manual laser

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Version 1.0Part Number 571 701 721

Revision 1.0March 2004

ICS 5000 Support SoftwareUser Manual

Corporate OfficeTrimble Construction Instruments Division5475 Kellenburger RoadDayton, Ohio 45424-1099U.S.A.800-538-7800 (Toll Free in U.S.A.)+1-937-233-8921 Phone+1-937-233-9441 Faxwww.trimble.com

Support OfficesNorth AmericaTrimble Construction Instruments Division5475 Kellenburger RoadDayton, Ohio 45424-1099U.S.A.800-538-7800 (Toll Free in U.S.A.)+1-937-233-8921 Phone+1-937-233-9441 Faxwww.trimble.comEuropeTrimble GmbHAm Prime Parc 11D-65479 RaunheimGermany+49-6142-2100-0 Phone+49-6142-2100-220 Faxwww.trimble.comTrimble ABRinkebyvägen 17Box 64SE-182 11 DanaderydSweden+46-8-662-10 00 Phone+46-8-753 24 64 FaxAsia-PacificTrimble ABSuite 16D, Building 2, Epoch Center4 Beiwa Road, Haidian DistrictBeijing 100089China+86-10-687-18-295+86-10-684-777-86

Copyright and TrademarksCopyright © 2004, Trimble Navigation Limited. All rights reserved.The Globe & Triangle logo and Trimble are trademarks of Trimble Navigation Limited, registered in the United States Patent and Trademark Office. All other trademarks are the property of their respective owners.

Release NoticeThis is the March 2004 release (Revision 1.0) of the ICS 5000 Support Software User Manual, part number 571 701 721. It applies to version 1.0 of the ICS 5000 Support Software.This product is unsupported and is provided “AS IS” as a courtesy. Trimble does not manufacture or offer support services for this product. Trimble makes no warranties with respect to this product, either express, implied, or statutory, including the warranties of merchantability, fitness for a particular purpose, title, and noninfringement.The following limited warranties give you specific legal rights. You may have others, which vary from state/jurisdiction to state/jurisdiction.

Software License, Limited WarrantyThis Trimble software product, whether provided as a stand-alone computer software product, built into hardware circuitry as firmware, embedded in flash memory, or stored on magnetic or other media, (the “Software”) is licensed and not sold, and its use is governed by the terms of the relevant End User License Agreement (“EULA”) included with the Software. In the absence of a separate EULA included with the Software providing different limited warranty terms, exclusions and limitations, the following terms and conditions shall apply. Trimble warrants that this Trimble Software product will substantially conform to Trimble’s applicable published specifications for the Software for a period of ninety (90) days, starting from the date of delivery.

Warranty RemediesTrimble's sole liability and your exclusive remedy under the warranties set forth above shall be, at Trimble’s option, to repair or replace any Product or Software that fails to conform to such warranty (“Nonconforming Product”) or refund the purchase price paid by you for any such Nonconforming Product, upon your return of any Nonconforming Product to Trimble in accordance with Trimble’s standard return material authorization procedures.

Warranty Exclusions and DisclaimerThese warranties shall be applied only in the event and to the extent that (i) the Products and Software are properly and correctly installed, configured, interfaced, maintained, stored, and operated in accordance with Trimble's relevant operator's manual and specifications, and; (ii) the Products and Software are not modified or misused. The preceding warranties shall not apply to, and Trimble shall not be responsible for defects or performance problems resulting from (i) the combination or utilization of the Product or Software with hardware or software products, information, data, systems, interfaces or devices not made, supplied or specified by Trimble; (ii) the operation of the Product or Software under any specification other than, or in addition to, Trimble's standard specifications for its products; (iii) the unauthorized modification or use of the Product or Software; (iv) damage caused by accident, lightning or other electrical discharge, fresh or salt water immersion or spray; or (v) normal wear and tear on consumable parts (e.g., batteries). Trimble does not warrant or guarantee the results obtained through the use of the Product.THE WARRANTIES ABOVE STATE TRIMBLE'S ENTIRE LIABILITY, AND YOUR EXCLUSIVE REMEDIES, RELATING TO PERFORMANCE OF THE PRODUCTS AND SOFTWARE. EXCEPT AS OTHERWISE EXPRESSLY PROVIDED HEREIN, THE PRODUCTS, SOFTWARE, AND ACCOMPANYING DOCUMENTATION AND MATERIALS ARE PROVIDED “AS-IS” AND WITHOUT EXPRESS OR IMPLIED WARRANTY OF ANY KIND BY EITHER TRIMBLE NAVIGATION LIMITED OR ANYONE WHO HAS BEEN INVOLVED IN ITS CREATION, PRODUCTION, INSTALLATION, OR DISTRIBUTION INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, TITLE, AND NONINFRINGEMENT. THE STATED EXPRESS WARRANTIES ARE IN LIEU OF ALL OBLIGATIONS OR LIABILITIES ON THE PART OF TRIMBLE ARISING OUT OF, OR IN CONNECTION WITH, ANY PRODUCTS OR SOFTWARE. SOME STATES AND JURISDICTIONS DO NOT ALLOW LIMITATIONS ON DURATION OR THE EXCLUSION OF AN IMPLIED WARRANTY, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.TRIMBLE NAVIGATION LIMITED IS NOT RESPONSIBLE FOR THE OPERATION OR FAILURE OF OPERATION OF GPS SATELLITES OR THE AVAILABILITY OF GPS SATELLITE SIGNALS.

Limitation of LiabilityTRIMBLE’S ENTIRE LIABILITY UNDER ANY PROVISION HEREIN SHALL BE LIMITED TO THE AMOUNT PAID BY YOU FOR THE PRODUCT OR SOFTWARE LICENSE. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL TRIMBLE OR ITS SUPPLIERS BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER UNDER ANY CIRCUMSTANCE OR LEGAL THEORY RELATING IN ANY WAY TO THE PRODUCTS, SOFTWARE AND ACCOMPANYING DOCUMENTATION AND MATERIALS, (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR ANY OTHER PECUNIARY LOSS), REGARDLESS WHETHER TRIMBLE HAS BEEN ADVISED OF THE POSSIBILITY OF ANY SUCH LOSS AND REGARDLESS OF THE COURSE OF DEALING WHICH DEVELOPS OR HAS DEVELOPED BETWEEN YOU AND TRIMBLE. BECAUSE SOME STATES AND JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES, THE ABOVE LIMITATION MAY NOT APPLY TO YOU.NOT WITHSTANDING THE ABOVE, IF YOU PURCHASED THIS PRODUCT OR SOFTWARE IN THE EUROPEAN UNION, THE ABOVE WARRANTY PROVISIONS MAY NOT APPLY. PLEASE CONTACT YOUR DEALER FOR APPLICABLE WARRANTY INFORMATION.

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Contents1 Introduction

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Related Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Your Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

2 Getting StartedIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2Support Computer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2Installing The Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

InstallShield Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Installed Directory Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7Starting the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8Software Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12Status Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12Shortcut Key Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

Opening An Existing Data File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13Existing .i5k Data Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13Importing DOS Software .dat Data Files . . . . . . . . . . . . . . . . . . . . . . 2.14

Going On Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15Establishing Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15Synchronizing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16Working On Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

3 General ConfigurationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Output Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Skew Control TCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

Sample Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

Alignment Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7Alignment Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

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Normal Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8Temporary Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

Offset and Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9Direction Sense/Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

Memory Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12

4 Basic Communications ConfigurationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

Default Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 4.2User Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Direct Connection Menu Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3RS-232 Interface Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4RS-422 Interface Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

Communications Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8Line Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10Read Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11Write Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11ASCII Format - User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12ASCII Options - User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14

Serial Communications Port Information . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15RS232 Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16RS422 Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16

Troubleshooting Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . 4.17No Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17Poor Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18

Multi-Drop Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19Multi-Drop Connection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20Multi-Drop Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 4.21Multi-Drop Step By Step Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23

5 Advanced Communications ConfigurationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Choosing A Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

Communication Protocol Switch-Over . . . . . . . . . . . . . . . . . . . . . . . 5.3Configuring DF1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4Communications Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7PLC/SLC Communications Configuration . . . . . . . . . . . . . . . . . . . . . 5.8PLC-5/XX Series Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9SLC 5/0X Series Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

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Message Instruction Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16Modbus® Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17

Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17DeviceNet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20ICS 5000 Software Configuration for DeviceNet . . . . . . . . . . . . . . . . . . 5.21DeviceNet Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 5.23DeviceNet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31

PROFIBUS Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35General Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35ICS 5000 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36Communications Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38Parameterization Telegram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43PROFIBUS Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49

Interbus Communications Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51ICS 5000 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54INTERBUS Network Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 5.56

Custom Read and Write Data Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.62Default Register Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63Custom Register Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63A Word About Number Conventions . . . . . . . . . . . . . . . . . . . . . . . . 5.66Advanced Communications Command Listing . . . . . . . . . . . . . . . . . . . 5.67

6 Station ConfigurationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2Stations Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

Station Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2Modify Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

7 Motion Control OverviewIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2TCS Algorithm - Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

PID Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2System Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

BCS Algorithm - Open Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5PDM Algorithm - Feedback Only and Collision Avoidance . . . . . . . . . . . . . . . . 7.5ICS Integrated Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

Advanced Position Control - In Search of the Trapezoidal Response . . . . . . . . 7.6System Integration with the ICS 5000 . . . . . . . . . . . . . . . . . . . . . . . . 7.7Motor Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7PLC or Host Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

8 Tools & UtilitiesIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

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Tools Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Over-/Undershoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4Motor Tuning Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5Random Moves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8Chart Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9

Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10Flash Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

9 TCS Control Algorithm ConfigurationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2System Integration Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Safe Shutdown of System Operations . . . . . . . . . . . . . . . . . . . . . . . . 9.2Status Interrogation and Response . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5Format “A” Configuration - Bi-Polar Output versions (–10 to + 10 VDC) . . . . . 9.6Format “B” Configuration - Uni-Polar Output versions (0 to +10 VDC) . . . . . . 9.7Format C Configuration - Uni-Polar Output versions (0 to +10 VDC) . . . . . . . 9.8Sampling Frequency Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 9.9Continuously Self Adaptive Function (Auto Gain Limit) . . . . . . . . . . . . . . 9.10Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10

Hardware Output Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12TCS Parameters Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14

Common Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15Advanced Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17Acceleration and Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19Noise and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20Beam Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21Wake Up Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22Sync Input Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24ASC Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26

Characterize Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29Characterization Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29Settling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31Accuracy/Time Trade -off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32Horizontal vs. Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33Ramp Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34Ending Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35Automatic Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36Delayed Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36

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Characterization Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.37Offset Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.39Deadband and Polarity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.40Speed Regulation or Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41Acceleration and Velocity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41Pink Noise Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43Pink Noise Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.44 Step Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.45Transient Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46Disturbance Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.49Finalizing the Characterization. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.50

Software Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.51Not Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.51High Deadband. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52Change Direction Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52Bad Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52Track or Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.53Non-Linearity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.53Speed Overshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.54

10 BCS Control Algorithm ConfigurationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2System Integration Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

