AXIMA Installation Manual

Transcription

1 AXIMA Installation Manual P/N Rev.: A1 Date: October 31, EMERSON Motion Control. All Rights Reserved. P/N 4002

2 AXIMA Installation Manual Information furnished by EMERSON Motion Control is believed to be accurate and reliable. However, no responsibility is assumed by EMERSON Motion Control for its use. EMERSON Motion Control reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. EMERSON Motion Control also assumes no responsibility for any errors that may appear in this document. Information in document is subject to change without notice. P/N Rev.: A1 Date: October 31, EMERSON Motion Control. All Rights Reserved. P/N

3 AXIMA Installation Manual 1997 EMERSON Motion Control. All Rights Reserved. Document Number: No part of this manual may be reproduced by any means without the written permission of EMERSON Motion Control. EMERSON Motion Control is a registered trademark of EMERSON Motion Control. Printed in U.S.A. October 1997, Revision A1 Modbus is a registered trademark of Modicon Inc. Data Highway Plus is a registered trademark of Allen-Bradley. FLM-2 SLO-BLO and Littlefuse are registered trademarks of Littlefuse Incorporated. Pheoenix is a registered trademark of Phoenix Contact Inc. Opto22 is a registered trademark of Opto22. This document has been prepared to conform to the current released version of hardware and software system. Because of our extensive development efforts and our desire to further improve and enhance the product, inconsistencies may exist between the product and documentation in some instances. Call your customer support representative if you encounter an inconsistency. ii

4 Customer Service EMERSON Motion Control offers a wide range of services to support our customer s needs. Listed below are some examples of these services. Service Support (612) EMERSON Motion Control s products are backed by a team of professionals who will service your installation wherever it may be. Our customer service center in Minneapolis, Minnesota is ready to help you solve those occasional problems over the telephone. Our customer service center is available 24 hours a day for emergency service to help speed any problem solving. Also, all hardware replacement parts, should they ever be needed, are available through our customer service organization. Need on-site help? EMERSON Motion Control provides service, in most cases, the next day. Just call EMERSON s customer service center when on-site service or maintenance is required. Training Services (612) EMERSON Motion Control maintains a highly trained staff of instructors to familiarize customers with EMERSON Motion Control s products and their applications. A number of courses are offered, many of which can be taught in your plant upon request. Application Engineering An experienced staff of factory application engineers provided complete customer support for tough or complex applications. Our engineers offer you a broad base of experience and knowledge of electronic motion control applications. Bulletin Board System (612) EMERSON Motion Control maintains a BBS which provides you access to software updates, and technical information and services. Communications protocol: 300 to 28,800 baud, N, 8, 1 FAX (612) Internet Website iii

5 AXIMA Installation Man- Table of Contents Hardware Installation Safety Considerations Mounting Requirements Selecting an Enclosure Connectors System Grounding Requirements Power Requirements Connectionsand Cabling Serial Communication COM 2 - RS422 Mode COM 2 - RS485 Mode Serial Port Specifications Serial Communication Grounding Multi-Drop Installations Controller ID Number/Address Axis Connections Encoder Signals Encoder Wiring Encoder Power Supply Analog Outputs Drive Enable Example Axis Connections Input/Output Connections Dedicated I/O User Defined I/O I/O Power Supply Battery Backup Jumpers Analog Input Option Overview Analog Inputs Connector Wiring v

6 AXIMA Installation Manual Expanded I/O Options Overview Sinking Versus Sourcing Direct Wiring Option External Components Option Connectivity Options Overview Modbus Connection Data Highway Plus Connection vi

7 AXIMA Installation Man- Hardware Installation The following installation requirements, methods and procedures are provided to assure reliable, trouble free installation and operation of your AXIMA controller. The methods and procedures outlined on the following pages include safety considerations, mounting requirements, grounding requirements and power requirements, grounding. Safety Considerations It is your responsibility to comply with the safety requirements of your system. This includes installing the system with an appropriate master interlock switch for emergency shutdown that will remove AC power from the system any time the equipment is not running or the emergency stop is activated. This reduces the possibility of electrocution or unwanted movement of the motor. The safety ground connections should only be disconnected for servicing, and only after all AC power has been removed. 1 P/N

