Specifications

ManualsBrandsChannel Master ManualsData Input DevicesCM-6104

User Guide Feedback Please send your comments to our email address: 6000user@cmotor.com

ABOUT THIS GUIDE

Chapter 1. Installation

What You Should Have (ship kit)........................................................... 2

Before You Begin ..................................................................................... 2

Recommended Installation Process............................................. 2

Electrical Noise Guidelines........................................................... 2

General Specifications............................................................................ 3

Pre-installation Adjustments................................................................... 4

Selecting Series or Parallel Motor Wiring.................................... 4

DIP Switch Settings – Motor Current, Address, Autobaud.......... 5

Changing the COM 2 Connector from RS-232 to RS-422/485... 6

Mounting the ZETA6104.......................................................................... 7

Electrical Connections............................................................................ 8

Verify Factory-Wired Connections............................................... 8

Pulse Cut-Off (P-CUT) — Emergency Stop Switch................... 8

Serial Communication................................................................... 9

Motor (Zeta motors only)............................................................. 10

End-of-Travel and Home Limit Inputs......................................... 11

Encoder......................................................................................... 12

Trigger Inputs................................................................................ 13

General-Purpose Programmable Inputs & Outputs................... 14

RP240 Remote Operator Panel................................................... 18

Input Power................................................................................... 18

Lengthening I/O Cables ................................................................ 19

Testing the Installation........................................................................... 20

Matching the Motor to the ZETA6104 (OPTIONAL)........................... 22

Mounting & Coupling the Motor............................................................ 24

Mounting the Motor....................................................................... 24

Coupling the Motor....................................................................... 25

Optimizing System Performance (OPTIONAL)................................. 26

Configuring Active Damping........................................................ 26

Configuring Electronic Viscosity (EV)........................................ 29

Record Your System's Configuration.................................................. 30

Recommended Set-up Program Elements................................ 30

What's Next?......................................................................................... 32

Program Your Motion Control Functions.................................... 32

Chapter 2. Troubleshooting

Troubleshooting Basics......................................................................... 34

Reducing Electrical Noise........................................................... 34

Diagnostic LEDs........................................................................... 34

Test Options.................................................................................. 34

Technical Support......................................................................... 34

Common Problems & Solutions........................................................... 35

Troubleshooting Serial Communication Problems............................. 36

Product Return Procedure.................................................................... 37

Appendix A (Resonance, Ringing & Damping).......................... 39

Appendix B (Using Non-Compumotor Motors)......................... 43

Index.................................................................................................. 47

Purpose of This Guide

This document is designed to help you install and troubleshoot your ZETA6104 hardware

system. Programming related issues are covered in the 6000 Series Programmer's Guide and

the 6000 Series Software Reference Guide.

“ZETA6104” Synonymous with “6104”

The ZETA6104 product is often referred to the as the “6104” because it is part of the 6000

family of products. The ZETA6104's software and the 6000 Series software documentation

(e.g.,

6000 Series Software Reference Guide

) refer to this product as the “6104.”

What You Should Know

To install and troubleshoot the ZETA6104, you should have a fundamental understanding of:

• Electronics concepts, such as voltage, current, switches.

• Mechanical motion control concepts, such as inertia, torque, velocity, distance, force.

• Serial communication and terminal emulator experience: RS-232C and/or RS-485

Related Publications

• 6000 Series Software Reference Guide, Parker Hannifin Corporation, Compumotor

Division; part number 88-012966-01

• 6000 Series Programmer’s Guide, Parker Hannifin Corporation, Compumotor Division;

part number 88-014540-01

• 6000 Series Following User Guide, Parker Hannifin Corporation, Compumotor

Division; part number 88-014217-01

• Motion Architect User Guide, Parker Hannifin Corporation, Compumotor Division; part

number 88-013056-01

• Current Parker Compumotor Motion Control Catalog

• Schram, Peter (editor). The National Electric Code Handbook (Third Edition). Quincy,

MA: National Fire Protection Association

Summary of content (52 pages)

