LS Industrial Systems XGT Series User manual

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Programmable Logic Controller

XGB Positioning Module

User’s Manual

z

Read this manual carefully before

installing, wiring, operating, servicing

or inspecting this equipment.

z Keep this manual within easy reach

for quick reference.

XGT Series

http://eng.lsis.biz

XBF-PD02

A

Safety Instruction

Before using the product …

For your safety and effective operation, please read the safety instructions thoroughly before using the product.

► Safety Instructions should always be observed in order to prevent accident or risk with the safe and

proper use the product.

► Instructions are divided into “Warning” and “Caution”, and the meaning of the terms is as follows.

This symbol indicates the possibility of serious injury or death if some applicable

instruction is violated

This symbol indicates the possibility of severe or slight injury, and property

damages if some applicable instruction is violated

Moreover, even classified events under its caution category may develop into serious accidents relying on

situations. Therefore we strongly advise users to observe all precautions properly just like warnings.

► The marks displayed on the product and in the user’s manual have the following meanings.

Be careful! Danger may be expected.

Be careful! Electric shock may occur.

► The user’s manual even after read shall be kept available and accessible to

any user of the product.

Warning

Caution

Safety Instruction

Safety Instructions for design process

 Please install a protection circuit on the exterior of PLC so that the whole system may

operate safely regardless of failures from external power or PLC. Any abnormal output or

operation from PLC may cause serious problems to safety in whole system.

- Install protection units on the exterior of PLC like an interlock circuit that deals with opposite

operations such as emergency stop, protection circuit, and forward/reverse rotation or install an

interlock circuit that deals with high/low limit under its position controls.

- If any system error (watch-dog timer error, module installation error, etc.) is detected during

CPU operation in PLC, all output signals are designed to be turned off and stopped for safety.

However, there are cases when output signals remain active due to device failures in Relay and

TR which can’t be detected. Thus, you are recommended to install an addition circuit to monitor

the output status for those critical outputs which may cause significant problems.

 Never overload more than rated current of output module nor allow to have a short circuit.

Over current for a long period time maycause a fire .

 Never let the external power of the output circuit to be on earlier than PLC power, which may

cause accidents from abnormal output oroperation.

 Please install interlock circuits in the sequence program for safe operations in the system

when exchange data with PLC or modify operation modes using a computer or other

external equipments Read specific instructions thoroughly when conducting control operations

with PLC.

Warning

Safety Instruction

Safety Instructions for design process

Safety Instructions on installation process

 I/O signal or communication line shall be wired at least 100mm away from a high-voltage

cable or power line. Fail to follow this

Caution

 Use PLC only in the environment specified in PLC manual or general standard of data

sheet. If not, electric shock, fire, abnormal operation of the product may be caused.

 Before install or remove the module, be sure PLC power is off. If not, electric shock or damage

on the product may be caused.

 Be sure that every module is securely attached after adding a module or an extension

connector. If the product is installed loosely or incorrectly, abnormal operation, error or dropping

may be caused. In addition, contact failures under poor cable installation will be causing

malfunctions as well.

 Be sure that screws get tighten securely under vibrating environments. Fail to do so will put

the product under direct vibrations which will cause electric shock, fire and abnormal operation.

 Do not come in contact with conducting parts in each module, which may cause electric

shock, malfunctions or abnormal operation.

Caution

Safety Instruction

Safety Instructions for wiring process

 Prior to wiring works, make sure that every power is turned off. If not, electric shock or

damage on the product may be caused.

 After wiring process is done, make sure that terminal covers are installed properly before

its use. Fail to install the cover may cause electric shocks.

Warning

 Check rated voltages and terminal arrangements in each product prior to its wiring

process. Applying incorrect voltages other than rated voltages and misarrangement among

terminals may cause fire or malfunctions.

 Secure terminal screws tightly applying with specified torque. If the screws get loose, short

circuit, fire or abnormal operation may be caused. Securing screws too tightly will cause

damages to the module or malfunctions, short circuit, and dropping.

