place during the next cycle. During the working segment the working ratio will always be maintained.

  • Page 11: Installing Your Pcm Module

    PCXWin Software Installing Your PCM Module PCM modules attach to the front of any FX Amplifier with two locking arms. All electrical connections (except I/O) are made via the 48 pin connector. All PCM modules are equipped with 8 input lines and 4 output lines, doubling the I/O capability of the standard FX drive.

  • Page 12: Output Wiring

    PCXWin Operators Manual Output Wiring Outputs are similar to inputs in that they can be connected to either sinking or sourcing type loads. Outputs require an external isolated supply voltage, usually the same supply as the inputs. Each output can sink or source 0.2 amps DC. The negative (-) lead of the external power supply must be connected to enclosure or safety ground.

  • Page 13: Programming The Pcm-22

    PCXWin Software Programming The PCM-22 The first step in programming your FX Drive with a PCM-22 is to configure the drive using the 5 menu options in the Drive Configuration screen. The Drive Parameters, Limits, Inputs and Outputs screens are explained in the PCX section of the FX manual (P/N 400282-00).
  • Page 14 PCXWin Operators Manual Figure 5 PCX Hierarchy Diagram #1...
  • Page 15 Individual setup information for each feature is covered on the following pages. 1. Drive Parameters: The first step in setting up the PCM-22 is to define the parameters in the Drive Parameters screen. A description of the parameters in this screen can be found in the PCX section of the FX Drives manual (P/N 400282-00).

  • Page 16: Master Axis Description

    Master Axis Description This screen is where you identify the Signal Source of the master axis. In addition to running Cycle Profiles the PCM-22 also has the ability to run synchronized indexes, however, in this screen only the Signal Source, Signal Polarity, Signal Interpretation and Signal For Sync Output From parameters are used by the PCM- 22 when running Cycle Profiles.

  • Page 17: Master Axis Setup

    Signal Source Select the origin of the signals (drive or encoder) used for master axis positional information. When a follower axis (PCM-22) is receiving its synchronization source from an FX drive lead axis, the count source becomes the binary 4096 counts per turn.
  • Page 18 The signal interpretation feature allows you to define how the follower reacts to clockwise and counterclockwise motion of the synchronization encoder. The recommended signal interpretation mode when using a PCM-22 module is mode #4, COMP +. Signal interpretation modes apply only to ratio synchronization.
  • Page 19 External Mode Override full speed. To calculate the master maximum velocity, use the parameters are not used by the following formula: PCM-22 when running Cycle Profiles. However, they would be used if MV MS Master MaxVelocity you were running synchronized indexes or jogs.
  • Page 20 PCXWin Operators Manual External Mode Override External mode override works in conjunction with input function #38 to override the current mode of operation. When input function #38 is assigned and active, the drive will exit its’ current operating mode and default to the mode selected with this parameter. There are three modes of operation, analog velocity, analog torque and bi- polar sync.

  • Page 21: Master Cycles

    Master Cycles A master cycle is defined as the distance between successive master zero points. The PCM-22 allows the drive to position and maintain a phase relationship of its motor to an independent axis. The FX Drive, with the PCM-22 acting as the follower axis, will produce one or more cycles of motion for every cycle produced by the master axis.

  • Page 22: Master Length Upper Limit

    As demonstrated by the equations above, the lower the average the faster length errors are corrected for, However, setting this value too low will adversely affect the PCM-22/drives ability to quickly correct for phase errors. Length variations and/or errors are slowly averaged into the...
  • Page 23 When an input is received from the zero master cycle sensor input and error is found to exist between the current cycle length and the length determined by the new sensor input. The PCM-22 takes this percentage of that error which it uses to correct the length error.

  • Page 24: Follower Cycles

    The PCM-22 allows the drive to position and maintain a phase relationship of its motor to an independent axis. The FX Drive, with the PCM-22 acting as the follower axis, will produce one cycle of motion for every cycle produced by the master axis.