8 AXIMA Installation Manual Mounting Requirements The AXIMA controller should be back mounted vertically in a metal NEMA enclosure. A minimum spacing of 4" must be maintained around the controller for ventilation. Figure 1 Mounting Dimensions 2

9 Hardware Installation Selecting an Enclosure The EMERSON Motion Control AXIMA controller multi-axis controller is designed for the industrial environment. However, no sophisticated electronic system can tolerate atmospheric contaminants such as moisture, oils, conductive dust, chemical contaminants and metallic particles. Therefore, if the AXIMA controller is going to be subject to this type of environment, it must be mounted in a metal enclosure with a minimum rating of NEMA 12.! CAUTION Connectors Voltages on pins 6 or 7 must not exceed ±12 VDC with respect to pin 13, analog ground. The AXIMA controller is available with two types of connectors for I/ O, axis connections and COM 2. Both connector types add to the depth of the AXIMA and should be considered when selecting an enclosure. Open Type (Emerson model # AX-STD-xx) The open connector has terminal screw access from the front and wire entry from the bottom. Hooded Type (Emerson model # AX-CBS-xx) The hooded connector has a plastic cover that covers the terminals and wire connections for a neater look. The wires enter the terminal from the front and the terminal screws are on the top. 3

10 AXIMA Installation Manual Figure 2 Input/Output Connector Clearance 4

11 System Grounding Requirements Hardware Installation The GND terminals of the AXIMA controller are internally bonded to the chassis. The enclosure GND and the AXIMA GND should be a common signal point that ultimately is a continuous path to earth ground. Figure 3 System Grounding Diagram These ground wires should not be shared with other equipment. 5

12 AXIMA Installation Manual Power Requirements The AC power connects to screw terminals on the top of the AXIMA controller chassis. The AC power input must be between 96 and 264 volts AC, single phase, 50 to 60 Hz. At 115 VAC, 1.0 amps RMS is required, at 230 VAC 0.5 amps RMS is required. However, at power up the logic supply has an in rush current that is typically 20 amps at 115 VAC and 40 amps at 230 VAC for 2 msec. This inrush current must be considered when choosing AC power fusing. Littlefuse's FLM-2 SLO-BLO type fuse or an equivalent can be used. The AXIMA controller also has a 2 amp circuit breaker built into the On/Off switch for additional AC line protection. The most significant AC power problem occurs when the secondary of the AC distribution transformer is not electrically referenced to earth ground (i.e., left floating). In this case, the voltages that develop between the AC power lines and earth ground can continuously exceed the rated voltage of 264 VAC. When this happens the protection circuit in the AXIMA controller will try to suppress this excess voltage. If the condition is prolonged, the AXIMA controller protection circuits will fail. 6

13 Hardware Installation Figure 4 AC Power Connector 7

14 AXIMA Installation Man- Serial Communication Connections and Cabling The AXIMA controller has two optically isolated serial ports (COM 1 and COM 2). COM 1 is an RS232C port. COM 2 can be configured for RS232C, RS422 or RS485 using jumpers on the daughter board located behind the hinged front cover of the AXIMA controller (see daughter drawing board below). AXIMA controller's are shipped with COM 2 in RS232C mode (jumper JP3 between pins 2 and 3). Figure 5 COM 2, RS232C Configuration Both serial ports are activated and will automatically detect the baud rate by receiving 1 carriage return after power up. Both serial ports can be open simultaneously and attached to different programs. For example, one port could be used as a programming and diagnostics port while the second port is communicating with an operator interface panel such as the EMERSON Motion Control s T-60 panel. The daughter board is mounted on the interface circuit board which is located directly behind the hinged front cover of the AXIMA controller. The cover is opened by loosening two screws on the front panel of the AXIMA controller, one on top and one at the bottom. NOTE: As baud rates increase or cable lengths get longer your susceptibility to noise increases. Therefore, if you are experiencing communication problems, it is 9 P/N