PAGE 1
ABO U T T H I S Chapter 1. Installation What You Should Have (ship kit) ........................................................... 2 Before You Begin ..................................................................................... 2 Recommended Installation Process ............................................. 2 Electrical Noise Guidelines ........................................................... 2 General Specifications ............................................................................
PAGE 2
PAGE 3
1 CHAP T E R ONE Installation IN THIS CHAPTER • • • • • • • • • • • Product ship kit list Things to consider before you install the ZETA6104 General specifications table Optional pre-installation alterations - Selecting series or parallel motor wiring - DIP switch settings – motor current, device address, autobaud feature - Changing the COM 2 port from RS-232C to RS-422/485 Mounting the ZETA6104 Connecting all electrical components (includes specifications) Testing the installation Matching the motor to
PAGE 4
What You Should Have (ship kit) Part Name Part Number One of the following line items: ZETA6104 standard product (with ship kit) ............................. ZETA6104 ZETA6104 with expanded memory (with ship kit).................. ZETA6104-M If an item is missing, call the factory (see phone numbers on inside front cover). Ship kit: 120VAC power cord ....................................................... 44-014768-01 Motor connector..............................................................
PAGE 5
General Specifications P a r a me t e r S pe c if ic a t ion Power AC input .................................................................... 95-132VAC, 50/60Hz, single-phase (refer to page 18 for peak power requirements, based on the motor you are using) Status LEDs/fault detection...................................... Refer to Status LEDs in Chapter 2 Environmental Operating Temperature ..........................................
PAGE 6
Pre-installation Adjustments Factory Settings May Be Sufficient (if so, skip this section) • • • • Zeta motors are pre-configured for series operation Motor current is factory set for the Zeta motor if it was ordered with the ZETA6104 Device address is set to zero (if daisy-chaining you can automatically establish with the ADDR command) Serial communication method is RS-232C Selecting Series or Parallel Motor Wiring Zeta Motor Curves oz-in (N-m) 75 (0.53) 60 (0.42) 45 (0.32) 30 (0.
PAGE 7
DIP Switch Settings – Motor Current, Address, Autobaud Move the Cover Top View of ZETA6104 CAUTION Do not set switches 6-11 to ON at the same time. This invokes a factory test mode in which the ZETA6104 executes a motion sequence upon power up.
PAGE 8
Changing the COM 2 Connector from RS-232 to RS-422/485 RS-232C Users COM 2 +5V Rx+ GND Rx– Rx Tx+ Tx Tx– SHLD GND RS-422/485 (optional) The ZETA6104's COM 2 port is factory configured for RS-232C communication (use the left-hand pin descriptions). If you do not need to use RS-422/485 communication, you may ignore this section and proceed to the Mounting instructions. RS-232 (factory default) Remove the two retainer screws.
PAGE 9
Mounting the ZETA6104 Before you mount the ZETA6104 Make sure you have performed all the necessary configuration tasks that require accessing internal components (DIP switches, potentiometers, and jumpers). You may be able to adjust DIP switches and pots after mounting, if you allow access to the top of the ZETA6104 chassis. • Select motor current (DIP switches). If you ordered a Zeta motor with your system and you intend to use series motor winding, use the factory setting.
PAGE 10
Electrical Connections Verify Factory-Wired Connections COM 1 Rx Tx GND SHLD +5V Rx+ GND Rx– Rx Tx+ Tx Tx– SHLD GND COM 2 ENCODER SHLD GND Z– Z+ B– B+ A– A+ +5V LIMITS GND HOM NEG POS I/O TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P P-CUT connected to GND. 6104 INDEXER DRIVE ZETA I/O POWER STEP OVER TEMP MOTOR FAULT INTERLOCK A CENTER TAP A+ EARTH B+ MOTOR A- TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P +5V connected to OUT-P, IN-P & AUX-P.
PAGE 11