Safe Shutdown of System Operations . . . . . . . . . . . . . . . . . . . . . . . . 10.2Status Interrogation and Response . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5Format A Configuration: Bi-Polar Output versions (-10 to +10VDC) . . . . . . . . 10.5BCS1 Configuration Codes for Control Format A. . . . . . . . . . . . . . . . . . 10.6Format B Configuration: Uni-Polar Output Version (0 to +10 VDC) . . . . . . . . 10.6BCS1 Configuration Codes for Control Format B. . . . . . . . . . . . . . . . . . 10.7Format C Configuration: Uni-Polar Output Version (0 to +10 VDC) . . . . . . . . 10.8BCS1 Configuration Codes for Control Format C. . . . . . . . . . . . . . . . . . 10.9Format D Configuration: Two Speed Output Version . . . . . . . . . . . . . . . . 10.9BCS2 Configuration Codes for Control Format D. . . . . . . . . . . . . . . . . 10.10Sampling Frequency Configuration . . . . . . . . . . . . . . . . . . . . . . . . 10.10Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

Hardware Output Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11BCS Parameters Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14Top Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17Beam Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18Wakeup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20Sync Input Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21

Control Parameters Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22Choosing Control Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . 10.22

ICS 5000 Support Software User Manual a.v

Selecting Other Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26Tuning The Speed Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28Adding Multiple Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30Optimizing Velocity Failure Level . . . . . . . . . . . . . . . . . . . . . . . . . 10.33Finalizing the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33

11 PDM Control Algorithm ConfigurationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2System Integration Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3

Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4Sampling Frequency Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 11.5Filter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5Collision Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12

PDM Parameters Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14Beam Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14Collision Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19Digital Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21Wakeup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22Finalizing the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23

A Commands and DiagnosticsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IIACK/NAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IISpecial Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IICommands and Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IIISingle or grouped Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VIIStatus Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VII

Self-Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VIIE Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VIIIW Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IX

Warning Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IXDiagnostic Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.X

Beam Break Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.XMotor Failure Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.XISettling Time Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.XIILaser Pointer (U3;J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.XIII

B Advanced Protocol SpecificsDF1 Protocol Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.I

Supported DF1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.IMessage Framing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.IFunction 0, Word Range Write. . . . . . . . . . . . . . . . . . . . . . . . . . . . B.II

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Function 0, Word Range Read . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.IIIFunction 67, Typed Write . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.IIIFunction 68, Typed Read. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.IVException Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.V

MODBUS Protocol Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.VSupported MODBUS Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . B.V

C Network Configuration FilesDeviceNet EDS File Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.IIPROFIBUS GSE File Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.III

Index

ICS 5000 Support Software User Manual a.vii

a.vi i i ICS 5000 Support Software User Manual

C H A P T E R

1
Introduction 1
In this chapter:

• Overview

• Getting Started

• Related Information

• Technical Assistance

• Your Comments

ICS 5000 Support Software User Manual 1.1

1 Introduction

1.2 IC

1.1 OverviewThe purpose of this manual is to acquaint you with the ICS 5000 Support Software. This manual covers the software’s use for setup and support of an ICS 5000 in any of it’s various configurations.

Trimble assumes that you are familiar with Microsoft Windows and know how to use a mouse, select options from menus and dialogs, make selections from lists, and refer to online help. Trimble also assumes you are familiar with the devices with which the ICS 5000 will be connected to and know how to configure this devices.

1.2 Getting StartedTrimble recommends that, after reading this chapter and installing the software, you work through Chapter 2, Getting Started on page 2.1. This chapter shows you how to get started with the software, and how to set up a new project.

The remaining chapters describe the extended functionality of ICS 5000 Support Software.

1.3 Related InformationSources of related information include the following:

• Help – the software has built-in, context-sensitive help that lets you quickly find the information you need. Access it from the Help menu. Alternatively, click the Help button in a dialog, or press [F1].

• Readme.txt file – a Readme.txt file contains information added after the documentation was completed. To read this file, double-click it or use a text editor to open it. The installation program also copies it into the program directory.

• Release notes – the release notes describe new features of the product, information not included in the manuals, and any changes to the manuals. They are provided as a .doc file on the CD and are installed in the program directory (typically C:\Program Files\Trimble\ICS 5000 Support Software) when you install the software. Use a text editor to view the contents of the release notes.

• Trimble training courses – consider a training course to help you use your Factory Automation system to its fullest potential. For more information, visit the Trimble web site at: www.trimble.com/factoryautomation.html.

1.4 Technical AssistanceIf you have a problem and cannot find the information you need in the product documentation, contact your local Trimble Representative. Alternatively, do one of the following:

• Request technical support using the Trimble web site at www.trimble.com/support/support.htm

S 5000 Support Software User Manual

http://www.trimble.com/factoryautomation.html



http://www.trimble.com/support/support.htm

Introduction 1

• Send an e-mail to [email protected].

1.5 Your CommentsYour feedback about the supporting documentation helps us to improve it with each revision. To forward your comments, do one of the following:

• Send an e-mail to [email protected].

• Complete the Reader Comment Form at the back of this manual and mail it according to the instructions at the bottom of the form.

If the reader comment form is not available, send comments and suggestions to the address in the front of this manual. Please mark it Attention: Factory Automation.


mailto:[email protected]


1 Introduction

1.4 IC

C H A P T E R

2
Getting Started 2
• Introduction

• Support Computer Requirements

• Installing The Software

• Installed Directory Overview

• Starting the Software

• Software Overview

• Opening An Existing Data File

• Going On Line


2 Getting Started

2.2 IC

2.1 IntroductionThis chapter covers the installation and initial operation of the ICS 5000 Support Software. The software has been designed to follow the normal Windows design criteria, and should feel comfortable to you if you are familiar with common Windows based applications.

Navigation is accomplished using either the Menu bar shown below

or the Toolbar shown below.

both of which are located at the top of the main program window.

In addition to the Menu bar and Toolbar, the basic program window includes a series of tabs which are used to display the major configuration sections of the program. In the figure that follows, the program window is depicted as it would be on startup. The default tabs are: General (do first), Communications, Stations and Tools. Finally, on the left side of each tab is a list of configuration screens that it contains. Some of the screen options will be unavailable when offline and depicted in a different shade of gray and made un-selectable until the software is ON Line with an ICS 5000.

2.2 Support Computer RequirementsThe support computer used to run this software must be using a Microsoft Windows operating system (9x, NT, 2000, XP) and have a serial communications port. If no serial port is installed on the computer, there are USB to serial converters that will work as well.


Getting Started 2

2.3 Installing The SoftwareTo install the ICS 5000 Support Software simply insert the Trimble ICS 5000 Resource CD-ROM and wait for the autorun feature to start the CD-ROM Navigation application. Follow the Welcome path to the screen shown in the figure that follows. Select the Install ICS 5000 Support Software link to launch the IInstallShield Wizard. If CD-ROM Navigation application does not start, use Windows Explorer to select the drive were your CD-ROM is located and run the Setup.exe application located in the root directory.

You can also use the CD-ROM Navigation application to view the Support Documents and provided Sales and Marketing literature by following their associated links.

2.3.1 InstallShield Operation

Once the Setup.exe file executes, it will load the InstallShield to preform the installation of the ICS 5000 Support Software. This is shown in the following image.


2 Getting Started

2.4 IC

Welcome Screen

Once the InstallShield application is loaded, the following welcome screen for the InstallShield Wizard will be displayed. The navigation keys at the bottom of the window are used throughout the progress of the software installation. Click Next to continue.

License Agreement

In order to proceed with the software installation, you must first accept the Trimble License Agreement shown in the following image. This agreement can be viewed by using the scroll bar on the right side of the text window. Once it is viewed, select the I accept... option and click Next. If you do not choose to accept this agreement, then the software installation will terminate.

User Information and Destination Folder

The InstallShield Wizard will then display the User name and Company name entered when Windows was installed. You can change either of these by entering new information or simply click Next to continue.


Getting Started 2

The InstallShield Wizard will now display the destination folder for the software installation shown in the figure that follows. The default installation folder is C:\Program Files\Trimble\ICS5000\. You can change this by clicking Change.

Clicking the Change button displays the Change Current Destination Folder window shown below. Use this window to select an alternate destination folder for the software installation. Once the destination folder has been selected, click OK to continue.


2 Getting Started

2.6 IC

Installation Type

The InstallShield Wizard will then ask you to select an installation Type: Typical, Minimal or Custom. Select the option that best suits your needs from the Setup Type window, shown below, then click Next to continue.

If you selected Custom as the Setup Type, then the following window will be displayed to assist you with configuring your custom installation.

Clicking the button next to either the Manuals or Firmware option will display the following configuration selection. Select the desired action from the list then click Next to continue.


Getting Started 2

Completing the Installation

The InstallShield Wizard has now configured the software for installation. Use the Back button to make changes or click Install to proceed with the installation.

Once the installation has completed, the InstallShield Wizard will display the following screen. A shortcut to the software has been installed in the Programs folder under the Windows Start Menu. Select how you would like to complete the installation from the options depicted in the following figure, then click Finish to end the InstallShield Wizard.

2.4 Installed Directory OverviewThe InstallShield Wizard creates two directories or folders under the destination folder that is specified. These folders, Data and Manuals, may or may not contain files depending upon the Installation Type you selected. See Installation Type, page 2.6. The Data folder is the default location for placement of the data (*.i5k) files created by the ICS 5000 Support Software and the Manuals folder contains the on-line documentation files if installed.


2 Getting Started

2.8 IC

The .i5k data files can be stored in any location on the support computer, but it is recommended that the Data folder of the installation folder be used. Because of the nature of the data contained within the file, a unique .i5k file will be needed for each vehicle to be controlled.

A detailed print out of the data can be created by selecting File / Print from the menu bar. Only one data file can be open at a time, and it is a good idea to create a unique description of the data contained in each file for easy identification at a later time.

2.5 Starting the SoftwareTo start the ICS 5000 Support Software, use the shortcut installed under the Programs folder of the Start menu. After a brief splash screen, the General tab with the Setup Description window appears. From here you can create a new setup, open an existing one, or go on line with an ICS 5000 unit. The initial display window also contains a description text box where information about each setup should be recorded. At startup, the software does not load any data file.

In it ally there are three paths to follow:

1. Open an existing data file using File / Open from the menu bar or the icon on the toolbar.

2. Retrieve data from the ICS 5000 using the Synchronize feature.

3. Start a new configuration using the File / New from the menu bar or the icon on the toolbar.

2.6 Software OverviewThe ICS 5000 Support Software’s usage revolves around the main program window. Within this window all software and hardware configuration takes place. The contents of the program window will change depending upon which control algorithm (TCS, BCS or PDM) is loaded and the connection status (ON Line or OFF Line). Details of these changes are presented where appropriate.

The main features of this window are:

a. the Menu bar

b. the Toolbar

c. assorted navigation Tabs (e.g. General, Communications, Stations, Tools, etc.)

d. the Status bar


Getting Started 2

Each of these elements has been designed to optimize navigation and ease of use.

2.6.1 Menu Bar

The Menu Bar provides access to the main menus used to navigate through the basic operations of the software (Open file, Close file, Go ON Line, etc.).

References to items selected from the Menu Bar are made as follows:

File / Open

File Menu

Use the File menu to perform basic functions (open, save, and new for example) on the data file created for each ICS 5000 configuration.