 Be sure to earth to the ground using Class 3 wires for FG terminals which is exclusively

used for PLC. If the terminals not grounded correctly, abnormal operation or electric shock

may be caused.

 Don’t let any foreign materials such as wiring waste inside the module while wiring,

which may cause fire, damage on the product or abnormal operation

.

 Make sure that pressed terminals get tighten following the specified torque. External

connector type shall be pressed or soldered using proper equipments.

Caution

Safety Instruction

Safety Instructions for test-operation and maintenance

 Don’t touch the terminal when powered. Electric shock or abnormal operation may occur.

 Prior to cleaning or tightening the terminal screws, let all the external power off including

PLC power. If not, electric shock or abnormal operation may occur.

 Don’t let the battery recharged, disassembled, heated, short or soldered. Heat, explosion

or ignition may cause injuries or fire

.

Warning

 Do not make modifications or disassemble each module. Fire, electric shock or abnormal

operation may occur.

 Prior to installing or disassembling the module, let all the external power off including

PLC power. If not, electric shock or abnormal operation may occur.

 Keep any wireless equipment such as walkie-talkie or cell phones at least 30cm away

from PLC. If not, abnormal operation may be caused.

 When making a modification on programs or using run to modify functions under PLC

operations, read and comprehend all contents in the manual fully. Mismanagement will

cause damages to products and accidents.

 Avoid any physical impact to the battery and prevent it from dropping as well. Damages

to battery may cause leakage from its fluid. When battery was dropped or exposed under strong

impact, never reuse the battery again. Moreover skilled workers are needed when exchanging

batteries.

Caution

Safety Instruction

Safety Instructions for waste disposal



Product or battery waste shall be processed as industrial waste. The waste may discharge

toxic materials or explode itself.

Caution

Revision History

Version Date Remark Page

V 1.0 ’10. 1 First Edition -

The number of User’s manual is indicated right part of the back cover. ※

About User’s Manual

Thank you for purchasing PLC of LS Industrial System Co.,Ltd.

Before use, make sure to carefully read and understand the User’s Manual about the functions, performances,

installation and programming of the product you purchased in order for correct use and importantly, let the end

user and maintenance administrator to be provided with the User’s Manual.

The User’s Manual describes the product. If necessary, you may refer to the following description and order

accordingly. In addition, you may connect our website (http://eng.lsis.biz/

) and download the information as a PDF

file.

Relevant User’s Manuals

Title Description

No. of User’s

Manual

XG5000 User’s Manual

(For XGI/XGR/XEC)

10310000821

XG5000 User’s Manual

(For XGK/XGB)

It describes how to use XG5000 software, especially

about online functions such as programming, printing,

monitoring and debugging by using XGB PLC.

10310000834

XGK/XGB

Instructions & Programming

User’s Manual

It is the user’s manual for programming to explain how

to use commands that are used in PLC system with

XGB main unit.

10310000833

XGI/XGR/XEC

Instructions & Programming

User’s Manual

It is the user’s manual for programming to explain how

to use commands that are used PLC system with XGB

IEC main unit.

10310000833

XGB Hardware

User’s Manual

It describes how to use the specification of power/input

/output/expansion modules, system configuration and

built-in High-speed counter for XGB main unit.

10310000926

XGB IEC Hardware

User’s Manual

It describes how to use the specification of power/input

/output/expansion modules, system configuration and

built-in High-speed counter for XGB IEC main unit.

10310000983

◎ Contents ◎

Chapter 1 Overview ............................................................................. 1-1~1-9

1.1

Characteristics......................................................................................................... 1-1

1.2 Purpose of Positioning Control................................................................................ 1-2

1.3

Signal Flow of Positioning Module........................................................................... 1-3

1.3.1

Operating sequence...................................................................................................1-3

1.3.2

Flow of position signal................................................................................................1-4

1.4 Function overview of positioning module.................................................................1-5

1.4.1 Position Control..........................................................................................................1-5

1.4.2

Interpolation Control...................................................................................................1-6

1.4.3

Speed Control.............................................................................................................1-9

Chapter 2 Specifications..........................................................................2-1~2-9

2.1

General Specifications............................................................................................. 2-1