Serial Communication RS-232C Connections RS-232C Daisy-Chain Connections* Unit 0 Tx Rx GND Rx Tx GND SHLD +5V Rx+ GND Rx– Rx Tx+ Tx Tx– SHLD GND COM 1 Tx Rx GND COM 2 Standard 25-Pin COM Port Pin Outs: Pin 3 = Transmit (Tx) Pin 2 = Receive (Rx) Pin 5 = Ground (GND) Pin 2 = Transmit (Tx) Pin 3 = Receive (Rx) Pin 7 = Ground (GND) Unit 2 Rx Tx GND SHLD Rx Tx GND SHLD Daisy Chain to a Computer or Terminal Unit 0 Unit 1 Rx Tx GND SHLD Serial Port Connection Standard 9-Pin COM Port Pin Outs: Unit
PAGE 12
Motor (Zeta motors only) WARNING REMOVE AC POWER FIRST before connecting or disconnecting the motor. Lethal voltages are present on the screw terminals. Zeta Motor Cable Color Codes Series Connection Yellow Blue Red Black Shield * White Green Orange Brown 6104 INDEXER DRIVE ZETA This is the way the Zeta motor is shipped from the factory. Zeta motor cable * Shield is connected to the motor case and to the ground pin on the ZETA6104's AC power connector. Do not lengthen or remove this jumper.
PAGE 13
End-of-Travel and Home Limit Inputs NOTES • Motion will not occur until you do one of the following: - Install end-of-travel (POS & NEG) limit switches - Disable the limits with the LHØ command (recommended only if load is not coupled) - Change the active level of the limits with the LHLVL command • Refer to the Basic Operations Setup chapter in the 6000 Series Programmer's Guide for in-depth discussions about using end-of-travel limits and homing.
PAGE 14
Encoder CONNECTIONS & INTERNAL SCHEMATICS ENCODER Connector Internal Schematic Max. Cable Length is 100 feet. Use 22 AWG wire. Shield Shield Ground Black Z Channel – Orange/White Z Channel + Orange B Channel – Green/White B Channel + Green A Channel – Brown/White A Channel + Brown +5VDC Red SHLD GND Isolated Ground ZZ+ Same Circuit B- as A Channel B+ AA+ +5V Chassis Ground +1.
PAGE 15
Trigger Inputs Internal Schematic ENCODER Connector TRG-A/B connected to GND (normally-open switches). SHLD GND ZZ+ BB+ AA+ +5V The active level (default is active low) can be changed with the INLVL command. These inputs are like the general-purpose inputs on the 50-pin header. The differences are (1) the triggers are pulled up via the AUX-P pull-up terminal; and (2) the triggers can be programmed with the INFNCi-H command to function as position capture inputs and registration inputs.
PAGE 16
General-Purpose Programmable Inputs & Outputs VM50 ADAPTOR — for screw-terminal connections Color stripe (pin #1) 1 PROGRAMMABLE I/O 2-Foot Cable (provided with VM50) 50 Pin outs on the VM50 are identical to the pin outs for the 50-pin connectors (only if the cable is connected as illustrated). Color stripe (pin #1) The VM50 snaps on to any standard DIN rail.
PAGE 17
INPUT CONNECTIONS — Connecting to electronic devices such as PLCs Connection to a Sinking Output Device Electronic Device ZETA6104 GND ISO GND +5V The output should be able to sink at least 1mA of current. Pulled up to +5V (sourcing) Out 5-24 Volts +5VDC IN-P Output Input Connection Ground Ground Connection 6.8 KΩ 74HCxx 47 KΩ PROGRAMMING TIP Connecting to a sinking output? Set the input's active level to low with the INLVL command (Ø = active low).
PAGE 18
OUTPUT CONNECTIONS (includes OUT-A) — for electronic devices such as PLCs Connection to a Sinking Input (active high) External Supply (up to 24VDC) Electronic Device + Connection to a Sourcing Input (active low) – External Supply (up to 24VDC) Electronic Device ZETA6104 GND + – ZETA6104 GND ISO GND ISO GND +5V +5V +5VDC +5VDC OUT-P Input Output Connection Ground Ground Connection V+ OUT-P Input Output Connection Ground Ground Connection 4.7 KΩ 4.
PAGE 19
THUMBWHEEL CONNECTIONS — for entering BCD data Connection to the Compumotor TM8 Module TM8 Thumbwheel Module + 1 2 3 4 5 6 7 8 +5 GND I5 I4 I3 I2 I1 O5 O4 O3 O2 O1 ZETA6104 Programmable Input #1 Programmable Input #2 Programmable Input #3 Programmable Input #4 Programmable Input #5 Pin #49 (+5VDC) Pin #48 (GND) Programmable Output #1 Programmable Output #2 Programmable Output #3 Optional Sign Bit Connection to your own Thumbwheel Module Input #9 (sign) Input #8 MSB Input #7 Input #6 Input #5 LS
PAGE 20
