AXIMA Installation Manual
AXIMA
Installation
Manual
P/N 400328-00
Rev.: A1
Date: October 31, 1997
© 1997 EMERSON Motion Control. All Rights Reserved.
P/N 400260-0
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 400328-00
Rev.: A1
Date: October 31, 1997
© 1997 EMERSON Motion Control. All Rights Reserved.
P/N 400290-00
AXIMA Installation Manual
© 1997 EMERSON Motion Control. All Rights Reserved.
Document Number: 400328-00
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
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) 474-8833
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) 474-1116
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) 474-8835
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) 474-8711
Internet Website
www.emersonemc.com
iii
AXIMA Installation ManTable of Contents
Hardware Installation
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 1
Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . 2
Selecting an Enclosure . . . . . . . . . . . . . . . . . . . . . 3
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Grounding Requirements . . . . . . . . . . . . . . . . 5
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connectionsand Cabling
Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . 9
COM 2 - RS422 Mode . . . . . . . . . . . . . . . . . . . . . . 10
COM 2 - RS485 Mode . . . . . . . . . . . . . . . . . . . . . . 11
Serial Port Specifications . . . . . . . . . . . . . . . . . . . 11
Serial Communication Grounding . . . . . . . . . . . . 11
Multi-Drop Installations . . . . . . . . . . . . . . . . . . . . 13
Controller ID Number/Address . . . . . . . . . . . . . . . . . . 15
Axis Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Encoder Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Encoder Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Encoder Power Supply . . . . . . . . . . . . . . . . . . . . . 19
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drive Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Example Axis Connections . . . . . . . . . . . . . . . . . . 22
Input/Output Connections. . . . . . . . . . . . . . . . . . . . . . 25
Dedicated I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
User Defined I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 25
I/O Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . 29
Battery Backup Jumpers. . . . . . . . . . . . . . . . . . . . . . . 31
Analog Input Option
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Analog Inputs Connector Wiring . . . . . . . . . . . . . . . . 34
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AXIMA Installation Manual
Expanded I/O Options
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sinking Versus Sourcing . . . . . . . . . . . . . . . . . . . . . .
Direct Wiring Option . . . . . . . . . . . . . . . . . . . . . . . . .
External Components Option . . . . . . . . . . . . . . . . . . .
37
37
37
40
Connectivity Options
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Modbus Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Data Highway Plus Connection . . . . . . . . . . . . . . . . . 52
vi
AXIMA Installation ManHardware 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 400290-00
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
2
Mounting Dimensions
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
Voltages on pins 6 or 7 must not exceed ±12 VDC with respect to pin
13, analog ground.
Connectors
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
AXIMA Installation Manual
Figure 2
4
Input/Output Connector Clearance
Hardware Installation
System Grounding Requirements
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
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
Hardware Installation
Figure 4
AC Power Connector
7
AXIMA Installation ManConnections
and Cabling
Serial Communication
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 400290-00
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
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
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:
12
Non-standard lengths can be special ordered.
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
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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 400263-00) for information on terminal mode
communications.
Figure 11
14
RS485 Multi-Drop Wiring Diagram
Connections and Cabling
Controller ID Number/Address
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.
SW1 Settings
AXIMA
ID
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
AXIMA Installation Manual
SW1 Settings
AXIMA
ID
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
16
AXIMA Controller Connectors (8 Axes)
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
Quadrature square wave
Maximum Rate
8 MHz.
Type
Differential Receiver, DS26LS32
Voltage
5 VDC maximum, 2 VDC minimum
Supply
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
AXIMA Installation Manual
Figure 14
18
Encoder Simulation Wiring Diagram
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
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
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
AXIMA Installation Manual
In the event the Drive Enable contacts are not used, the following
power sequence must be followed:
1.
2.
3.
4.
5.
6.
Apply power to the AXIMA controller.
Apply power to the drives.
Enable the drives.
Normal machine operation.
Disable or power down the drives.
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 400268-00) 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 18.