2.2

Performance Specifications..................................................................................... 2-2

2.2.1 Function Specifications...............................................................................................2-2

2.3

External I/O Interface Specifications........................................................................ 2-3

2.3.1

Input Specifications.....................................................................................................2-3

2.3.2

Output Specifications..................................................................................................2-4

2.3.3

Specifications on Interface with External Equipment.................................................2-5

2.4

The Name of Each Part........................................................................................... 2-8

2.4.1

The name of each part...............................................................................................2-8

2.5

Connection to XGT Servo System........................................................................... 2-9

Chapter 3 Operation Order and Installation................................................ 3-14

3.1 Installation ............................................................................................................... 3-1

3.1.1 Installation Environment.............................................................................................3-1

3.1.2

Notices in Handling ....................................................................................................3-1

3.2 Notices in Wiring...................................................................................................... 3-2

3.2.1 Notices in Wiring ........................................................................................................3-2

3.2.2 Connection Example of Servo and Stepping Motor Drive Machine...........................3-3

3.2.3

Encoder Input (DC 5V Voltage Output) Wiring Example..........................................3-13

3.2.4

Encoder Input (5V Line Driver Output) Wiring Example ..........................................3-14

Chapter 4

Positioning Parameter & Operation Data............................4-1~4-24

4.1 Parameter & Operation data.................................................................................... 4-1

4.2

Basic Parameter...................................................................................................... 4-2

4.2.1 Basic parameter .........................................................................................................4-2

4.2.2

Basic parameter setting..............................................................................................4-3

4.3

Home/Manual parameter....................................................................................... 4-13

4.3.1 Contents of Home/Manual parameter......................................................................4-13

4.3.2

Home/Manual parameter setting..............................................................................4-13

4.4

Common Parameter............................................................................................... 4-16

4.4.1 Common parameter .................................................................................................4-16

4.4.2

Common Parameter Setting.....................................................................................4-16

4.5 I/O Signal Parameter............................................................................................. 4-19

4.5.1 I/O Signal Parameter................................................................................................4-19

4.5.2

Setting of I/O Signal Parameter................................................................................4-19

4.6 Operation Data ...................................................................................................... 4-20

4.6.1 Operation Data.........................................................................................................4-20

4.6.2

Operation Data Setting.............................................................................................4-20

Chapter 5 Program Configuration and Operation Method..................5-1~5-10

5.1 Internal Memory....................................................................................................... 5-1

5.1.1 Teaching Data ............................................................................................................5-1

5.1.2 State Information........................................................................................................5-3

5.2

I/O Signal................................................................................................................. 5-8

5.2.1 Contents of I/O Signal................................................................................................5-8

5.2.2

Use of I/O Signal........................................................................................................5-9

Chapter 6

Command..............................................................................6-1~6-39

6.1 Contents of General Command............................................................................... 6-1

6.1.1

Internal Memory Read................................................................................................6-1

6.1.2

Internal Memory Write................................................................................................6-2

6.2 Dedicated Commands............................................................................................. 6-3

6.3

Use of Dedicated Command ...................................................................................6-4

6.3.1 Homing start...............................................................................................................6-4

6.3.2 Floating origin setting (Command : FLT)....................................................................6-5

6.3.3

Direct start (Command : DST)....................................................................................6-6

6.3.4

Indirect start (Command : IST)

........................................................................................6-7

6.3.5 Linear Interpolation (Command: LIN).........................................................................6-8

6.3.6 Circular Interpolation (Command: CIN)......................................................................6-9

6.3.7

Simultaneous Start (Command : SST).....................................................................6-10

6.3.8

Speed/Position Switching Control (Command : VTP)..............................................6-11

6.3.9

Position/Speed Switching Control (Command : PTV)..............................................6-12

6.3.10

Deceleration Stop (Command : STP).....................................................................6-13

6.3.11

Synchronous Start by Position (Command : SSP).................................................6-14

6.3.12

Synchronous Start by Speed (Command : SSS)...................................................6-15

6.3.13

Position Override (Command : POR).....................................................................6-16