RP240 Remote Operator Panel RP240 Connections when using RS-422/485 Optional Grounding Connection SHLD GND Z– Z+ B– B+ A– A+ +5V LIMITS GND HOM NEG POS I/O TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P 1 2 PROGR PORT1........Select COM 1 as the affected port. DRPCHK1.... On powerup, check for RP240 on COM 1. PORT2........Select COM 2 as the affected port. DRPCHKØ.... On powerup, do not check for RP240 ..................on COM 2.
PAGE 21
Lengthening I/O Cables Bear in mind that lengthening cables increases noise sensitivity. (The maximum length of cables is ultimately determined by the environment in which the equipment will be used.) If you lengthen the cables, follow the precautions below to minimize noise problems. • Use a minimum wire size of 22 AWG. • Use twisted pair shielded cables and connect the shield to a SHLD terminal on the ZETA6104. Leave the other end of the shield disconnected.
PAGE 22
Testing the Installation WARNING This test procedure allows you to control I/O and produce motion. Make sure that exercising the I/O will not damage equipment or injure personnel. We recommend that you leave the motor uncoupled from the load, but if you have coupled the load to the motor, make sure that you can move the load without damaging equipment or injuring personnel.
PAGE 23
Connections Test Procedure Response Format (left to right) End-of-travel and Home Limits NOTE: If you are not using end-of-travel limits, issue the Disable Limits (LHØ) command and ignore the first two bits in each response field. TLIM response: bit 1= POS (positive travel) limit bit 2= NEG (negative travel) limit bit 3 = HOM (home) limit 1. Enable the hardware end-of-travel limits with the LH3 command. 2. 3. 4. 5. 6. Close the end-of-travel switches and open the home switch. Enter the TLIM command.
PAGE 24
Matching the Motor to the ZETA6104 (OPTIONAL) Due to slight manufacturing variations, each motor has its own particular characteristics. In the procedure below, you will adjust three potentiometers (pots), to match your ZETA6104 to your specific motor. You will also select the best current waveform to use with your motor. If you purchased a ZETA6104 system (ZETA6104 and Zeta motor together), the ZETA6104 and the Zeta motor were matched to each other at the factory.
PAGE 25
Step 3 Run your motor at the resonant speed listed in the Offset Adjust column. Vary the speed slightly until you find the resonance point. To initiate motion, type these commands (followed by a carriage return) to the ZETA6104 from the terminal emulator: MC1 (This command makes the motion run continuously until you issue a !S command.) Vn (This command sets the velocity to n . For example, V4.66 sets the velocity to 4.66 rps.) GO (This command initiate motion.
PAGE 26
Mounting & Coupling the Motor WARNINGS • • • Improper motor mounting and coupling can jeopardize personal safety, and compromise system performance. Never disassemble the motor; doing so will cause contamination, significant reduction in magnetization, and loss of torque. Improper shaft machining will destroy the motor’s bearings, and void the warranty. Consult a factory Applications Engineer (see phone number on inside of front cover) before you machine the motor shaft.
PAGE 27
Coupling the Motor Align the motor shaft and load as accurately as possible. In most applications, some misalignment is unavoidable, due to tolerance buildups in components. However, excessive misalignment may degrade your system’s performance. The three misalignment conditions, which can exist in any combination, are illustrated below. The type of misalignment in your system will affect your choice of coupler (described below).
PAGE 28
Optimizing System Performance (OPTIONAL) The ZETA6104 is equipped with three damping circuits that minimize resonance and ringing, and thus enhance stepper performance: The ZETA6104 automatically switches between the damping circuits, based upon the motor’s speed. • Anti-Resonance – General-purpose damping circuit. The ZETA6104 ships from the factory with anti-resonance enabled (see DAREN command). No configuration is necessary.
PAGE 29