From this menu you have the following options:


2 Getting Started

2.10

• File / New - Closes the current data file and creates a new ICS 5000 setup. When a New command is executed, a Warning window appears prompting the user to save the existing file before continuing.

• File / Import - Launches the file import utility allowing the user to import data files created by our old DOS based Support Software.

• File / Open - Opens an existing .i5k file.

• File / Save - Save the existing data to the open .i5k file. If no file is open, then this selection functions the same as Save As.

• File / Save As - Save the existing data to a new .i5k file.

• File / Print - Prints the current data loaded in the software.

• File / Exit - Exits the software prompting the user to save the data before exiting.

Plus a list of recently opened files is displayed.

Connections Menu

Use the Connections menu to handle all communications related tasks. This menu contains everything you need to connect to the ICS 5000 and upload or download the configuration file. Item availability varies depending upon connection status.

The Off Line version of the Connections menu provides access to only the COM Port Settings, Work ON Line and Direct connection menu items.

The On Line version of the Connections menu provides access to the COM Port Settings, Work OFF Line, Upload from ICS, Download To ICS and Direct connection menu items.

See Chapter 2.8, Going On Line on page 2.15 for details on the function of each of these menu items.

ICS 5000 Support Software User Manual

Getting Started 2

Options Menu

Use the Options menu to access program options such as Language, Password, View “P” array and View ICS file.

From this menu you have the following options:

• Options / Language - Use this option to configure the language used for the program interface.

• Options / Password - This option is used by Trimble engineers to enable advanced diagnostics. Features enabled by this password can cause unexpected operation, so it should only be used by qualified personnel.

• Options / View “P” array - Use this option to display the “P” or parameter array used by the ICS 5000.

• Options / View ICS file - Use this option to display the .i5k file used by the ICS 5000.

Utilities Menu

Use the Utilities menu to reach the various maintenance tools provided for the ICS 5000. These include the Flash Loader for firmware updates and the Hardware Configuration.


2 Getting Started

2.12

Help Menu

Use the Help menu to activate the ICS 5000 Support Software Help System or view the About information which contains important revision information about the software.

2.6.2 Toolbar

The Toolbar contains quick links to commonly used features of the ICS 5000 Support Software. Some of the features are not available until the software is ON Line with an ICS 5000 as shown figure below.

Once communications have been established with an ICS 5000, the Toolbar changes to reflect the additional features activated as shown below.

2.6.3 Status Bar

The Status Bar (shown below) located at the bottom of the program window displays the current working data path and file along with the communications settings (COM1: 19200,N,8,1). Also, if the data has been changed using the software, the word Modified will be displayed until it has been synchronized with the ICS 5000.

2.6.4 Shortcut Key Combinations

Shortcut Key combinations may be used to reach any of the program screens in the ICS 5000 Support Software. These three key combinations are presented throughout this manual and are displayed as follows:

[Alt] + [T] + [1]

Simply substitute the letter for the desired tab (G, M, S, P, Z, or T) and the number for the desired item on that tab (typically 1 through 9).

Note – Destinations of the Shortcut Key Combinations will very based upon the control algorithm selected.


Getting Started 2

2.7 Opening An Existing Data File

2.7.1 Existing .i5k Data Files

There are two methods which can be used to open an existing data file. From the Menu Bar by selecting File / Open

or from the Toolbar by using the tool.

When opening a file, the following dialog appears:

Use the Look in list to select the location of your data file.

All valid data files (.i5k) will be displayed. Once the file has been located, double click on the file name or select it then click Open to open the file.


2 Getting Started

2.14

This will display the Setup Description window complete with any description that has been entered. The configuration shown in the following figure is for an ICS 5000 configured with the TCS control algorithm.

Read the description carefully to insure it matches the setup for the ICS 5000 that is being used before continuing on to the next section Going On Line. If the description does not match, then open another file or create a new setup using the File / New menu item or the Erase current ICS file tool on the Toolbar.

2.7.2 Importing DOS Software .dat Data Files

The ICS 5000 Support Software also has the capability of importing data created using Trimble’s previous DOS based Support Software. Simply select File / Import from the Menu Bar to begin. This will display the Browse for Folders window shown in the figure that follows. Use this window to locate the folder that contains

CWarning – Starting a new setup will erase the existing data for the project you are working with. You will be prompted to save the current data before continuing.


Getting Started 2

the data you wish to import then click OK to finish. When finished, the program will display the Setup Description window complete with any description that was entered.

2.8 Going On LineTo go On Line with the ICS 5000 unit either select Connection / Work ON Line or the Go ON Line tool on the toolbar. Once the connection is established, the Go ON Line icon changes to indicate the connection and an ICS 5000 icon will appear in the lower left corner of the program window. The software can be returned to the Off Line mode by selecting Connection / Work Off Line or click the Go ON Line tool on the toolbar.

Note – ICS 5000 units are shipped from the factory with default communications parameters only. These settings are:Baud rate - 9600; Parity - None; Bits per word - 8; and Stop bits - 1.

2.8.1 Establishing Communication

If the initial communication attempt should fail, then the Following dialog box will be displayed:

Unless the User settings are known, select the Set PC to DEFAULT settings option and click Test.


2 Getting Started

2.16

The ICS 5000 Support Software will attempt to establish communications using the default communications parameters (9600, N, 8, 1). If communications are still not established, then you will be prompted to cycle power to the ICS 5000 unit (power down the unit for approximately 5 seconds then reapply power). After power is reapplied, the ICS 5000 will switch to the default communication parameters automatically allowing the software to establish communications.

See Chapter 4, Basic Communications Configuration on page 4.1 for information on the USER settings and for details on configuring the RS-232 and RS-422 interfaces on the ICS 5000.

2.8.2 Synchronizing Data

Upon connecting with the ICS 5000 the Support Software displays following status window:

During the synchronization process data is exchanged between the ICS 5000 and the computer running the ICS 5000 Support Software to insure that both sets of parameters are the same.

After communications are established, the Support Software will preform a Self-Test and Firmware/Version Check to insure proper operation and compatibility. Once this is confirmed, synchronization of the data will begin.

If changes have been made to the data in either the ICS 5000 or the ICS 5000 Support Software project files, then the synchronization will pause and prompt you for direction. If, however, no data is loaded into the ICS 5000 Support Software, then the data within the ICS 5000 will automatically be uploaded to the computer.

Synchronization of the Control Parameters and Station Locations is handled independently. Therefore it is possible to select Write to ICS from one dialog box to download one set of parameters and Read from ICS from the other to upload. Clicking Cancel will terminate the synchronization and return the software to the OFF Line mode.


Getting Started 2

If changes have been made to the Control Parameters then the following dialog box will be displayed. Click Write to ICS to download the Control Parameters from the open Support Software project file to the ICS 5000. Click Read from ICS to upload the Control Parameters from the ICS 5000 to the Support Software, overwriting the data in the open project file.

If changes have been made to the Station Look up table then a similar dialog box will be displayed asking you to decide what action to take. Click Write to ICS to download the Station Lookup Table from the open Support Software project file to the ICS 5000. Click Read from ICS to upload the Station Lookup Table from the ICS 5000 to the Support Software, overwriting the data in the open project file.

2.8.3 Working On Line

When the ICS 5000 Support Software is ON Line with an ICS 5000 unit, the ICS 5000 icon appears at the bottom left corner of the program window as shown in the figure that follows.

Updating The Data In The ICS 5000

When changes are made to the setup using ICS 5000 Support Software, they need to be written to the ICS 5000 before they become active. For example: If you move a Station Location using the Support Software, the change will not effect the vehicle positioning until the changes are written to the memory of the ICS 5000. The


2 Getting Started

2.18

Support Software alerts you that changes have been made and need to be sent to the ICS 5000 by changing the icon displayed in the bottom left corner of the program window as follows:

To write all changes made by the Support Software to the ICS 5000 unit, simply click the icon displayed with the yellow arrow, or click the icon on the Toolbar. This will synchronize the data files, insuring that both sets of parameters are the same.

CWarning – Writing changes made to the ICS 5000 does not also save the data file on the computer. To do this the user must select the File / Save menu item or click the Save icon on the Toolbar.


C H A P T E R

3
General Configuration 3
In this chapter:

• Introduction

• Description

• Control Options

• Sample Rate

• Alignment

• Travel Limits

• Offset and Polarity

• Memory Protection

• Tolerance


3 General Configuration

3.2 IC

3.1 IntroductionThis chapter covers the general configuration of the ICS 5000 (TCS, BCS and PDM control algorithms) using the General (do first) [Alt] + [G] tab shown in the following figure. Each new configuration should begin here.

The ICS 5000 Support Software has been structured so that the order of the program tabs follows the typical order of tasks completed during an installation. The General (do first) tab contains links to the following screens:

• Description

• Control Options

• Sample Rate

• Alignment

• Travel Limits

• Offset and Polarity

• Memory Protection

• Tolerance

The function of each of these screens will be discussed in detail in the following sections. The shortcut key combinations for reach each screen are also provided at the beginning of each section.



3.2 Description[Alt] + [G] + [1]

Use the Description screen to uniquely describe the setup data that is contained in the .i5k data file. This description is particularly helpful if there are multiple ICS 5000 units being supported. Data displayed above the Setup Description window gives detailed information about the ICS 5000 unit to which the data was last loaded (Serial Number and Firmware Revision) along with details about the units configuration (Algorithm, Output Format and Protocol).

3.3 Control Options[Alt] + [G] + [2]

The configuration of an ICS 5000 begins by selecting the Algorithm and Output Format needed to interface with the hardware of the axis to be controlled (PLC and Motor Drive). This is done from the Control Options screen shown in the following figure.



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3.3.1 Algorithm

If you want to use the ICS 5000 to control the vehicle (motion control), choose TCS or Skew Control TCS for closed-loop control or BCS for open loop control. If you only require position, velocity and/or acceleration data or you want the ICS 5000 to be used for collision avoidance then choose PDM.

Changing the Algorithm type (from TCS to BCS for example) requires that the ICS 5000 Support Software erase the existing data file before continuing. The following message will be displayed, but the user will not be prompted to save the data.

3.3.2 Output Format

Once the control algorithm has been selected, you must select an Output Format that is supported by the motor controller you are using. There are four Output Formats supported by the ICS 5000, and they are labeled A through D. Selecting an option from this group formats the ICS 5000 I/O as stated. For more information on the operation of the ICS 5000 I/O, please consult the ICS 5000 Installation Manual Publ. No.571 701 451.

Note – The TCS algorithm only supports formats A through C while the BCS algorithm supports all formats. The outputs for the PDM algorithm are not configurable in this manner.

3.3.3 Skew Control TCS

The Skew Control TCS algorithm option refers to a special implementation of the ICS 5000’s TCS algorithm designed to interface with a Trimble ASC (Advanced Skew Controller) module. This solution is used to control the skew of wide vehicles such as bridge cranes, and it’s installation and operation are covered in the Advanced Skew Controller Installation Manual Publ. No. 571 701 327. The ICS 5000 is configured just as it would be for the TCS algorithm. Subtle differences in the operation of the software are present when working with an ASC based system, and they will be documented where they occur.