  • Page 25: Follower Cycles Screen

    When an input is received from the zero follower cycle sensor input and error is found to exist between the current cycle length and the length determined by the new sensor input. The PCM-22 takes this percentage of that error which it uses to correct the length error.
  • Page 26 Where: Old is equal to the original operational follower length. ML is equal to the current measured follower length. And NL is the new follower length calculated by the PCM-22. Therefore, the lower the average the faster length errors are corrected for.
  • Page 27 For example: If a new master sensor indicates an error in the follower position in relation to the master position the PCM-22 will try to correct for the error within one cycle. The parameter is used to scale both the master and follower errors individually and the sum of the two scaled values is the total phase positioning error for the system.
  • Page 28 PCXWin Operators Manual Batch Count This parameter is used in conjunction with the Batch Count Reached output (output #43). The batch count reached output becomes active when the batch counter reaches this number. The batch count is incremented automatically when the cycle counter reaches the programmed cycle count.
  • Page 29 PCXWin Software Upper Working Ratio Limit This parameter limits the maximum working ratio. Lower Working Ratio Limit This parameter limits the maximum working ratio. Offset/Phase Fine Increment This parameter is used to select the amount of increment/decrement distance which occurs when the follower offset or master phase increment/decrement input are toggled while the fine phase adjustment input is active.

  • Page 30: Inputs/Outputs

    Inputs/Outputs This section list all the input and output functions which are available with a PCM-22. Refer to the FX Drives manual (P/N 400282-00) for complete instructions on assigning the input and output functions listed below. The FX Drives manual also provides information and instructions on input polarity, input response time, input filtering and high speed inputs.
  • Page 31 PCXWin Software • When clear to initiate input is high (On), unlimited initiates are allowed. when low (Off) initiates are inhibited.
  • Page 32 PCXWin Operators Manual Hold This function stops index motion or home motion as long as the input is active. Index or home motion resumes when this input is released. Decel time is set with the stop/hold decel time parameter in limits dialog box.
  • Page 33 PCXWin Software 14 Index Select Allows you to choose an index using input lines and sets the starting input line number for a given number of index select lines. For example: If your system requires four index select lines you could assign any four consecutive input lines.
  • Page 34 PCXWin Operators Manual 21 Reset Fault Duplicates the function of the reset switch on the front of the digital drive. It will clear non-fatal drive faults. 22 Zero Position Sets the current position of the motor to zero. All absolute positions will be referenced to this set zero position.
  • Page 35 PCXWin Software 30 Program Select Lines This input function allows you to select a program with input lines and sets the starting input line number for a number of program select lines. For example: If your system requires four program select lines, you could assign any four consecutive Input Lines.
  • Page 36 PCXWin Operators Manual 37 Feed Sensor (1) Defines which input line will be used for the feed sensor indexes. 38 External Mode Override An active input allows direct and immediate movement of the FX drive motor using the bi-polar sync setup in the master axis dialog box.
  • Page 37 PCXWin Software 46 Zero Follower Cycle This input establishes follower zero degree point. If the Zero Follower Cycle sensor is used to sense and redefine each Follower Cycle, this input must be assigned to high speed input lines 1 or 2. If the Zero Follower Cycle input is used to manually establish the first zero position with the follower stationary, it can be set to any input line.
  • Page 38 PCXWin Operators Manual 74 Reset Cycle Counter This input is used in conjunction with the cycle count parameter (in the follower cycles screen) to reset the cycle counter after the cycle count value has been reached. 75 Reset Batch Counter This input is used in conjunction with the batch count parameter (in the follower cycles screen) to reset the batch counter after the batch count value has been reached.

  • Page 39: Output Functions

    PCXWin Software Output Functions Outputs require an external isolated supply voltage, usually the same supply as the inputs. Each output can sink or source 0.2 amps Ready If the microprocessor and its memory are operating correctly, this output is on continuously after power up. It turns Off when either a watchdog timer fault or non-volatile memory fault occurs.
  • Page 40 PCXWin Operators Manual Home Completed This output comes on after the completion of a home cycle and stays on continuously unless absolute position is lost. 10 Sensor Limit Distance Hit This output comes on during a feed sensor index if the sensor limit distance is exceeded before a sensor signal is received.
  • Page 41 PCXWin Software 17 At Sync This output is activated when the follower axis is in sync with the master axis (i.e. the acceleration portion of the index is complete). For example; In a fly cut-off system, the cut-off can not be made until the follower and master are in sync.
  • Page 42 PCXWin Operators Manual 42 Cycle Count Reached This output will become active when the cycle count number (set in the follower cycles screen) is reached. 43 Batch Count Reached This output will become active when the batch count number (set in the follower cycles screen) is reached.

  • Page 43: Executing Follower Cycles

    Typically, this home would be a feed to sensor type, where the home sensor is also the follower zero sensor. Therefore, your program would have a home command followed by an execute follower cycle command. Figure 12 PCM-22 Program Using The “Y” Function...