Step 2 Establish appropriate inductance and static torque settings. If you ordered your ZETA6104 and Zeta motor together as a system, these setting were made at the factory (they are automatically saved in battery-backed RAM). Use the DMTIND command to set the inductance, and use the DMTSTT command to set the static torque (see table below). Zeta Motor --- INDUCTANCE --Range DMTIND MH Setting --- STATIC TORQUE --Range DMTSTT N-m Oz-in Setting ZETA57-51S 20.08 & greater DMTIND1 * 0.26 – 0.
PAGE 30
Step 4 Make a baseline move with active damping disabled. This is your baseline move. Notice the sound, amount of motor vibration, etc. This move shows how your system operates with anti-resonance enabled, and active damping disabled. Each time you adjust the DACTDP setting (in steps 5-7), you will compare results against this baseline move. 1. Issue the DACTDPØ command to disable active damping. 2. Make a move that is representative of your application, with similar velocity and acceleration.
PAGE 31
Configuring Electronic Viscosity (EV) Before You Start • If you configured active damping (see procedure above), leave the DACTDP setting set at the value you chose. You do not need to disable active damping while you configure EV. • Couple the motor to the load (see pages 24-25 for details). EV must be configured under the normal mechanical operating conditions for your application. • Record the DELVIS command setting.
PAGE 32
Record Your System's Configuration You may wish to record your configuration information in the chart below.
PAGE 33
Set-up Program Example (as viewed in the terminal emulator) Assumptions: The ZETA6104 is used with a Zeta83-93 motor wired in series. RS-232C is connected to the COM 1 serial port. An RP240 is connected to the COM 2 serial port.
PAGE 34
What's Next? By now, you should have completed the following tasks, as instructed earlier in this chapter: 1. 2. 3. 4. 5. 6. 7. 8.
PAGE 35
2 CHAP T E R T WO Troubleshooting IN THIS CHAPTER • Troubleshooting basics: - Reducing electrical noise - Diagnostic LEDs - Test options - Technical support • Solutions to common problems • Resolving serial communication problems • Product return procedure
PAGE 36
Troubleshooting Basics When your system does not function properly (or as you expect it to operate), the first thing that you must do is identify and isolate the problem. When you have accomplished this, you can effectively begin to resolve the problem. The first step is to isolate each system component and ensure that each component functions properly when it is run independently. You may have to dismantle your system and put it back together piece by piece to detect the problem.
PAGE 37
Common Problems & Solutions NOTE Some software-related causes are provided because it is sometimes difficult to identify a problem as either hardware or software related. Problem Communication (serial) not operative, or receive garbled characters Cause 1. Improper interface connections or communication protocol 2. COM port disabled 3. In daisy chain, unit may not be set to proper address Direction is reversed. 1. Phase of step motor reversed (motor does not move in the commanded direction). 2.
PAGE 38
Troubleshooting Serial Communication Problems General Notes • Power up your computer or terminal BEFORE you power up the ZETA6104. • Make sure the serial interface is connected as instructed on page 9. Shield the cable to earth ground at one end only. The maximum RS-232 cable length is 50 feet (15.25 meters). • RS-232: Handshaking must be disabled. Most software packages allow you to do this.
PAGE 39
Product Return Procedure Step 1 Obtain the serial number and the model number of the defective unit, and secure a purchase order number to cover repair costs in the event the unit is determined by the manufacturers to be out of warranty.
PAGE 40
PAGE 41
Appendix A Resonance, Ringing & Damping— Discussion & Theory In this appendix we will discuss resonance and ringing in step motors. This information will help you configure the ZETA6104’s damping features—anti-resonance, active damping, and electronic viscosity. All step motors have natural resonant frequencies, due to the nature of their mechanical construction. Internally, the rotor acts very similarly to a mass suspended on a spring—it can oscillate about its commanded position.