CWarning – Changing the Algorithm type used by the ICS 5000 will require that the ICS 5000 Support Software erase the current setup.



The first thing you may notice when choosing to use the Skew Control TCS algorithm is that ICS 5000 Support Software checks the status of the Connection / Direct Connection setting. If this is enabled, meaning the computer will be directly connected to the ICS 5000, then you will see the following message:

Click Yes to disable Direct Connection allowing the ICS 5000 Support Software to communicate through the ASC module.

3.4 Sample Rate[Alt] + [G] + [3]

Use the Sample Rate selection screen shown in the figure that follows to configure the rate at which the ICS 5000 samples the distance data.

Using a high sample rate provides faster data updates, but also results in more noise or distance fluctuation because less filtering is applied. Using a low sample rate reduces the data update rate, but improves the stability of the distance reading. It is generally preferred to start with a sample rate of 30 Hz. and adjust the frequency only if the results are sub-standard.

BTip – Details on configuring the various control algorithms (TCS, BCS, and PDM) are provided in separate chapters in this manual.

BTip – When choosing a sample rate for the ICS 5000 consider the responsiveness of the vehicle being controlled. The larger and less responsive the machine, the slower the sample rate. Typical industrial vehicles do well with 30 or 49 Hz.



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There is a trade-off between noise and performance, much like a filter. A high sample rate gives higher performance but also higher noise. A low sample rate gives lower performance but has less noise. The following are some examples of when to use specific sample rates:

• For slowly moving vehicles with a huge mass and a high time constant a low sampling frequency is recommended. - 19.35 Hz.

• For quickly moving vehicles with low mass and a low time constant a high sampling frequency is recommended. - 69.50 Hz.

• For medium sized vehicles like stacker cranes and a time constant not too high a medium sampling frequency is recommended. - 30.58 or 49.32.

• Most vehicles will have a good response with a sampling frequency of 30.58 or 49.32 Hz.

3.5 Alignment[Alt] + [G] + [4]

Because the ICS 5000 uses infrared light to measure distance, the measurement beam is not visible. Use the Laser Alignment screen shown below to check the alignment of the ICS 5000 measurement beam with the reflector. This screen provides a real-time feedback of the return signal strength and a check box to enable the Pointing Laser alignment aid.

CWarning – Changing the Sampling Frequency of the ICS 5000 once a Characterization is complete will require you to re-Characterize the system.

BTip – If ICS 5000 is used as a replacement unit for an old system, 30.58 Hz should be used to avoid having to re-characterize.



Typically the first step toward using the ICS 5000 involves aligning the unit with the reflective target. This must be completed before distance measurement will be possible.

3.5.1 Alignment Laser

Some models of the ICS 5000 are equipped with a visible pointing laser that is aligned with the measurement beam. This laser, when enabled, will strike the target or other surface approximately 30 mm below the measurement beam allowing un-aided visual alignment of the unit. When you have enabled the Pointing Laser selecting the box, the Laser Alignment screen changes as shown in the following figure:

Select the Pointing Laser check box to turn the laser on. Un-selecting the box or selecting another screen will turn the laser off. Remember to open the mechanical shutter covering the laser opening (located on the front of the ICS 5000) to allow the light to exit. If this is not done, then the laser will not be visible.

3.5.2 Alignment Statistics

At the bottom of the Laser Alignment window, there is an area titled Statistics. It contains a Reset button along with the Maximum and Minimum values for Signal Strength recorded since the screen was opened.Use these results to check the alignment of the entire length of travel for the vehicle. Remember to reset the values prior to beginning by clicking Reset. During this test the vehicle will have to be moved using Manual control.



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3.6 Travel Limits[Alt] + [G] + [5]

Use the Travel Limits screen to define or redefine the operating limits of the system. These limits, shown below, are the only way the ICS 5000 has of knowing what the distance limitations of the system are.

There are two sets of limits that the ICS 5000 uses: Temporary Limits and Normal Limits. The Normal Limits are the actual operational limits of the system, and are captured by moving the vehicle to the limit. The Temporary Limits are used only during restricted operation such as initial configuration or system maintenance.

3.6.1 Normal Limits

To set the Normal Limits move the vehicle to the desired limit (Near or Far) and click the Capture button associated with the limit. The Normal limits are typically just inside of the overtravel limitswitches, but beyond any destination to which the vehicle needs to move.

3.6.2 Temporary Limits

Once the Normal Limits are set, Temporary Limits can be applied by dragging one of the arrow markers below the scale or entering a value in either the Temporary Near Limit or Temporary Far Limit field. The numeric readout these fields will also change as the arrow marker is moved. The current vehicle position is displayed in the middle of the screen and represented by the arrow marker above the scale.

The Normal limit values are displayed below the scale. These values are for reference only and cannot be changed without re-capturing the limit

Note – To restore the Normal limits after you have finished using the temporary ones, drag the Arrow markers to their original positions or enter the normal limit values for each end.



Note – Remember to restore the Normal Limits before placing the system back into service. Failure to do so will limit the range of motion for the system and may result in system faults because some destination will be out of range.

3.7 Offset and Polarity[Alt] + [G] + [6]

Use the Offset and Polarity screen to adjust the zero measurement point of the ICS 5000 and the direction in which distance increments. The screen, shown below, is divided into two sections: Offset (mm) and Direction Sense/Polarity. For reference, the end of travel limits and current position are also displayed.

3.7.1 Offset

There are four options from which you can select the method to use to adjust the Offset:

a. Enter a new offset manually...

b. Adjust offset so position reads...

c. Position objects closer by...

d. Position objects farther by...

To apply an offset to the distance measurement, first you must select which of the methods you would like to use. Then enter the desired value in the numeric field and click Apply.

BTip – Remember that the changes made will not be applied to the system until the updates are transferred to the ICS 5000 unit by clicking on the Refresh icon.



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Enter a new offset manually...

When this Offset method is used, you simply enter a value which is used to offset the measurement zero point of the ICS 5000.

Adjust offset so position reads...

You use this Offset method to enter an actual position which the ICS 5000 should read. For example, if you want to move the ICS 5000 from its current location to a new one, you can adjust the offset so the position reads the same value as when the ICS 5000 what in it’s previous location. This eliminates the need to change programmed destinations or look-up tables.

Position objects closer by... / Position objects farther by...

Use ether of the last two options (Position objects closer by... or Position objects farther by...) to “tweak” the position reading to adjust position closer or farther from the ICS 5000 by the specified amount.

3.7.2 Direction Sense/Polarity

The Direction Sense/Polarity effects the way the direction sense (incrementing and decrementing of distance) is applied. Normal direction sense increments values as the distance increases between the ICS 5000 and the reflective target. Reversed direction sense decrements values as the distance increases.

For example, if the current distance you are reading with Normal direction sense enabled and the offset set to 0 mm is 1000 mm, changing to Reversed direction sense will result in a reading of -1000 mm.

BTip – Polarity and Offset can be used to position two vehicles from opposite ends of the same length of travel using the same destination locations. Adjust the Offset in one ICS 5000 so that the distance at a known location matches the other ICS 5000. Then enable Reversed direction sense in the same unit to which the Offset was applied.



3.8 Memory Protection[Alt] + [G] + [7]

The parameters from a Characterization are stored in an internal memory inside the ICS 5000. There are four different ways of configuring the write protection for this memory. Use the Memory Protection screen, shown below, to control how the ICS 5000’s memory reacts to enable the downloading of parameters to an ICS 5000 from a PLC or computer.

Details of the four options available are as follows:

1. Use the ICS 5000 Support Software only to download new parameters to the ICS 5000 unit. The memory is write protected when you exit the software.

2. Use your own program to perform the down loading of parameters. Send U-1;J12345 to make the memory write enabled and U-1;J1 to make the memory write protected.

3. The memory is always write enabled and you can use your own program to download the parameters to the ICS 5000.

4. Configures how many seconds after start up or a reset the memory should be write enabled. The BT command will reset the ICS 5000 unit. Your down loading program must complete the down loading in less than the time you enter. Valid times are from 1 to 3599 seconds.

CWarning – Care must be taken when making the memory in the ICS 5000 writable. If the memory is left in this condition during normal vehicle operation, then unexpected results can occur.



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3.9 Tolerance[Alt] + [G] + [7]

Use the Positioning Tolerance/Accuracy screen, shown in the following figure, to control positioning repeatability of the control loop in the ICS 5000. The Tolerance value is changed by entering, or using the arrow keys to select, the desired Tolerance value.

The Tolerance setting controls two aspects of the ICS 5000’s operation:

• The accuracy of the measuring process by controlling the time interval between auto-calibrations. This works out to about 1 minute per mm of tolerance.

• The accuracy to which the TCS and BCS algorithms position the machine. Before the ICS 5000 will change the status to “on station” (E=16), two conditions must be met:

– The position error must be 1/2 of the tolerance for 3 consecutive readings.

– The first and last readings must be on the same side of 0.

Three Example Scenarios are provided at the bottom of the screen to aid you in selecting the proper tolerance. Two of the examples depict the combinations of readings that result in a status of “on station”, while the final example depicts three readings within tolerance that did not result in a status of “on station”.

The following figure contains the result of the first Example Senario.

Note – Avoid excessively small tolerances; they increase positioning time and usually exceed the mechanical capabilities of the system the ICS 5000 is controlling.


C H A P T E R

4
Basic Communications Configuration 4
In this chapter:

• Introduction

• Communications Configuration Tab

• Serial Communications Port Information

• Troubleshooting Communications Problems

• Multi-Drop Configuration


4 Basic Communications Configuration

4.2 IC

4.1 IntroductionThis chapter covers the configuration of the ICS 5000’s serial communications interfaces. The unit has one RS-232 port and one RS-422 port which support ASCII, DF1, MODBUS and INTERBUS. A secondary RS422 port is used to implement Multi-Drop, Interbus, and for advanced troubleshooting.

4.1.1 Default Communication Parameters

During the first five seconds after a start up or reset, the ICS 5000 is configured for a Default set of communication parameters. If no communication is established during the first five seconds the system is switched to the User set of configuration. If no communication parameters are configured in User Mode the system will remain in Default Mode. The Default communication parameters are: Baud rate 9600, No parity, 8 Data bits and 1 Stop bit.

4.1.2 User Communication Parameters

The ICS 5000 Support Software automatically displays the Communications Settings dialog box (shown below) whenever an attempt to go ON Line fails. You can also access this screen by selecting Connection / COM Port Settings from the File menu or clicking the Settings button on the Terminal screen of the Tools tab.

Select Set PC to DEFAULT settings: to communicate with the ICS 5000 using the Default parameters, and select Set PC to USER settings: to communicate with the ICS 5000 using some other user defined settings. When the User Settings option is



selected, click Next to proceed to the PC Lines Settings screen (pictured below). This screen allows you to custom configure the Baud Rate, Parity, Data Bits, and Stop Bits for the PC interface.