15 AXIMA Installation Manual recommended that you install a for RS485, in the R9 location. Additionally, if you determine that your system requires a terminating resistor and you are using the AXIMA controller in a multi-drop configuration, install the R9 resistor in the last AXIMA controller in your multi-drop configuration. Figure 6 Location of R9 on the Daughter Board To communicate with more than one AXIMA controller using the AXIMA Software, you must use COM 2 configured as an RS422 or RS485 connected in a multi-drop configuration. COM 2 - RS422 Mode To use COM 2 in RS422 mode, set JP3 between pins 1 and 2 and remove JP1 on the daughterboard by cutting it with a wire cutter. 10

16 Connections and Cabling COM 2 - RS485 Mode To use COM 2 in RS485 mode, set the jumper of JP3 between pins 1 and 2 and leave JP1 and JP2 in the factory positions. To create a properly terminated serial communications line, it is recommend that you terminate the host device receive lines with a 120 1/2 watt resister Figure 7 COM 2, RS485 Configuration Serial Port Specifications It is recommended that all communication lines be twisted pair shielded cable. Cables should be routed away from motor power and other high voltage or noisy wiring. Table 1 Serial Communications Setup Serial Communication Setup Max baud rate 19.2k Stop bit 1 Data bits 8 Parity none Serial Communication Grounding The AXIMA controller provides an isolated logic supply for its communication circuitry. ISO-COM is the circuit common for both COM port circuits. COM 1 and COM 2 devices, such as PC serial 11

17 AXIMA Installation Manual ports, typically have signal ground connected to earth ground internally to the PC. If your COM devices do not have signal grounds that are common with respect to each other (such as both connected to earth ground) then you must connect them together. Failure to connect device grounds together could cause damage to the device or the AXIMA controller. Figure 8 Serial Communications Grounding Diagram Serial Communication Cables The RS232 serial communication cables should be no longer than 50 feet to comply with RS232C specifications. However, longer cables may be used at slower baud rates (less than 4800). The wiring diagrams below show the TIX and TIA serial cables which are available from EMERSON Motion Control in 10, 25 and 50 foot lengths. NOTE: Non-standard lengths can be special ordered. 12

18 Connections and Cabling Figure 9 RS232C Serial Communication Cables Multi-Drop Installations If your application uses more than one AXIMA controller (up to 32 can be linked serially), each AXIMA controller must have a different ID number. This allows each AXIMA controller to be addressed individually over the same multi-drop serial cable. Controller ID numbers are set using the DIP switch SW1 on the controller circuit board located inside the AXIMA controller. There are 32 possible addresses available. Figure 10 SW1, Located on the Controller Circuit Board 13

19 AXIMA Installation Manual The figure below shows a wiring diagram for serial communications in an RS485 multi-drop configuration. Refer to the AXIMA Software User s Guide (P/N ) for information on terminal mode communications. Figure 11 RS485 Multi-Drop Wiring Diagram 14

20 Controller ID Number/Address Connections and Cabling The following table shows how the switch positions relate to the AXIMA controller axis ID number. Note that switches SW1-1 through SW1-3 are reserved and should be left in the OFF position. AXIMA ID SW1 Settings SW1-8 SW1-7 SW1-6 SW1-5 SW1-4 0 OFF OFF OFF OFF OFF 1 ON OFF OFF OFF OFF 2 OFF ON OFF OFF OFF 3 ON ON OFF OFF OFF 4 OFF OFF ON OFF OFF 5 ON OFF ON OFF OFF 6 OFF ON ON OFF OFF 7 ON ON ON OFF OFF 8 OFF OFF OFF ON OFF 9 ON OFF OFF ON OFF A OFF ON OFF ON OFF B ON ON OFF ON OFF C OFF OFF ON ON OFF D ON OFF ON ON OFF E OFF ON ON ON OFF F ON ON ON ON OFF G OFF OFF OFF OFF ON H ON OFF OFF OFF ON I OFF ON OFF OFF ON J ON ON OFF OFF ON K OFF OFF ON OFF ON L ON OFF ON OFF ON M OFF ON ON OFF ON N ON ON ON OFF ON O OFF OFF OFF ON ON P ON OFF OFF ON ON 15

21 AXIMA Installation Manual AXIMA ID SW1 Settings SW1-8 SW1-7 SW1-6 SW1-5 SW1-4 Q OFF ON OFF ON ON R ON ON OFF ON ON S OFF OFF ON ON ON T ON OFF ON ON ON U OFF ON ON ON ON V ON ON ON ON ON Axis Connections The AXIMA controller can be configured as a two, four, six, or eight axis system. On the front panel of the AXIMA controller there can be up to eight, 14 position terminal block connectors. Figure 12 AXIMA Controller Connectors (8 Axes) 16