6.3.14

Speed Override (Command : SOR).......................................................................6-17

6.3.15

Position Assigned Speed Override (Command : PSO)..........................................6-18

6.3.16

Inching Operation (Command : INCH)...................................................................6-19

6.3.17

Start Step No. Change (Command : SNS).............................................................6-20

6.3.18

Repeat Step No. Change (Command : SRS) ........................................................6-21

6.3.19

M code Release (Command : MOF)......................................................................6-22

6.3.20

Current Position Preset (Command : PRS) ...........................................................6-23

6.3.21

Encoder Preset (Command : EPRS) .....................................................................6-24

6.3.22 Single Teaching (Command: TEA).........................................................................6-25

6.3.23

Teaching Array(Command : TEAA)

.............................................................................6-26

6.3.24

Teaching Array Data Setting (Command: TWR)....................................................6-27

6.3.25

Basic Parameter Teaching (Command : TBP).......................................................6-29

6.3.26

Homing/Manual Parameter Teaching (Command : THP)......................................6-31

6.3.27

I/O Signal Parameter Teaching (Command : TSP)................................................6-33

6.3.28

Common Parameter Teaching (Command : TCP).................................................6-34

6.3.29

Operation Data Teaching (Command: TMD) .........................................................6-35

6.3.30

Parameter/Operation Data Save (Command : WRT) ............................................6-37

6.3.31

Emergency Stop (Command : EMG) .....................................................................6-38

6.3.32

Error Reset (Command : CLR) ..............................................................................6-38

6.3.33

Operation State Reading (Command: SRD)..........................................................6-39

Chapter 7 Function Block......................................................................7-1~7-37

7.1 Common Issues of Function Block.......................................................................... 7-1

7.2

Function Block of Positioning Module .....................................................................7-2

7.3

Function Block related to Module Information Read................................................7-3

7.3.1 Operation Information Read (APM_CRD) .................................................................7-3

7.3.2

Operation State Bit Information Read (APM_SRD)...................................................7-4

7.3.3

Encoder Value Read (APM_ENCRD)........................................................................7-6

7.4 Parameter/Operation Data Teaching Function Block ..............................................7-7

7.4.1 Basic Parameter Teaching (APM_SBP) ...................................................................7-7

7.4.2

Homing/Manual Parameter Teaching (APM_SHP)....................................................7-8

7.4.3

I/O Signal Parameter Teaching (APM_SIP)...............................................................7-9

7.4.4

Common Parameter Teaching (APM_SCP) ............................................................7-10

7.4.5

Operation Data Teaching (APM_SMD)....................................................................7-11

7.4.6

Single Teaching (APM_TEA)...................................................................................7-12

7.4.7

Teaching Array (APM_ATEA)...................................................................................7-13

7.4.8

Saving Parameter/Operation Data (APM_WRT).....................................................7-14

7.5 Start/Stop Function Block....................................................................................... 7-15

7.5.1 Homing Start (APM_ORG).......................................................................................7-15

7.5.2

Direct Start (APM_DST)...........................................................................................7-16

7.5.3

Indirect Start (APM_IST)..........................................................................................7-17

7.5.4

Linear Interpolation (APM_LIN) ...............................................................................7-18

7.5.5

Circular interpolation (APM_CIN).............................................................................7-19

7.5.6

Simultaneous Start (APM_SST)...............................................................................7-20

7.5.7

Deceleration Stop (APM_STP) ................................................................................7-21

7.5.8

Emergency Stop (APM_EMG).................................................................................7-22

7.6 Manual Operation Function Block ......................................................................... 7-23

7.6.1 Inching Operation (APM_INC).................................................................................7-23

7.7 Synchronization Start Function Blocks.................................................................. 7-24

7.7.1 Position Synchronization (APM_SSP).....................................................................7-24

7.7.2

Speed Synchronization (APM_SSS)........................................................................7-25

7.8 Modification Function Block................................................................................... 7-26

7.8.1 Position Override (APM_POR) ................................................................................7-26

7.8.2

Speed Override (APM_SOR)...................................................................................7-27