PAGE 42
Inside a step motor, the rotor behaves like a mass on a spring, as mentioned above. When commanded to quickly accelerate to a given velocity, the rotor will “ring” about that velocity, oscillating back and forth. As shown in the next drawing, the ringing decays—grows smaller over time—and the rotor eventually settles at the commanded velocity.
PAGE 43
Velocity Anti-Resonance or Active Damping (above 3 rps) 3 rps 3 rps Electronic Viscosity (below 3 rps) Time Above 3 rps, the ZETA6104 automatically enables either anti-resonance or active damping— but not both at the same time. They are mutually exclusive. If active damping is set to zero (DACTDPØ), the ZETA6104 enables anti-resonance. If the DACTDP command is set to any setting other than zero, the ZETA6104 enables active damping. This relationship is shown in the next drawing.
PAGE 44
Active Damping Active damping monitors the ZETA6104’s motor terminals and, like anti-resonance, uses the same current command modulator to modify motor current. Active damping uses a different method to extract information about rotor position error, however. The circuit’s gains are adjustable—you can configure it for your particular system. The DMTIND and DMTSTT commands scale the circuit for motor inductance and static torque, respectively. The DACTDP command scales the circuit for system inertia.
PAGE 45
Appendix B Using Non-Compumotor Motors We recommend that you use Compumotor ZETA Series motors with the ZETA6104. If you use a non-Compumotor motor, it must meet the following requirements: • A minimum inductance of 2 mH, series or parallel, is required. (Compumotor recommends a minimum inductance of 5 mH.) • A minimum of 500VDC high-pot insulation rating from phase-to-phase and phase-toground. • The motor must be designed for use with a bipolar drive (no common center tap).
PAGE 46
1. Determine, with an ohmmeter, which three of the six motor leads are common (one phase). 2. Label each one of these three motor leads A. 3. Using the ohmmeter, verify that the remaining three leads are common. 4. Label the remaining three leads B. 5. Set the ohmmeter range to the 100 ohm scale (approximately). 6. Connect the ohmmeter's negative lead to one of the motor leads labeled A. Alternately measure the resistance to the two remaining motor leads also labeled A.
PAGE 47
Terminal Connections After you determine the motor's wiring configuration, connect the motor leads to the ZETA6104's 9-pin MOTOR connector according to the following figure.
PAGE 48
Setting Motor Current – Non-Compumotor Motors To set motor current for a non-Compumotor motor, refer to the formulas below that correspond to your motor (4-lead, 6-lead, 8-lead) and use the current settings shown on page 5 to set the motor's current. WARNING Do not connect or disconnect the motor with the power on. Doing so will damage the contacts of the motor connector and may cause personal injury.
PAGE 49
I N D E X 3rd harmonic 23 4-lead motor wiring 43 6-lead motor wiring 44 8-lead motor wiring 44 5V power supply connections 8 load limit 3 6000user@cmotor.
PAGE 50
DIP switch settings address 5 autobaud feature 5 bias & termination resistors 6 motor current 5 disassembling the ZETA6104 6 DMTIND (inductance) command 27 part of setup program 30 DMTSTT (static torque) command 27 part of set-up program 30 drive/motor matching 22 DRPCHK command 18 part of set-up program 30 DWAVEF (waveform) command 23 part of set-up program 30 E e-mail address for feedback i electrical noise 2, 34 suppressing 19 electronic viscosity configuration procedure 29 definition 42 emergency stop
PAGE 51
R reference documentation i removing the ZETA6104 chassis 6 resistors, termination/bias calculating 9 selecting 6 resolution, decoded quadrature 12 resonance 39 return procedure 37 ringing 40 rotor inertia, zeta motors 3 RP240, connections 18 testing 21 RS-232C (see serial communication) RS-422/485 (see serial communication) S safety 2 safety stops (see end-of-travel limits) schematics, internal (see also back cover) encoder inputs 12 limit inputs 11 P-CUT input 8 programmable inputs and outputs 14 trigger
PAGE 52