The next screen that is displayed allows you to configure additional PC communications settings. From the PC Format Settings screen you can change the Address, Preamble, and Postamble settings. If you are OFF Line when you entered this screen, then click Done to finish. If you are ON Line when you entered this screen, then click Test to attempt communication.

4.1.3 Direct Connection Menu Item

The Connection / Direct Connection item on the Menu Bar is used to determine if the ICS 5000 Support Software will be communicating directly with an ICS 5000 (Direct Connection checked) or with an ICS 5000 via an external device such as the Trimble ASC or a modem (Direct Connection unchecked).

The default setting is checked, or Direct Connection enabled. If you are configuring a Skew Control TCS unit, the ICS 5000 Support Software will check the status of the Direct Connection setting. If it is enabled, the software will prompt you to disable Direct Connection if you intend on communicating with the ICS 5000 through the ASC unit. Alternatively, if you are configuring a unit other than a Skew Control TCS unit and the Direct Connection setting is disabled, the software will prompt you to enable the feature. It should be enabled unless you are communicating through a modem.



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4.1.4 RS-232 Interface Basics

The ICS 5000 uses a 16 pin connection socket for the RS 232C interface. This connection is depicted in Figure 4.1 which follows. When using an IBM compatible portable computer with the cable connected from COM1directly into the back of the ICS 5000 the following hardware will be required for communication with the setup software:

Figure 4.1 RS-232 Interface Wiring Details

• A female 9 pin D-sub miniature connector to the connection socket on the computer.

• A shielded cable with three wires connected to the D-sub and the 16 pin connection socket at the ICS 5000.

Note – Some older style ICS 5000 units will only have a 12 pin connection socket for communications. The pin configurations for RS-232 and RS-422, however, remain the same.

4.1.5 RS-422 Interface Basics

The 16 pin connection socket for communication also supports the RS-422 standard. This connection is depicted in Figure 4.2 which follows. If the PLC is using the RS-422 standard when communicating with the ICS 5000 can the same



cable be used by an IBM compatible computer. (See Figure 4.3 for more details.) The following hardware will be required for communication with the setup software:

Figure 4.2 RS-422 Interface Wiring Details

• An RS-232/422 converter.

• A female 9 pin D-sub miniature connector to the connection socket on the computer. A shielded cable with three wires connected to the D-sub and the RS-232/422 converter.

• A shielded cable with at least two twisted pairs (four wires) connected to the RS-232/ 422 converter and to the cable between the ICS 5000 and the PLC. Type of connectors depends on the types the PLC system and the converter used.

Figure 4.3 RS-232 to RS-422 Communication Wiring using Converter

The RS-422 standard implements balanced voltage and the suppression of common mode interference is very good. If communication cables in lengths exceeding 15 meters are being used we always recommend RS-422 instead of RS-232. Use only shielded, twisted pair interconnection cables.



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4.2 Communications Configuration Tab[Alt] + [M]

There are several different methods with which to interface an ICS 5000 depending upon the type of PLC or Host Controller that is being used. The Communications tab on the ICS 5000 Support Software, which is shown in the following figure, is used to configure all aspects of the communications between the ICS 5000 and any external device.

The Communications tab contains links to the following screens:

• Protocols

• Port Options

• Line Settings

• Addressing

• Read Table

• Write Table

• ASCII Format - User Settings

• ASCII Options - User Settings


BTip – At boot up, both serial ports on the ICS 5000 will use the ASCII protocol with default communication parameters (9600, N,8,1) for 5 seconds. The unit will then automatically switch to one of the other RS232/422 protocols if it has been enabled (see Port Options).



Note – When an ICS 5000 is purchased, the required protocol support (DeviceNet, DF1, PROFIBUS etc.) must be indicated. ASCII protocol is the only one enabled in a standard unit.

4.2.1 Protocols

[Alt] + [M] + [1]

Use the Protocols screen to enable any of the advanced communications protocols available in the ICS 5000. Remember that all protocols, except for the default ASCII, must be purchased before they can be enabled. The Protocols screen is divided into two groups: RS232/422 Protocols and Other Protocols.

RS232/422 Protocols

Use the RS232/422 Protocols group of the Protocols screen to enable the desired RS232/422 protocol - ASCII, MODBUS, DF1, or Interbus. To enable a protocol you must first select it from the Protocols screen, then enable it using Port Options on page 4.8. The protocols in this section also require that the serial parameters (baud rate, parity, data bits and stop bits) be configured as shown in Line Settings on page 4.9. The default protocol selection is ASCII

Other Protocols

Additional protocols that require more advanced communication hardware configuration are enabled using the Other Protocols group of the Protocols screen. These protocols require a dedicated hardware interface port (such as DeviceNet or PROFIBUS) or require the use of multiple serial ports (multi-drop). The default selection is None of the above. Details on enabling and configuring the ICS 5000 to

BTip – At boot up, both serial ports on the ICS 5000 will use the ASCII protocol with default communication parameters (9600, N,8,1) for 5 seconds. The unit will then automatically switch to one of the other RS232/422 protocols if it has been enabled (see Port Options, page 4.8).



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support these protocols is presented in the next chapter - Chapter 5, Advanced Communications Configuration on page 5.1. The default selection for the Other Protocols group is None of the Above.

Communication Protocol Switch-over

For systems configured with the MODBUS or DF1 protocol, the switch-over from ASCII to the selected protocol occurs as follows:

1. Directly after boot-up the units are set to communicate in the ASCII mode. When connected to the PLC the first message will cause the protocol to switch but it will not be answered.

2. The second and all other messages will be answered in the new protocol. To go back to the ASCII protocol or to use the setup software again, reset the unit. This arrangement makes it easy to shift back and forth between the PLC and a PC running the setup software.

4.2.2 Port Options

[Alt] + [M] + [2]

The Port Options screen enables you to configure how the two serial ports are going to function once the ICS 5000 switches to it’s User communication parameters. For five seconds after boot-up, both serial ports operate using Default parameters (9600 baud, No parity, one stop bit, and eight bits/char). This provides the ICS 5000 Support Software a means to connect to the ICS 5000 even if user settings are not known or incompatible. If no ASCII message using the Default parameters is received, then the ports will switch automatically to their User settings based upon how the options on Port Options screen, shown below, are configured. There are separate settings for the RS-232 and RS-422 ports.



4.2.3 Line Settings

[Alt] + [M] + [3]

Use the Line Settings screen, shown below, to configure the User communication parameters (baud rate, parity, data bits and stop bits) for the two serial ports (RS232/422), and the baud rate for the FieldBus (DeviceNet or PROFIBUS) if used. Five seconds after boot-up, each serial port has the option of switching to the USER settings defined in the RS232/422 USER Settings group. This is NOT true for INTERBUS which uses pre-defined settings.

Use the FieldBus group to control the DeviceNet or PROFIBUS baud rate which goes into effect immediately. Once DeviceNet or PROFIBUS is selected, the FieldBus group title will change to reflect the selected fieldbus and the Baud Rate dropdown list will activate.



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4.2.4 Addressing

[Alt] + [M] + [4]

The Addressing screen of the Communications tab allows you to configure the unique addresses available to the various communications protocols. This screen is comprised of three settings groups: ASCII Address - User Settings; MODBUS/DF1 Address; and Fieldbus Address.

ASCII Address - USER Settings

The ASCII protocol can use up to a 3 character address to uniquely represent each unit. From the ASCII Address - USER settings group shown below, this address is enabled by first clicking the Enable check box then entering the address character(s). If the desired address consists of characters found on the keyboard, enter them in the box to the left of the equal sign (=), otherwise enter the ASCII code for each character in the boxes to the right. As you enter the ASCII code, the character will be displayed.

MODBUS/DF1 Address

Use the MODBUS/DF1 Address group shown below to configure an address for the ICS 5000 to use when using either of those protocols. The ICS 5000 using MODBUS or DF1 protocols must have a unique address. If you use the MODBUS/DF1 Address in combination with the ASCII Address then the MODBUS/DF1 Address and the first character of the ASCII address are the same.



Fieldbus Address

The ICS 5000 needs a unique Network or MAC ID to be properly identified on the network. You do this from the Fieldbus Address group of the Addressing screen shown in the figure that follows. The FieldBus Address group title will change to reflect the selected fieldbus as will the Network ID/MAC ID selector range. For PROFIBUS enter a value from 0 to 126 and for DeviceNet, a value from 0 to 63.

4.2.5 Read Table

[Alt] + [M] + [5]

MODBUS, DFl, DeviceNet and PROFIBUS represent data in integer arrays (e.g. 40001-40006 or N7:0-N7:5). By default, the data in each array element is pre-defined (e.g. Element0 = Status Register) but you can create your own definitions by filling out the Read Table (ICS-to-host) shown in the figure that follows. This lets you group important pieces of data together to simplify and speed up the reading process. You MUST do this for DEVICENET and PROFIBUS.

Details on configuring the Read Table are presented in Custom Read and Write Data Tables on page 5.62.

4.2.6 Write Table

[Alt] + [M] + [6]

MODBUS, DFl, DEVICENET and PROFIBUS represent data in integer arrays (e.g. 40001-40006 or N7:0-5). By default, the data in each array element is pre-defined (e.g. Element0 = Status Register) but you can create your own definitions by filling



4.12

out the Write Table (host-to-ICS). This lets you group important pieces of data together to simplify and speed up the writing process. You MUST do this for DEVICENET and PROFIBUS.

Details on configuring the Write Table are presented in Custom Read and Write Data Tables on page 5.62.

4.2.7 ASCII Format - User Settings

[Alt] + [M] + [7]

Use the ASCII Format -User Settings screen shown below to configure the basic User communication settings in the ICS 5000. The User settings are activated automatically unless communication is established with the unit using the Default settings (9600, N, 8, 1) within the first five seconds after power up.

BTip – Unless you have specific requirements for communication, use the default settings on this screen.



ACK Message

The ICS 5000 can acknowledge or ACK successfully received commands using a 1-3 character ACK Message. Use the ACK Message group of the ASCII Format -User Settings screen shown below to configure this. If the desired message consists of characters found on the keyboard, enter them in the left-most box, otherwise enter the ASCII code for each character in the right 3 boxes. Enter all zeros to disable the ACK Message. ASCII code 6 is the default value.

NAK Message

The ICS 5000 can not-acknowledge or NAK commands received with Parity, Framing, or Overrun errors using a 1-3 character NAK Message. Use the NCK Message group of the ASCII Format -User Settings screen shown below to configure this. Enter all zeros to disable the NAK Message. ASCII code 21 is the default value.

Preamble

The ICS 5000 can attach and expect a Preamble character at the beginning of each message much like an address. The Preamble character is activated from the Preamble group of the ASCII Format -User Settings screen shown below by selecting the Enable check box and entering the desired value. The default value is 0 to disable.

Postamble

The ICS 5000 terminates all messages with a Postamble character. You configure this character plus enable the optional Line Feed character from the Postamble group of the ASCII Format -User Settings screen which is shown below. ASCII code 13 (Carriage Return) is the default. Select the Line Feed check box to add a line feed to the termination.