22 Connections and Cabling Encoder Signals Encoder signals are low voltage, high frequency signals susceptible to noise if not properly shielded. For reliable operation it is important that encoder cables be shielded and routed away from motor power or other high voltage signals. Shields should be connected at the controller end. Specifications Input Signal Maximum Rate Type Voltage Supply Quadrature square wave 8 MHz. Differential Receiver, DS26LS32 5 VDC maximum, 2 VDC minimum 5 VDC 250 ma maximum per axis Encoder Wiring The encoder signals may come from an encoder or from the encoder simulation output of a brushless servo drive (see wiring diagrams below). Figure 13 Encoder Signal Wiring Diagram 17

23 AXIMA Installation Manual Figure 14 Encoder Simulation Wiring Diagram 18

24 Connections and Cabling Shown below is the wiring diagram for the ENCO cable which is available form EMERSON Motion Control in 15, 25 and 50 foot lengths. Figure 15 ENCO Encoder Cable Encoder Power Supply The AXIMA controller can be used to provide the 5 volt power source for external encoders. Connections are provided on each Axis I/O connector. The current on the 5 volt must be limited to 250 milliamps per axis and the maximum current for 8 encoders must be limited to 2 amps. Each 5 volt Encoder Supply has a 1 ohm resistor in series with the internal 5 volt logic supply, thus excessive currents will lower the voltage supplied to the encoder. Analog Outputs The AXIMA controller's analog command output to the servo amplifier is a precision 16 bit output. These signals are susceptible to noise if not properly shielded. For reliable operation it is important that command cables be shielded and routed away from motor power or other high voltage signals shields should be connected at the AXIMA controller end. The input stage of the amplifier should be a differential circuit. The output voltage is ± 10 VDC, output current is 5 ma maximum. 19

25 AXIMA Installation Manual Figure 16 Command Output Drive Enable Each axis has a Drive Enable relay contact. The contact has a maximum rating of 30 VDC and is capable of switching 0.5 amps for a resistive load. All Drive Enable relays are interlocked with the Watchdog relay. Each relay is also individually energized by one of the general purpose outputs. Axis 1 Drive Enable is energized by output 32, Axis 2 drive enable is energized by output 33 and so on. The drive enable outputs can be used as required by the application. For example, a drive enable output can be used for each amplifier or 20

26 Connections and Cabling one drive enable output can be wired to enable all the amplifiers to conserve general purpose outputs Figure 17 Drive Enable Circuit NOTE: It is recommended that the Drive Enable relay contacts be used. If these contacts are not used, physically connecting a drive (MX, LX or other) to the controller while that drive is enabled may cause unwanted motion. 21

27 AXIMA Installation Manual In the event the Drive Enable contacts are not used, the following power sequence must be followed: 1. Apply power to the AXIMA controller. 2. Apply power to the drives. 3. Enable the drives. 4. Normal machine operation. 5. Disable or power down the drives. 6. Power down the AXIMA controller. Example Axis Connections If desired, the AXIMA controller can be used to generate a torque or current command instead of a speed command. When the drives are used in torque mode, the drive velocity loop gain adjustments no longer need to be considered. This can simplify the tuning procedure for some applications. MX Drives To operate an MX drive in torque mode, set the command selector bit bø6 in the MX drive, to 1. Refer to the MX Drives Setup and Programming Operator s Manual (P/N ) for detailed information on setting and saving this bit status. LX Drives To operate an LX drive in torque mode, connect the AXIMA controller command wires to the Current CMD and Common inputs on the LX drive (terminal pins 2 and 3) as shown in Figure