  • Page 44: Creatinga Motion Program

    Multiple programs can be created using PCX software and stored in the PCM-22, each designed for a different machine function. The PCM-22 is capable of storing up to 256 indexes, 100 motion programs (∅ to 99), and a maximum of 1024 program steps in the non-volatile memory.
  • Page 45 PCXWin Software Figure 13 Motion Profile Of Example Program show the program setup screens used to generate the motion program in . The program count determines how many times the program will be executed. In this example the program count for Program 1 is 10.

  • Page 46: Time Base (Indexes And Homes)

    PCXWin Operators Manual Time Base (Indexes And Homes) The "Time Base" feature is available from the Index and Home screens and can be set to Real Time, Synchronized or Analog. The Time Base feature relates to the velocity scale factor pre- determined by drive parameters.
  • Page 47 PCXWin Software Figure 15 Compound Index Example The drive will continue at that velocity until it approaches the programmed distance of Index 2, then decelerate at the Index #2 deceleration rate to the Index #3 programmed velocity. It will continue at that velocity until it approaches the programmed distance of Index #3, at which time it will decelerate at the Index #3 deceleration rate and stop.
  • Page 48 PCXWin Operators Manual After completing Index #1, the drive will accelerate at the acceleration rate of Index #2 until it reaches the programmed velocity of Index #2. After completing Index #2 the drive will accelerate to the programmed velocity of Index #3 and move at that velocity until it approaches the programmed distance, at which time it will decelerate at the Index #3 deceleration rate and stop.
  • Page 49 PCXWin Software Call Home The Call Home function is used to initiate a previously programmed Home Cycle. There are two Home Cycles that can be called within a program. Call Index The Call Index function is used to initiate the execution of an index. When this function is used, the index number must also be given.
  • Page 50 PCXWin Operators Manual Call Program The Call Program function is used to initiate a program from within a program. You can use the "P" function to call additional programs as sub-routines of your original program. This is called "Nesting". PCX allows you to nest up to 30 programs under any one Program Call function before returning to the original program.
  • Page 51 PCXWin Software Time Base This code determines whether the Time Base for any programming function placed after the Time Base code in a program (including Dwells and Homes) is Synchronized (sync encoder), Real Time (normal) or Analog. It is important to remember that if you want a limited number of program steps done in Synchronized mode, you must restore the Time Base to Real Time after those program steps.
  • Page 52 PCXWin Operators Manual The second and fourth choices are alike in that they are asking for an OR condition of the selected Input Lines before jumping to the destination program step. That is, the Jump will be made if Line 1 OR Line 3 OR Line 4 is on or off, depending on your selection.
  • Page 53 PCXWin Software You may now choose which lines to monitor during this step by entering a (1) in the field corresponding to the input line you wish to monitor. Any field that has a zero or an "X" will cause that input line to be ignored during execution of this step.

  • Page 54: Suspend/Resume Functions

    PCXWin Operators Manual Suspend/Resume Functions The Suspend Function is used to temporally suspend the operation of a running program and is initiated with Input Function #31. The Resume Function causes the system to finish the program that was suspended. Resume is initiated with Input Function #32. When a Suspend command is received, the FX Drive will stop motion using the Stop/Hold Decel ramp entered in the Limits screen.
  • Page 55 PCXWin Software Figure 23 Suspend Setup Screen Run Program On Suspend This feature allows another program to be automatically initiated when a Suspend is accepted. After the FX Drive stops on Suspend, the program you specify in the program number parameter will be executed without the need for a Program Initiate.
  • Page 56 PCXWin Operators Manual Return/Remember Position Index Number This parameter determines which index is to be initiated when a Resume is accepted and the "Automatically Return After Program" feature is used. When a Suspend input is accepted, the current position will be saved to this index. All other index information should be set up by the operator.

  • Page 57: Encoder Operation

    PCXWin Software Encoder Operation The SCS-2 sync encoder is a two channel amplified sine wave encoder. Each of the channels has 1000 lines. The PCM-14 inputs are A, A {complement}, B and B {compliment}. Quadrature encoding of these two signals produces a signal whose frequency is 4 times the line count.

  • Page 58: Multi Axis Synchronization

    PCXWin Operators Manual Multi Axis Synchronization If an external encoder is used as the method of accomplishing synchronization, The connection of the external encoder to the first axis is accomplished with this sync cable. As many as 10 axis can be synchronized to a single encoder.
  • Page 59 PCXWin Software Sync Cables The MSC-XXX cable is available in three different lengths. • MSC-015 = 15 FT. • MSC-025 = 25 FT. • MSC-050 = 50 FT. Figure 26 MSC Cable Wiring Diagram For some applications it may be an advantage to not have an external encoder as the source of synchronization.

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