BTip – This feature is rarely used.



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4.2.8 ASCII Options - User Settings

[Alt] + [M] + [8]

Use the ASCII Options -User Settings screen shown below to configure additional User communication settings in the ICS 5000. The User settings are activated automatically unless communications is established with the unit using the Default settings (9600, N, 8, 1) within the first five seconds after power up.

Enable ECHO

The ECHO option is enabled by selecting the Enable ECHO check box (shown below), and causes the ICS 5000 to echo back each character it receives as a confirmation.

NAK Slow Messages

The NAK Slow Messages option is enabled by selecting the NAK Slow Messages check box (shown below), and causes the ICS 5000 to send the NAK message if there is a large time interval between received characters. This is very useful in high noise environments.

BTip – Unless you have specific requirements for communication, use the default settings on this screen.



Enable INTERUPTS

The INTERUPTS option is enabled by selecting the Enable INTERUPTS check box (shown below), and causes the ICS 5000 to send a status report (E command) whenever the status changes.

MODEM Compatible

The MODEM compatible option is used when the ICS 5000 will be connected to a MODEM for remote support. It is enabled by selecting the MODEM Compatible check box (shown below).

ON Command Delay

The ON Command Delay option is used to pace the replies from an ON Command, such as XON for continuous reading of distance, to reduce communication traffic. When using multi-drop, it's best to set the ON Command Delay to the number of ICS 5000 units in the network. Set the ON Command Delay by entering a number from 1 to 15 in the box as shown below. The default value is 0 to disable.

4.3 Serial Communications Port InformationThe ICS 5000 has two serial communications ports available for user configuration. One RS-232 port and one RS-422 port. A second RS-422 port is available for use with the Multi-Drop feature, INTERBUS, and Trimble Diagnostic software. All of



4.16

these ports are located on the 16 pin SERIAL COM PORTS plug-in terminal strip on the rear of the unit, which is shown in Figure 4.4 below. The hardware configuration of the serial communications ports is detailed in the next sections.

Figure 4.4 Rear Panel View

4.3.1 RS232 Port Configuration

The 16 pin SERIAL COM PORTS plug-in terminal strip on the rear panel uses the terminals described in Table 4.1 below for RS-232 communication.

4.3.2 RS422 Port Configuration

The 16 pin SERIAL COM PORTS plug-in terminal strip on the rear panel uses the terminals described in Table 4.2 below for RS-422 communication.

Table 4.1 RS-232 Port PinoutTerminal Function Description

12 TXD This pin provides the serial output from the ICS unit.

11 RXD This pin provides the serial input to the ICS unit.

10 COM Tied to the opto-isolated ground of the interface circuit.


6 RB Negative polarity of the serial input.

7 RA Positive polarity of the serial input.



4.4 Troubleshooting Communications ProblemsExperience has taught us that properly establishing ASCII serial communications between the PLC and the ICS 5000 is about half of the work involved with the entire integration of an ICS 5000. DF1 and Modbus greatly streamline this task by removing all of the string manipulation required with ASCII, and DeviceNet and PROFIBUS further simplify things by adding a predefined hardware interface. Time should be spent to insure that the communications driver supports all error codes and makes them easily accessible to maintenance personnel during troubleshooting. A well developed driver will save time and money in the long run.

The following sections provide some basic background on troubleshooting serial communication problems with the ICS 5000.

4.4.1 No Communication

RS-232 Troubleshooting

1. A default set of the communication parameters can be activated for five seconds by resetting the power to the unit and selecting a menu item when entering the software.

2. Check that the signal ground pin no. 10 is connected.

3. Check that the Transmission channel pin no. 12 on the ICS 5000 is connected to your computer’s or PLC’s receiving channel.

4. Check that the Receiving channel pin no. 11 on the ICS 5000 is connected to your computer’s or PLC’s transmission channel.

5. If after all of this there is still no communications, it may be helpful to obtain a Break-out Box. This device uses LED’s to indicate the status of the various signals on a serial link. Based upon the voltage level present at the pin the LED’s will illuminate RED or GREEN or not illuminate at all. On a working, correctly wired cable, usually all that needs to be done is swapping pins 11 and 12 on the ICS 5000 screw terminal. This can be done by inserting a null modem adapter in series with the cable. If this still does not do the trick check the cable for poor connections.

8 TB Negative polarity of the serial output.

9 TA Positive polarity of the serial output.

10 COM Tied to the opto-isolated ground of the interface circuit.




4.18

RS-422 Troubleshooting

1. A default set of the communication parameters can be activated for five seconds by resetting the power to the unit and selecting a menu item when entering the software.

2. Check that the positive transmission channel, TA (pin 9), on the ICS 5000 is connected to your computer’s or PLC’s positive receiving channel, RA.

3. Check that the negative transmission channel, TB (pin 8), on the ICS 5000 is connected to your computer’s or PLC’s negative receiving channel, RB.

4. Check that the positive receiving channel, RA (pin 7), on the ICS 5000 is connected to your computer’s or PLC’s positive transmission channel, TA.

5. Check that the negative receiving channel, RB (pin 6), on the ICS 5000 is connected to your computer’s or PLC’s negative transmission channel, TB.

4.4.2 Poor Communication

Serial communications can be effected by several different things including cable length and electrical noise that is either radiated through the air or conducted over the connection cable. Cable length is limited by the overall capacitance of the cable. According to the EIA standard the total cable capacitance should not exceed 2500 pico-farads for RS232. For distances greater than 15 meters use the RS422 connection.

Table 4.3 RS-232 Communication VariablesVARIABLES DESCRIPTION OTHER INFORMATION

Hardware PIN # 12 Transmission channel 1 = -5 to -15 VDC

0 = +5 to +15 VDC

Pin # 11 Receiving channel 1 = -3 to -15 VDC

0 = +3 to +15 VDC

Pin # 10 Isolated Signal common

Software Baud Rate Transmission Speed in Bits/Second

From 1200 to 38400 b/s

Parity Error Detection Even, Odd or None

Word Length Length of transmitted word in bits

7 or 8 bits/word

Stop Bits Number of termination bits attached to each word

1 or 2



EMI (= Electro-Magnetic Interference) problems can be more difficult to solve. The communications cable that connects the ICS 5000 to the PC (or PLC) acts as an antenna when it passes through an electronic field. The following list presents the most common cures for communication problems. If communications cable runs are treated properly, your chances for success are greatly increased.

Keys to successful serial communications cabling

• Twisted Pair

• Insure that the cable selected is shielded.

• Protect cable from switching high voltage sources (AC motor control power).

• Ground cable correctly (avoid current ground loops).

4.5 Multi-Drop ConfigurationMulti-drop, is a protocol for passing data between several daisy chained ICS 5000 units. Up to 10 units can be connected in a Multi-drop network (see Figure 4.5 which follows). ASCII, Modbus and DF1 communication protocols are supported and configured in the same way as for stand alone ICS 5000 units.

Figure 4.5 Multi-Drop Communications Wiring Overview

CWarning – All units must be powered up and contain valid parameters for the network to function properly. If power is removed from any one unit, the remaining units “down stream” from the Host or PLC will not be able to communicate.



4.20

4.5.1 Multi-Drop Connection Details

The first ICS 5000 is connected to the PLC or Host Controller using either RS-232 or RS-422. The serial data is then passed from the secondary RS-422 port on the first unit to the primary RS-422 port on the second unit. This is then repeated until all units are linked.

Serial Comm connector pins 1 through 5 support RS-422 port #2, pins 6 through 10 support RS-422 port #1 and pins 10 through 12 support the RS-232 port A complete pin listing of the serial communications connections on the back of the ICS 5000 is found in Table 4.4 that follows

Figure 4.6 Multi-Drop Communications Wiring Terminal Details.

Table 4.4 Multi-Drop Wiring DetailsPin # Function Description

1 RB (422 Port 2) RS-422 Receiver Negative

2 RA (422 Port 2) RS-422 Receiver Positive

3 TA ((422 Port 2) RS-422 Transmitter Positive

4 TB (422 Port 2) RS-422 Transmitter Negative

5 Com (422 Port 2) GND (tied to the ICS chassis)

6 RB (422 Port 1) RS-422 Receiver Negative

7 RA (422 Port 1) RS-422 Receiver Positive

8 TB (422 Port 1) RS-422 Transmitter Negative

9 TA (422 Port 1) RS-422 Transmitter Positive

10 Com (422 Port 1 & 232 Port) Isolated Signal Common

11 RXD RS-232 Received Data

12 TXD RS-232 Transmitted Data



4.5.2 Multi-Drop Software Configuration

Configuration of the ICS 5000 for a multidrop network is straight forward. The four steps that must be followed are as follows:

1. Enable Multi-Drop operation - Either as Unit 1 Using RS-232 or as Any Unit Using RS-422

2. Enable RS-422 communications

3. Configure Serial communications

4. Set the unique unit address.

Note – Do Not enable Multi-Drop on last unit on the network. Simply enable RS-422 communications and terminate the Multi-Drop chain at that unit.

Note – Multi-Drop communications is not supported in firmware revisions before 3.01. Before attempting to setup a multi-drop network, insure that all ICS units contain firmware 3.01 or higher.

Enabling Multi-Drop

Configure the ICS 5000 to use Multi-Drop communications from the Protocols screen ( [ALT] + [M] + [1] ) of the Communications tab which is shown in the figure that follows. You simply select the configuration for the ICS 5000 you are working with from the Other Protocols group.

• Select MULTI-DROP using RS232 to configure the ICS 5000 to act as the first unit with communication to the host or PLC using RS-232.

• Select MULTI-DROP using RS422 to configure the ICS 5000 to act as any unit, including the first, communicating solely with RS-422.

• Select None of the Above to configure the ICS 5000 to act as the last unit.

Note – Do Not enable Multi-Drop on last unit on “chain”.



4.22

Enabling RS-422 Communications

Every ICS 5000 unit on the Multi-Drop network (except for the first unit when using a host supporting RS-232) must have it’s RS-422 port enabled. Configure the ICS 5000 to use RS-422 communications from the Port Options screen of the Communications tab ( [ALT] + [M] + [2] ), which is shown in the figure that follows. You simply select 1 Use ASCII protocol from the RS422 Port Options group to enable the port.

If you are using the MODBUS or DF1 protocol then option 1 from the RS422 Port Options group will be worded as follows:

• Use ASCII protocol until host starts using MODBUS protocol

or

• Use ASCII protocol until host starts using DF1 protocol

Configuring Serial Communications

The configuration of the Multi-Drop network is the simplest when using the ICS 5000’s Default communications parameters of 9600 baud, No Parity, 8 Bits per Word and 1 Stop Bit. This way the network can be configured without any additional communications wiring. To leave the ICS 5000 configured with the default parameters, simply skip to the Addressing section below.

Configure the serial communications parameters for both ports to match your setup as described earlier in this chapter starting with Line Settings, page 4.9.

BTip – Because of the way the ICS 5000 is configured when in Default communications mode, no additional wiring for setup is required. Details for configuring each ICS 5000 in your Multi-Drop network are provided in the next section.