22
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 I2t (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
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
24
AXIMA to MX Drive Connections.
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
AXIMA Installation Manual
requires a minimum of 2mA at 10 VDC to be recognized as a valid
input.
Figure 22
26
Sourcing Mode Input Diagram
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
AXIMA Installation Manual
Encoder Input Signals
Position Capture Input
1
24 or 25
2
24 or 25
3
26 ro 27
4
26 or 27
5
28 or 29
6
28 or 29
7
30 or 31
8
30 or 31
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 400262-00).
Outputs
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
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 5.5 Amps @ 24 volts.
Each input requires 5 mA @ 24 VDC (2 mA @ 10 VDC) to activate.
When an input is activated an input LED indicator is also activated
29
AXIMA Installation Manual
which draws an additional 10 mA @ 24V per input from the power
supply.
Each output requires 5 mA @ 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
0.697 amps. This value was found using the following formula:
(15mA * 4 IN) + (155mA * 4 OT) + (8.3mA * 2 R) + (WDR) = 0.705 amps
Where:
IN = inputs
OT = outputs
R = relays on outputs #32 and 33
WDR = Watchdog Relay (8.3mA)
30
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 400264-00) 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
AXIMA Installation ManAnalog Input Option
Overview
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.
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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
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
AXIMA Installation ManExpanded 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.
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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
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
0
37
0
37
1
39
1
39
2
38
2
38
3
40
3
40
4
35
4
35
5
42
5
42
6
36
6
36
7
41
7
41
8
47
8
47
9
50
9
50
10
44
10
44
11
48
11
48
12
49
12
49
13
43
13
43
14
46
14
46
15
45
15
45
16
14
16
14
17
12
17
12
18
13
18
13
19
11
19
11
20
16
20
16
21
9
21
9
22
15
22
15
23
10
23
10
24
4
24
4
25
1
25
1
26
7
26
7
27
3
27
3
28
2
28
2
29
8
29
8
30
5
30
5
31
6
31
6
39
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
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
G4OAC24
Digital DC output
module
Digital AC output
module
Input voltage range
10-32 VDC
90-140 VAC
Input voltage nominal
24 VDC
120 VAC
Input current @ nominal
16 mA
9 ma rms
Logic voltage nominal
24 VDC
24 VDC
Logic current @ 24 VDC
18 mA
18 mA
Turn on time
5 ms
20 ms
Turn off time
5 ms
20 ms
G4ODC24
G4OAC24
Digital DC output
module
Digital AC output
module
Output voltage range
5-60 VDC
12-140 VAC
Output voltage maximum
60 VDC
120 VAC
Output current @ max
voltage
3 amps
3 amps rms
Off state leakage @ max
voltage
1 mA
5 ma rms
Logic voltage nominal
24 VDC
24 VDC
Logic current @ 24 VDC
18 mA
18 mA
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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
42
Hardware Setup for External I/O Mounting Racks
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
AXIMA Installation Manual
Connection Diagrams For Mounting Rack
Input Connections
Figure 34
24 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
Expanded I/O Options
Figure 35 120 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
AXIMA Installation Manual
Output Connections
Figure 36
24 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
Expanded I/O Options
Figure 37 120 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
AXIMA Installation ManConnectivity 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 RS485 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.
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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
Connectivity Options
Modbus Connection
The RS-232C serial port Com 3 (nine pin DB connector) pin-out is
shown below.
Pin
Signal
1
Shield
2
RX (Receive)
3
TX (Transmit)
4
485 Data (+)
5
Signal Ground
6
NC (No Connect)
7
RTS (Request to Send)
8
CTS (Clear to Send)
9
485 Data (-)
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
Signal
1
485 Data (+)
2
Signal Ground
3
485 Data (-)
4
485 Data (+)
5
Signal Ground
6
485 Data (-)
51
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
52
Signal
"Blue Hose" wires
1, 4
Line 1 (485 Data +)
Clear
2, 5
Shield
(bare)
3, 6
Line 2 (485 Data -)
Blue
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