28 Connections and Cabling Figure 18 LX Drive Torque Mode Wiring Diagram The current command input of the LX amplifier is a single ended input not a differential input. If the CMD output of the AXIMA controller is mistakenly connected to the common input of LX, this could damage the AXIMA controller analog output signal. Since the input is single ended, it will be more susceptible to noise. Be sure the LX common pin number 11 and the AXIMA controller Logic GND terminals are connected to a single point ground as shown in Figure 4. When the LX amplifier is used in current mode, the LX I 2 t (high RMS) circuitry is by-passed and does not fold back the current to the motor. To prevent damage to the amplifier or motor, the high RMS output of the LX must be connected to an AXIMA controller input. This input must be programmed to limit the AXIMA controller command voltage using the command limit instruction to decrease or shut off the analog command. This input could also be used to turn off the drive enable output. When using the LX drive in current mode the LX limit switch inputs are inactive. 23

29 AXIMA Installation Manual AXIMA To LX Drive Connections (Velocity Mode) The wiring diagram below shows the typical command connections between the AXIMA controller and an LX drive (operating in velocity mode). Figure 19 AXIMA to LX Drive Connections (Velocity Mode). AXIMA To MX Drive Connections The wiring diagram below shows the typical command connections between the AXIMA controller and an MX drive. Figure 20 AXIMA to MX Drive Connections. 24

30 Connections and Cabling Input/Output Connections The AXIMA controller has 64 general purpose optically isolated I/O points. 32 inputs and 32 outputs. An LED indicator on the front of the AXIMA controller is associated with each I/O point. The input and output indicators will illuminate if current is flowing in the associated line. Inputs are numbered 0 through 31 and outputs are labeled 32 through 63. Dedicated I/O Watchdog Output If the hardware on the AXIMA controller board detects a Watchdog timer fault the Watchdog (WD) output circuit is open. The circuit is closed under normal operating conditions. The Watchdog contacts are rated for maximum 30 VDC and 0.5A for a resistive load. The decimal points on the status display indicate the condition of Watchdog output. Figure 21 Watchdog (WD) Output Circuit User Defined I/O Inputs The inputs can be wired for either sink or source mode in groups of four. The input voltage range is 10 to 30 VDC. Each input line 25

31 AXIMA Installation Manual requires a minimum of 2mA at 10 VDC to be recognized as a valid input. Figure 22 Sourcing Mode Input Diagram 26

32 Connections and Cabling Figure 23 Sinking Mode Input Diagram Special Purpose Inputs Inputs 24 through 31 can be assigned to trigger the high speed hardware encoder position capture function. Only these inputs have direct connection to the encoder DSP gate arrays. If your application requires accurate positioning or measurements based inputs from sensors or switches, inputs 24 through 31 should be used. See the position capture input table below. 27

33 AXIMA Installation Manual Since these inputs go through filtering and optoi-solation, there is a 10 microsecond delay from the time the input is turned on until the position is captured. The capture can be programmed to trigger on rising or falling edge of the input. Due to the characteristics of the optoisolaters, faster triggering speeds can be obtained by using the rising edge. See the Home and Encoder Capture Instructions in the AXIMA Software Reference Manual (P/N ). Outputs Encoder Input Signals Position Capture Input 1 24 or or ro or or or or or 31 Outputs can be operated in sink mode only. Maximum allowable output voltage is 30 VDC, maximum current is 150 ma per output. Outputs 32 through 39 are connected to the Axis Enable relay coils for Axis 1 through 8 respectively. If an Axis Enable contact is not used the associated output can be used as a general purpose output. NOTE: It is your responsibility to limit the current to 150 ma or less If the Axis Enable contact is used this output can still be used for such functions as signaling a PLC the status of the Axis Enable output or driving a solid-state relay to release a motor brake. If inductive loads such as DC relay coils or solenoids are connected to 28

34 Connections and Cabling the outputs, a suppression diode must installed in parallel with the load. Figure 24 Output Circuit I/O Power Supply The AXIMA controller requires an I/O power supply which must be supplied by the user. This supply is the "machine side" of the inputs and outputs and also provides power for the Drive Enable and watch dog timer relay coils and the I/O LED indicators. The system is designed to operate from a 24 volt power supply but will function between 18 VDC and 30 VDC. NOTE: For situations where all 32 inputs, 32 outputs and 9 relays are being used simultaneously, your power supply must supply at least volts. Each input requires 5 24 VDC (2 10 VDC) to activate. When an input is activated an input LED indicator is also activated 29