7.8.3 Position Assigned Speed Override (APM_PSO)......................................................7-28

7.8.4

Position/Speed Switching Control (APM_PTV)........................................................7-29

7.8.5

Speed/Position Switching Control (APM_VTP)........................................................7-30

7.8.6

Start Step Number Change (APM_SNS).................................................................7-31

7.8.7

Repeat Step No. Change (APM_SRS)....................................................................7-32

7.8.8

Current Position Change (APM_PRS).....................................................................7-33

7.8.9

Encoder Value Preset (APM_EPRE).......................................................................7-34

7.9 Error Function blocks ............................................................................................7-35

7.9.1 Error Reset (APM_RST)..........................................................................................7-35

7.10 Other Function Blocks......................................................................................... 7-36

7.10.1 Floating Origin Setting (APM_FLT)........................................................................7-36

7.10.2

M code Release (APM_MOF)................................................................................7-37

Chapter 8 Program.................................................................................8-1~8-91

8.1 Example of XBC Programming ............................................................................... 8-1

8.1.1 General description....................................................................................................8-1

8.1.2

Current State Read....................................................................................................8-1

8.1.3

Operation Test............................................................................................................8-3

8.1.4

Parameter and Operation Data Setting......................................................................8-7

8.1.5

Positioning Operation...............................................................................................8-15

8.1.6

Operation Setting Change while Operating.............................................................8-26

8.1.7

Error .........................................................................................................................8-35

8.2 Example of IEC type Programming....................................................................... 8-36

8.2.1 General description..................................................................................................8-36

8.2.2

Current State Read..................................................................................................8-36

8.2.3

Operation Test..........................................................................................................8-41

8.2.4

Parameter and Operation Data Setting....................................................................8-47

8.2.5

Positioning Operation...............................................................................................8-56

8.2.6

Operation Setting Change while Operating.............................................................8-73

8.2.7

Error .........................................................................................................................8-90

Chapter 9 Functions ..............................................................................9-1~9-99

9.1 Homing.................................................................................................................... 9-1

9.1.1 Homing method..........................................................................................................9-1

9.1.2

Parameters for Homing..............................................................................................9-1

9.1.3

Origin Detection after DOG Off..................................................................................9-2

9.1.4

Origin Detection after Deceleration when DOG On...................................................9-4

9.1.5

Origin Detection by DOG...........................................................................................9-5

9.1.6

Origin Detection by Origin and Upper/Lower Limit ....................................................9-6

9.1.7

Origin Detection by Upper/Lower Limit......................................................................9-7

9.2 Positioning Control ..................................................................................................9-8

9.2.1 Operation Data for Positioning Control......................................................................9-9

9.2.2

Operation mode of Positioning Control....................................................................9-10

9.2.3

Positioning Control...................................................................................................9-17

9.2.4

Speed Control ..........................................................................................................9-19

9.2.5

Linear Interpolation Control......................................................................................9-21

9.2.6

Designate Midpoint of Circular Interpolation............................................................9-26

9.2.7

Circular interpolation control of designating Center point........................................9-33

9.2.8

Circular interpolation control with designated radius...............................................9-41

9.2.9

Speed/Position Switching Control............................................................................9-49

9.2.10

Position/Speed Switching Control..........................................................................9-51

9.2.11

Start of Positioning .................................................................................................9-53

9.2.12

Positioning stop......................................................................................................9-55

9.3 Manual Operation Control ..................................................................................... 9-61

9.3.1 Jog Operation ..........................................................................................................9-61

9.3.2

Inching Operation.....................................................................................................9-65

9.4 Synchronous Control............................................................................................. 9-67

9.4.1 Speed Synchronous Control....................................................................................9-67

9.4.2

Position synchronous control...................................................................................9-72

9.5 Modification Function of Control............................................................................ 9-76

9.5.1 Floating Origin Setting .............................................................................................9-76

9.5.2

Position Override .....................................................................................................9-77

9.5.3

Speed Override........................................................................................................9-80

9.5.4

Positioning Speed Override .....................................................................................9-82

9.5.5

Current Position Preset............................................................................................9-85