Addressing

As with any protocol that allows communication to multiple ICS 5000 units from a single port, addressing is extremely important when using Multi-Drop. The Address character(s) that proceed each message that is sent and received allow the program or bus controller to route data correctly. Each ICS 5000 unit will only respond to data that contains the address it uses, and all data transmitted from the ICS 5000 units will also contain their respective addresses. Please refer to Addressing, page 4.10 for details on how to configure the ICS 5000 to use Addressing.

Configuring Remaining Units

As Multi-Drop support and addressing are enabled in each ICS 5000, using the default parameters to establish communication will provide easy access to the next unit for configuration. Once you have completed the setup of a unit, save the setup using File / Save As then go OFF Line by clicking the button on the toolbar. Insure power is on to the next unit in the chain, then continue as follows.

Use the Connection / Comm Port Settings menu item to display the PC Communications Settings dialog box. Click Set PC to DEFAULT Settings: then

to reset the communications parameters to the default settings and attempt to communicate with the Multi-Drop network. The unit(s) on the network that have already been configured will not respond as they are using User communications settings with an address character. If no response is received from the next unit to be configured, cycle power when prompted. The software will automatically “attach” to the unit and begin synchronizing data. Click the Write To ICS button to copy the setup data to the new unit, then change the Address character before continuing on to the next unit.

Once configuration of each unit is complete, the individual units can be accessed directly loading the correct .i5k file then communicating to the Multi-Drop network using the User communications parameters.

4.5.3 Multi-Drop Step By Step Setup

1. Connect laptop to RS-232 port (or RS-422 port via a converter) of ICS 5000 #1.

2. Start the ICS 5000 Support Software.

3. Open the .i5k file for ICS 5000 #1 or create a new one.

4. Using default settings establish communications with ICS 5000 #1. This will require that you cycle power to the unit if you are using RS-422.

5. Enable RS-422 communications using the Port Options screen , choose 1 Use ASCII protocol ...

6. Enable Multi-Drop from the Protocols screen, choose either MULTI-DROP using RS-232 or MULTI-DROP using RS-422.

Note – Do Not enable Multi-Drop on last unit on “chain”.



4.24

7. Use the Line Settings screen to setup the “User” communications parameters that you would like to use. Remember that the network setup will be easier if you choose the default (and standard) parameters of 9600 baud, No parity, 8 Bits per Word and 1 Stop Bit.

8. Enable addressing from the Addressing screen and to specify a unique ASCII Address.

9. If not done already, prepare ICS 5000 #2 for communications by connecting the communications to the first unit and applying power.

10. Open the .i5k file for ICS 5000 #2 or create a new one.

11. Repeat the above procedure starting at Step 4 for as many ICS 5000 unit as needed.

Note – Multi-Drop communications is not supported in firmware revisions before 3.01. Before attempting to setup a multi-drop network, insure that all ICS 5000 units contain firmware 3.01 or greater.


C H A P T E R

5
Advanced Communications Configuration 5
In this chapter:

• Introduction

• Choosing A Communications Protocol

• Configuring DF1 Communication

• Modbus® Configuration

• DeviceNet Configuration

• PROFIBUS Configuration

• Interbus Communications Configuration

• Custom Read and Write Data Tables


5 Advanced Communications Configuration

5.2 IC

5.1 IntroductionThis chapter covers the configuration of the ICS 5000’s advanced communications protocols. The advanced communications protocols are as follows:

• DF1

• MODBUS®

• DeviceNet

• PROFIBUS

• INTERBUS

Generally there are two steps required to configure the ICS 5000 to use any of these protocols:

1. Enable and configure desired protocol

2. Develop custom Read and Write data tables to match the application

Once configured, it is up to the user to correctly wire the communications cabling according to the guidelines specified by the selected protocol. Finally, the configuration of the PLC or computer must be completed so that the same protocol is use, and the communications settings match those configured in the ICS 5000.

The following image details the location of the communication ports available on the ICS 5000.

Figure 5.1 ICS 5000 Communications Port Layout



5.2 Choosing A Communications Protocol[Alt] + [M] + [1]

At boot up, both serial ports on the ICS 5000 use the ASCII protocol for five seconds, after which any of the additional RS232/422 or Field bus protocols can be used. The ICS 5000 supports ASCII, MODBUS and DF1 protocols for communication via the serial ports. Any of which can be used in conjunction with Multi-Drop for communicating with multiple units using a single host serial port. The ICS 5000 also supports the Devicenet, PROFIBUS and INTERBUS field buses for more advanced hardware networking. The figure below shows the Protocols screen of the Communications tab which lists all protocols available with the ICS 5000.

5.2.1 Communication Protocol Switch-Over

For systems configured with the MODBUS protocol or the DF1 protocol, the protocol switch-over is as follows:

Directly after boot-up the ICS 5000 is set to communicate in the ASCII mode. If no ASCII message is received, then the ICS 5000 respond as configured in the Port Options screen. The default method, however, reacts as follows:

When connected to the PLC the first message will cause the protocol to switch but it will not be answered. The second and all other messages will be answered in the new protocol. To go back to the ASCII protocol or to use the setup software again, reset the unit. This arrangement makes it easy to shift back and forth between the PLC and a PC running the setup software.



5.4 IC

5.3 Configuring DF1 Communication

5.3.1 Overview

With the exception of the skew control mode, any of the control algorithms in the ICS 5000 can be configured to use the DF1 protocol. The ICS 5000 supports DF1 via its RS-232 and RS-422 serial ports. Inside the ICS 5000, DF1 is supported by a 16 bit register and a 32 bit register. The 32 bit register are for PLC’s that supports DINT files (AB’s ControlLogix PLC).

Note – As with the other optional communication protocols supported by the ICS 5000, DF1 must be enabled via the ICS 5000 Support Software (Beta Release) before it can be used to communicate with the unit.

Configuration of the ICS 5000 for DF1 communications requires the following steps:

1. Enable the alternate communications protocol (DF1)

2. Configure the serial communications parameters to match the PLC or SLC

3. Configure the node address to match that used by the PLC or SLC

4. Configure custom data registers (optional)

5. Correctly wire the serial communications

All steps must be configured correctly to enable communication between the ICS 5000 and the PLC or SLC. Once the ICS 5000 has been configured, it should be reset to enable the new communications protocol. Once the unit is communicating via DF1, it will need to be reset to communicate using ASCII. To reset the unit, unplug the communications link from the PLC or SLC and cycle power to the ICS 5000.

5.3.2 Software Configuration

There are several steps that must be completed to allow the ICS 5000 to communicate using DF1 protocol. Poor or no communication may result if any of the steps are completed incorrectly or skipped. The following sections detail each of these steps.



Enabling the DF1 Protocol

For ICS 5000 to use the DF1 protocol, it must first be enabled. You accomplish this by selecting DF1 from the RS323/422 Protocols group of the Protocols screen ( [Alt] + [M] + [1] ) as shown in the figure that follows.

DF1 Serial Port Options

Now that the DF1 protocol has been enabled, you must select the serial port (RS- 232 or RS-422) which the ICS 5000 will use to communicate with the PLC or SLC. Use the Port Options screen ( [Alt] + [M] + [2] ) of the Communications tab, shown in the image that follows, to configure the operation of both ports. The port that is to be used should be set to 1 Use ASCII protocol until host starts using DF1 protocol. This way the ICS will always initialize to ASCII for setup then automatically switch to DF1 once the PCL or SLC starts communicating. Another option is to use choice 3 Switch To DF1 Protocol Without Waiting For Host. This option allows the port to switch automatically without the slight delay associated with the first option. However, establishing communications with the ICS 5000



5.6 IC

Support Software is more difficult with option 3 as power to the unit must be reset any time ASCII communication is used. The Port Options screen of the Communications tab is shown in the following image.

Line Settings

Use the Line Settings screen, shown in the figure that follows, to configure the basic serial communications parameters. Five seconds after boot-up, both serial ports (RS-232 & RS-422) have the option of switching to user-controlled line settings (USER Settings - see DF1 Serial Port Options on page 5.5) you define. These settings must match the serial port on the PLC or SLC that you are using.

BTip – Shut down any communication port not being used to avoid accidental messages from being received by the ICS 5000.



DF1 Address

Each piece of hardware that resides on a DF1 network must have a “Node” Address to uniquely identify the device. Use the Addressing screen ( [Alt] + [M] + [4] ) of the Communications tab, shown in the image that follows, to set this address. If you are also using an ASCII address, the DF1 address and the first character of the ASCII address are the same. The DF1 address must be between 0 and 63 and unique to the network.

Note – When multi-drop is used, all addresses on the network must be unique.

Custom Read and Write Data Table definition

While the DF1 protocol does not require the use of custom data tables, their use, however, may be advantageous for you project. See A Word About Number Conventions on page 5.66 for details on configuring this data.

5.3.3 Communications Cabling

The most common misunderstanding is that the ICS 5000 connects directly to the DH+ cable (or BLUE HOSE as it is commonly referred). The ICS 5000 is an serial device that supports DF1 protocol. There are three common hookup configurations:

1. Connect a serial cable from channel 0 of your PLC to the ICS 5000.

2. Connect a serial cable from a KE card to the ICS 5000 and plug the KE card into the PLC.

3. Connect an RS-232 cable from a KF2 module to the ICS 5000 and connect the DH+ cable (BLUE HOSE) to the KF2 module.

CWarning – Do not run the Setup software on one of the ports at the same time as MODBUS or DF1 are running on the other port. If you do, there will be two masters (PC and PLC) that are in control of the ICS 5000 unit (your vehicle).



5.8 IC

There are pros and cons to each communications configuration, so it is up to you to choose the configuration most suitable to the application. The ICS 5000 supports DF1 communications on either of it’s serial ports (RS-232 or RS-422). Therefore, cabling depends upon which port you use and the port (or channel) on the processor you use. The next two sections provide details on wiring your communications connections.

Channel 0

Cabling between the ICS 5000 and the PLC or SLC to support communications on CHANNEL 0 is relatively straightforward. The configuration used (a “null modem” style) is the same as that used to communicate with the ICS 5000 from a PC or Laptop computer. If you can establish communications from your computer to the ICS 5000, then the PLC or SLC should be able to communicate using the same cable, providing the appropriate connector is used. The PLC-5 series of controllers utilizes a female DB-25 connector for CHANNEL 0 while the SLC controllers use a male DB-9 (identical to most laptop). Gender changers and 9 to 25 pin converters can be purchased at most electronic supply stores.

The Multi-Drop feature in the ICS 5000 has been developed to expand the CHANNEL 0 connection by allowing multiple ICS 5000 units to communicate to the PLC via that one port. Except for wiring between units, no additional communications hardware is required. For more information on configuring the ICS 5000 to support Multi-Drop, consult Multi-Drop Configuration, page 4.19 or contact Trimble Technical Support.