35 AXIMA Installation Manual which draws an additional 10 24V per input from the power supply. Each output requires 5 24 VDC to activate the indicator LED. Each output can sink up to 150 ma to drive a load. Outputs # 32 through 39 require an additional 8.3 ma each to drive the drive enable relays. Your power supply must be sufficient enough to supply minimum current to all inputs, outputs and relays simultaneously in the event that all inputs, outputs and relays are being used simultaneously. Each Input: (number of inputs) * (5mA + 10mA) Each Output: (number of outputs) * (5mA + Load Current) Outputs # 32-39: (number of outputs 32-39) * (8.3mA) Watch Dog Relay: 8.3mA Suppose you had four inputs (# 1 through 4), and four outputs (# 1 and 2 & 32 and 33) with a 150 ma load, and your power supply was 24VDC, in the worst case scenario (all inputs and outputs are being used simultaneously) the current load on the power supply would be amps. This value was found using the following formula: (15mA * 4 IN) + (155mA * 4 OT) + (8.3mA * 2 R) + (WDR) = amps Where: IN = inputs OT = outputs R = relays on outputs #32 and 33 WDR = Watchdog Relay (8.3mA) 30

36 Connections and Cabling Battery Backup Jumpers There are two jumpers located on the AXIMA controller's daughterboard which determine if the battery pack is enabled or disabled. When enabled, user programs stored in the AXIMA controller's memory are retained when power is removed. AXIMA controller's are shipped with the jumpers in the enabled position (default factory setting) as shown in the drawing below. NOTE: The AXIMA controller's battery pack has a life expectancy of approximately 10 years. To clear non-volatile RAM memory, turn power off and remove the jumpers. Figure 25 Battery Pack Enable Jumpers It is recommended that you leave the jumpers in the enabled position so that your programs can be retained. You can use the generic instruction BRESET to disable the battery and clear all non-volatile RAM locations. Refer to the AXIMA Generic Instructions Reference Manual (P/N ) for a description of the BRESET Instruction. If you wish to save the application currently in the AXIMA controller, you must copy it to your PC (or a floppy disk) before using the BRESET Instruction and powering down. 31

37 AXIMA Installation Man- Overview Analog Input Option An analog input feature is available as a factory option. It allows the AXIMA controller to accept single-ended and differential inputs. You can configure these inputs with up to eight single-ended inputs, four differential inputs or combinations of single and differential inputs. NOTE: If you wish to add the Analog Input Option to an existing AXIMA controller, it must be returned to the factory. The AXIMA controller takes raw voltage (±10 volts) from the analog input terminal and converts it to user units. Each analog input channel can be assigned to a Pre-defined Variable which can be used in a Motion or an Auxiliary Program. 33 P/N

38 AXIMA Installation Manual The analog input is located in the center right of the AXIMA controller s front panel. The maximum input voltage is ±10 VDC. Figure 26 Location of Analog Inputs Analog Inputs Connector Wiring The diagrams below show single-ended and differential configurations. Single-ended wiring configurations are with respect to the common C terminal. For example, voltages between input terminals 1 and C, input terminals 2 and C, etc. Differential wiring means that the voltage is measured between a pair of terminals. For example, voltage between input terminals 1 and 2, 3 and 4.! CAUTION The maximum voltage between any input terminal and 'C' is ±10 VDC. 34

39 Analog Input Option Figure 27 Single Ended Versus Differential Wiring Figure 28 Analog Input Circuit Using the AXIMA Software, any software channel can be attached to any hardware channel or pair of hardware channels. This gives you the flexibility to determine how the channel attachments are configured. If you choose a single-ended connection type, the negative terminal is automatically connected to terminal C. A reverse-polarity singleended channel is not allowed. When using a differential configuration, the AXIMA controller s A/D converter measures the difference between two hardware channels and directs the value to a software channel. The AXIMA controller does not allow you to assign terminal number 1 as the negative input. To measure differential values between terminal 1 and another terminal, the polarity must be reversed by connecting the positive input to terminal 1, and connecting the negative input to the desired terminal. 35