9.5.6

Encoder Preset ........................................................................................................9-86

9.5.7

Start Step no. Change..............................................................................................9-87

9.5.8

Repeat Operation Step no. Change.........................................................................9-88

9.6 Auxiliary Function of Control .................................................................................9-90

9.6.1 Upper/Lower limit.....................................................................................................9-90

9.6.2

M code .....................................................................................................................9-92

9.7 Data Modification Function.................................................................................... 9-94

9.7.1 Teaching Array .........................................................................................................9-94

9.7.2

Parameter Change from Program ...........................................................................9-95

9.7.3

Data Change from Program.....................................................................................9-99

Chapter 10 Positioning Monitoring Package ...................................10-1~10-10

10.1 Positioning Monitoring Package.......................................................................... 10-1

10.1.1 Introduction of Positioning Monitoring Package.....................................................10-1

10.2 Menus and Functions of Positioning Monitoring.................................................. 10-3

10.2.1 Monitoring and Command......................................................................................10-3

10.3 Parameter/Operation Data Setting Using Monitoring Package........................... 10-9

10.3.1 Changing the Position Parameter..........................................................................10-9

10.3.2

Change of Position Operation Data.....................................................................10-10

Appendix 1 Positioning Error Information & Solutions.......App. 1-1~App.1-8

Chapter 1 Overview

1-1

Chapter 1 Overview

This user’s manual describes the standard of positioning module, installation method, the method to use each positioning function,

programming and the wiring with external equipment.

1.1 Characteristics

The characteristics of positioning module are as follows.

(1) The positioning module is available for XGB Series. (It can’t be used with XBM-Dx-xxS.)

(2) Various positioning control function

It has various functions needed for positioning system such as positioning control, speed control etc.

(a) Up to 150 operation data including positioning address and operation method, operation pattern is available to set for each axis.

With this operation data, positioning for each axis is carried out

(b) Various operations are available.

1) Position Control

2) Speed Control

3) Synchronous Control

4) Linear Interpolation

5) Circular Interpolation

(c) Switching Control in operation is available.

1) Position/Speed Control Switching

2) Speed/Position Control Switching.

(d) Various Homing Control Function.

1) 5 methods are available for Homing

a) The origin detection after DOG Off

b)The origin detection after deceleration in case of DOG On

c) The origin detection by DOG

d) The origin detection by DOG and upper-lower limit

e) The origin detection by upper-lower limit

2) Available to execute the positioning control (floating origin setting) from random position to the origin of machine

(3) Easy maintenance

Various data such as positioning data, parameter etc. are saved on flash memory in module. Therefore, data will be saved

forever (The frequency of writing is limited to 100,000)

(4) The number of positioning module using in one basic unit is not limited

(But, it is available to use within the range satisfied with the capacity of 5V source supply current of basic unit.)

(5) Self-diagnosis, monitoring, test by strong positioning software package is available.

(a) Monitoring (Module & External Input/output Signal) Function

(b) Reading and Saving Module Parameter/Operation Data

(c) Operation data edition of each axis is available in Excel program

(6) Applicable XGB basic unit and XG5000 version for positioning module

XGB basic unit Version

XBC – Dx-xxH V1.8 or upper

XEC – Dx-xxH V1.2 or upper

XG5000 V3.1 or upper

Chapter 1 Overview

1-2

1.2 Purpose of Positioning Control

The purpose of positioning module is to transfer the moving objects (unprocessed items, tools etc.) with setting speed

from the current position and stop them on the setting position correctly. And it also controls the position of high

precision by positioning pulse string signal as it is connected to various servo driving devices or stepping motor

control driving devices. In application, it can be used widely with engineering machine, semiconductor assembly

machine, grinder, small machine center, lifter etc.

< XGB positioning function general >

< Positioning system inner block diagram >

Chapter 1 Overview

1-3

1.3 Signal Flow of Positioning Module

1.3.1 Operating sequence

The flow of PLC system using the positioning module is as follows.

Chapter 1 Overview

1-4

1.3.2 Flow of position signal

Flow of position signal is as follows.

< XGB Positioning signal flow >

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