40 AXIMA Installation Man- Expanded I/O Options Overview There are two options for wiring the expanded I/O; by using direct wiring or external components. The direct wiring option is exactly that. All connections are directly wired from the AXIMA controller to the individual drives. The external components option uses the XIOR-32 mounting rack and digital input and output modules to control the I/O connections. All communication and feedback is wired independently. Sinking Versus Sourcing In a sinking input situation the current flows from the external source to the input terminal. The input is high. In a sourcing situation the current flows from the input terminal to the external circuit. The input is low. In a sinking output situation the current can flow from the external circuit into the output terminal. The output is low. In a sourcing output situation the current can flow from the terminal to the external circuit. The output is high. Direct Wiring Option Using the direct wiring option, the expanded inputs and outputs can be wired directly to the bottom of the AXIMA controller using a ribbon cable as sinking I/O only. To use the direct wiring option, you must meet the following criteria: For Inputs: Electrical specs of 24 VDC and less than 11 ma of current. 37 P/N

41 AXIMA Installation Manual For Outputs: Electrical specs of 24 VDC and less than 40 ma of current. Specifications For Direct Wiring Option The equivalent circuits of the expanded I/O, electrical specifications and the pin assignments are shown below. You are responsible for determining if your 24 VDC supply can handle the additional current load. Figure 29 Expanded Input Equivalent Circuit (Sinking) Figure 30 Expanded Output Equivalent Circuit (Sinking) Use the Table on the following page to determine the pin assignments of the 50 pin input and output connectors located on the bottom panel of the AXIMA. 38

42 Expanded I/O Options Table 7 Expanded I/O Pin Assignments Inputs Pin Assignments Outputs Pin Assignments Input Number Pin Number Input Number Pin Number

43 AXIMA Installation Manual Figure 31 Expanded I/O Connectors (Bottom View of AXIMA Controller) External Components Option If your I/O devices do not meet the criteria established for the direct wiring option, then external components are required. These components must be assembled and wired by the user. External components include I/O mounting rack(s), digital input modules, digital output modules and connectorized ribbon cables, all of which are available from EMERSON Motion Control. With the external components option your electrical specifications are determined by the module you select. These modules allow you to wire the I/O for sinking or sourcing. There is some time delay inherent in these devices that should be accounted for in time critical applications. 40

44 Expanded I/O Options Quantities of the external components required depend on the number of expanded I/O used. For example, for the full use of 32 expanded inputs and 32 expanded outputs, the required quantities are: (2) I/O mounting racks (32) Digital input modules (P/N IDC-24-G4 or IAC-24-G4) (32) Digital output modules (P/N ODC-24-G4 or OAC-24-G4) (2) Connectorized ribbon cables (P/N XIOR-XXX) Digital Module Specifications From these specifications you can choose the type of module needed for your particular application. Additional digital I/O modules are also available from Opto 22 in a variety of specifications. Table 8 Digital I/O Module Specifications Digital Input And Output Module Specifications G4ODC24 Digital DC output module G4OAC24 Digital AC output module Input voltage range VDC VAC Input voltage nominal 24 VDC 120 VAC Input nominal 16 ma 9 ma rms Logic voltage nominal 24 VDC 24 VDC Logic 24 VDC 18 ma 18 ma Turn on time 5 ms 20 ms Turn off time 5 ms 20 ms G4ODC24 Digital DC output module G4OAC24 Digital AC output module Output voltage range 5-60 VDC VAC Output voltage maximum 60 VDC 120 VAC Output max voltage Off state max voltage 3 amps 3 amps rms 1 ma 5 ma rms Logic voltage nominal 24 VDC 24 VDC Logic 24 VDC 18 ma 18 ma 41

45 AXIMA Installation Manual Digital Input And Output Module Specifications Logic pickup voltage 19.5 VDC 19.5 VDC Logic dropout voltage 1 VDC 1 VDC Turn on time 50 usec 8.3 msec Turn off time 50 usec 8.3 msec Hardware Configuration and Assembly The figure below shows the external connections required when using the expanded I/O's in conjunction with digital I/O modules. For the direct wiring option, the mounting racks and modules are not used and the ribbon cables would be connected to a terminal strip interface. Figure 32 Hardware Setup for External I/O Mounting Racks 42

46 Expanded I/O Options 24 VDC Power Supply Loading You are responsible for determining if your 24 VDC supply can handle the additional current load. When using 24 VDC modules: Inputs (on): 45 ma per input. Outputs (on): (Load current + 21 ma) per output.* Outputs (off): 3 ma per output. When using 120 VAC modules: Inputs (on): 29 ma per input. Outputs (on): 21 ma per output. Outputs (off): 2.4 ma per output. * The load current for the output modules must be limited to no more than 3 amps. Figure 33 Power Wiring for External I/O Mounting Racks EMERSON Motion Control recommends that you use twisted pairs for the 24 VDC power wiring. 43

47 AXIMA Installation Manual Connection Diagrams For Mounting Rack Input Connections Figure VDC Digital Input Module Connection Diagram For sinking inputs Switch on the 24 VDC common as shown in the diagram above and wire 24 VDC to the other terminal. For sourcing inputs Switch 24 VDC as shown in the diagram above, and wire 24 VDC common to the other terminal. When wiring inputs, you can wire the switch to either the Odd or Even Terminal. 44

48 Expanded I/O Options Figure VAC Digital Input Module Connection Diagram For sinking inputs Switch on the neutral as shown in the diagram above and wire 120 VAC to the other terminal. For sourcing inputs Switch 120 VAC as shown in the diagram above, and wire neutral to the other terminal. When wiring inputs, you can wire the switch to either the Odd or Even Terminal. 45

49 AXIMA Installation Manual Output Connections Figure VDC Digital Output Module Connection Diagram For sinking outputs Wire the load to the Odd # Terminal on the mounting rack. Tie the other side of the load to 24 VDC. The 24 volt common should be wired to the Even # Terminal. For sourcing outputs Wire 24 VDC to the Odd # Terminal on the mounting rack. Wire the load to the Even # Terminal. Tie the other side of the load to 24 volt common. If your load is inductive, it is recommended to use a commutating diode across the load to clamp any voltage transients during switching. 46

50 Expanded I/O Options Figure VAC Digital Output Module Connection Diagram For sinking outputs Wire the load to the Odd # Terminal on the mounting rack. Tie the other side of the load to 120 VAC. Neutral should be wired to the Even # Terminal. For sourcing outputs Wire 120 VAC to the Odd # Terminal on the mounting rack. Wire the load to the Even # Terminal. Tie the other side of the load to Neutral. 47

51 AXIMA Installation Man- Connectivity Options Overview Modbus and Data Highway Plus (DH+) are factory options that allow the AXIMA controller to communicate with the Modicon Modbus serial communication protocol or Allen Bradley s Data Highway Plus. NOTE: The AXIMA controller can be equipped with either Modbus or DH+. They cannot be used simultaneously. AXIMA controller equipped with the Modbus option have two serial connectors on the left-side of the AXIMA controller, Com 3 and Com 4. Com 3 is an RS-232C nine-pin DB connector and Com 4 is an RS- 485 six-pin Phoenix connector used for multi-drop systems. AXIMA controller equipped with the DH+ option are equipped with one serial connector (Com 4) on the left-side of the AXIMA controller. Com 4 is an RS-485 six-pin Phoenix connector. 49 P/N

52 AXIMA Installation Manual Figure 38 Bottom Plate Showing Com 3 and Com 4. The figure above shows the Modbus configuration with the Com 3 and Com 4 connectors. When equipped The DH+ option, only Com 4 (six-pin Phoenix connector) would be available. 50

53 Connectivity Options Modbus Connection The RS-232C serial port Com 3 (nine pin DB connector) pin-out is shown below. Pin 1 Shield 2 RX (Receive) 3 TX (Transmit) Data (+) 5 Signal Ground 6 NC (No Connect) 7 RTS (Request to Send) 8 CTS (Clear to Send) Data (-) Signal The RS-485 serial port Com 4 (six-pin Phoenix connector) pin-out is shown below. Pin 1 is internally connected to 4, pin 2 is connected to pin 5, and pin 3 is connected to pin 6. Pin Data (+) 2 Signal Ground Data (-) Data (+) 5 Signal Ground Data (-) Signal 51

54 AXIMA Installation Manual Data Highway Plus Connection The DH+ network connections are available using the six-pin Phoenix connector (Com 4). The connector pin-out is shown below. Pin Signal "Blue Hose" wires 1, 4 Line 1 (485 Data +) Clear 2, 5 Shield (bare) 3, 6 Line 2 (485 Data -) Blue 52