CHANNEL 1A

The cabling between the ICS 5000 and the PLC or SLC to support communications on CHANNEL 1A is a bit more complicated due to the introduction of a DH+ to Serial interface module. The ICS 5000 can not be connected directly to the DH+ port of the PLC This connection is accomplished by using a Rockwell Automation KF-2 Module or equivalent. For wiring information, consult the User Manual of the Interface Module used.

5.3.4 PLC/SLC Communications Configuration

The Rockwell Automation’s higher-level processors come equipped with a standard communications port as CHANNEL 0 (DB-25 on PLC-5/XX and DB-9 on SLC-5/0X) and a Data Highway Plus (DH+) port as CHANNEL 1 (typically a three pin plug). Each of these ports must be configured by the user. Processors that support DF1 communications with the Trimble ICS 5000 on either channel are shown in Table 5.1 below.

Table 5.1 PLC/SLC CompatibilityPLC Processors SLC Processors

5/11 5/03 (no DH+ support on channel 1)

5/20 5/04

5/30 5/05



5.3.5 PLC-5/XX Series Controllers

PLC-5 series controllers are “full size” rack mounted processors and I/O cards. Virtually all processors in this family support communication to the Trimble ICS 5000 via both CHANNEL 0 and CHANNEL 1. Configuration of the communications ports and the message instructions to enable communication between the PLC and the ICS 5000 is described in the following sections.

CHANNEL 0 Configuration

Configuration of CANNEL 0 is shown in the figure below. The Communication Mode should be set to System (Point-To-Point). The Diagnostic File - Specifies an unused data file (9-999) to store channel data status information. The system automatically creates an integer file. This is set to zero (the default) so it is disabled. The PLC's Serial Port should be configured to match the ICS 5000's. In this example we are using 9600 baud, 8 bits per character, 1 stop bit with no parity. Error Detect(ion) is set to BCC and the Control Line configuration is set to Full Duplex Modem.

This will fully configure the processor CHANNEL 0 communications port. Communications via any of the other processor channel will be handled differently.

Note – If these changes are to be made “On-line” with the processor in “Run”, the processor will have to be placed into “Program” and then returned to “Run” before they can take effect.

5/40, 5/40L, 5/40V,

5/40VL

5/60, 5/60L

5/80, 5/80V, 5/80VL

Table 5.1 PLC/SLC CompatibilityPLC Processors SLC Processors



5.10

CHANNEL 1A Configuration

Configuration of CANNEL 1A is shown in the figure below. Note that several of the settings are fixed. The I/O Channel Mode is set to Data Highway Plus (DH+) because this is the processor's default communications port. The Diagnostic File specifies an unused data file (9-999) to store channel data status information. The system automatically creates an integer file. This is set to zero (the default) so it is disabled. Baud Rate must be 57.6 kBaud if CHANNEL 1A is configured for DH+. The Node Address is set to the address number of the processor. If the Data Highway Plus channel is CHANNEL 1A, the station (node) number is set with switch SW1 on the processor. Link ID is used only if another communication protocol (Data Highway or Data Highway II for example) is used. The Global Status Flags File reduces DH+ traffic by allowing stations to share information rather than send messages. It is not required to setup communications to a Trimble ICS 5000.

This will fully configure the processor CHANNEL 1A communications port. Communications via any of the other processor channel will be handled differently.




Message (MSG) Instruction Setup

The Message instruction for a PLC-5/XX controller is configured the same way regardless of which channel is used to communicate to the ICS 5000. This instruction can be found under the Input/Output instruction sub-group tab of the RS Logic 5 Software. It can also be inserted by typing MSG on an empty rung. The figure below shows a rung with an inserted message instruction.

When the message instruction is inserted into a rung of logic, the user is required to enter a control block. The Control Block should be assigned according to Table 5.2 that follows. Failure to assign the correct control block will result in an error from the message instruction. The message control block in the example ladder above is N100:0. Control blocks from other message instructions (N100:28 and N100:42 in this example) are used to sequence the operation of the message instruction on this rung.

When using the message instruction, care should be taken to insure that all communications attempts have been completed successfully. To assist with this, the control block contains status bits that can be used to monitor the message instruction. These bits include: EN - enabled bit; DN - done bit and ER - error bit.

Note – The processor will boot to run mode and begin executing the program before the DH+ port is ready to communicate. This should be taken into consideration when the code is being written, and the message commands should not be enabled until the port is ready.

The status bits can be utilized to synchronize multiple message instructions, monitor communications for timeouts and to perform retries in the event of an error or communications time out. They are addressed as follows:

Table 5.2 Control Block Address SelectionIf you have this processor: Use this Control Block address:

Original PLC-5 An integer (N) file address. Example: N7:0

Enhanced PLC-5, Ethernet PLC-5, or VME PLC-5

An integer (N) or message (MG) file address. Example: MG10:0Using the MG control block, the control block size is fixed at 56 words.

Ethernet PLC-5, ConrolNet PLC-5, VME PLC-5

A message (MG) file type to access the VMEbus, Ethernet, or ControlNet network.



5.12

{Control Block}/15 - enabled bit

{Control Block}/13 - done bit

{Control Block}/12 - error bit

Where {Control Block} is the file for the message instruction to be monitored (N100:0 in the previous example).

Once the Control Block is correctly defined, the setup screen (see the following figure) will be displayed. This screen contains the remaining configuration that needs to be done before the message instruction will pass data between the PLC and the ICS 5000. From this screen the user may configure THIS PLC-5 and the TARGET DEVICE (the ICS 5000).

For THIS PLC-5, the Communications Command specifies whether the instruction performs a read (read data from the ICS 5000) or a write (write data to the ICS 5000) operation and the type of device that is being communicated with. The Data Table Address specifies either the source (write) or destination (read) of the data transferred using the instruction. Finally, the Size in Elements refers to the number of data elements to be read from or written to the ICS 5000. See the section of this document entitled “Interpreting Data in the PLC/SLC” for more information on the data written to and read from the ICS 50000.

For the TARGET DEVICE (ICS 5000), the Data Table Address relates to the data layout within the ICS 5000 (N7:0 in this example). The Data Table Address is mostly symbolic. Only the portion of the address after the colon (:) is used by the ICS 5000. The N# can be set to any value. The Local Station Address is the address character setup in the ICS 5000 (33 in this example). The Local/Remote mode should be set to Local.

5.3.6 SLC 5/0X Series Controllers

SLC 5/0X series controllers are “medium size” rack mounted processors and I/O cards. Only the upper level (5/03, 5/04 and 5/05) processors in this family support communication to the Trimble systems via CHANNEL 0, and only 5/04 and 5/05 processors support communication via DH+ on CHANNEL 1A. Lower level (5/03



and below) processors may support only DH-485 communication on CHANNEL 1A, but configuration of that protocol is not covered in this document. Configuration of the communications port and the message instructions to enable communication between the SLC and the ICS 5000 is described in the following sections.

CHANNEL 0 Configuration

Configuration for CANNEL 0 is depicted in the figure below. Insure that the System configuration and not the User configuration is active by checking the General tab of the CHANNEL CONFIGURATION dialogue box. The Driver should be set to DF1 Full Duplex. The serial port settings should be configured to match the distance meter. In this example we are using 9600 baud, 8 bits per character, 1 stop bit with no parity. The Source ID is not used in this application.

Protocol Control is setup as follows: Control Line is set to No Handshaking, Error Detection utilizes BCC, and Embedded Responses are Enabled. The values for ACK Timeout, NAK Retries and ENQ Retries can be left at the default values. Checking the box enables Duplicate Packet Detect.




5.14

CHANNEL 1A Configuration

Configuration for CANNEL 1A is depicted in the figure below. The Driver should be set to DH+ (the default). The Baud should be set to match the DH+ baud rate. The Node Address should match the processors node address.


Message (MSG) Instruction Setup

The setup of the SLC 5/0X message instruction for communications over either of the two channels is almost the same. By simply changing the Channel value referenced in the MESSAGE SETUP dialogue box (picture follows), communications can be directed to either channel. The Message instruction can be found under the Input/Output instruction sub-group tab of the RS Logic 500 Software. It can also be inserted by typing MSG on an empty rung. The figure that follows shows a rung with an inserted message instruction.

When the message instruction is inserted into a rung of logic, the user is required to enter some brief information about the instruction. The Read/Write parameter should be set to match the action the instruction is to perform (in this case it is set to Read). The Target Device should be set to PLC5 because the ICS 5000 emulates a



PLC-5 series controller. Local/Remote should be set to Local. A Control Block should be selected from your unused files (N100:0 is the control block file for this example). Any unused integer file may be used for the control block. Control blocks from other message instructions (N100:28 and N100:42 in this example) are used to sequence the operation of the message instruction on this rung.

Care should be taken when using the message instruction to insure that all communications have been completed successfully. To assist with this, the control block contains status bits that can be used to monitor the message block. These bits include: EN - enabled bit, DN - done bit and ER - error bit.

Note – The processor will boot to run mode and begin executing the program before the DH+ port is ready to communicate. This should be taken into consideration when the code is being written, and the message commands should not be enabled until the port is available.

The status bits can be utilized to synchronize multiple message instructions, monitor communications for timeouts and to perform retries in the event of an error or communications timeout. They are addressed as follows:

{Control Block}/15 - enabled bit

{Control Block}/13 - done bit

{Control Block}/12 - error bit

Where {Control Block} is the file for the message instruction to be monitored (N100:0 in the previous example).

Once the control block is correctly defined, the setup screen (see the figure that follows) will be displayed. This screen contains the remaining configuration that needs to be done before the message instruction will pass data between the SLC and the ICS 5000.

The Channel value on the SLC is the set to 0 for communication via CHANNEL 0 and 1 for communication via CHANNEL 1A. The Target Node (ICS 5000) is set to match the address setup in the ICS 5000 (33 in this example). The Local File Address in the SLC is the source of data to be written or the destination of data to be read. The Targets File Address relates to the data layout within the ICS 5000 (N7:0 in this example). The Targets File Address is mostly symbolic. Only the portion of the address after the colon (:) is used by the ICS 5000. The N# can be set to any value. The Message Length in Elements is the amount of data to be read from or



5.16

written to the ICS 5000. The Message Timeout is the length of the message timer in seconds. A timeout of 0 seconds means that there is no timer and the message will wait indefinitely for a reply.

5.3.7 Message Instruction Basics

This section is a primer for Message instruction usage. It is only intended as an introduction, so please do not consider it to be a complete tutorial. For more information on the subject, consult the programming reference that accompanies your processor.

Figure 5.2 that follows depicts communication between a processor and two Trimble ICS 5000 positioning systems.

Figure 5.2 PLC / ICS 5000 Data Flow

In this example, four message instructions are used to read and write to the two ICS 5000s. The message with control block that begins at N100:0 is writing two blocks of data from processor file N200 beginning at word 3 to the first ICS 5000 beginning at register 3. This instruction could be used to write a value only to the Distance Destination registers, which would initiate a move. The second message command uses a control block beginning at N101:0. Here the first 7 registers are read from the ICS 5000 and stored in processor data file N201 beginning at word 0. This instruction could be used to the read status and the distance, while the combination of the first two message commands would be an appropriate way to read and write the minimal amount of data to the ICS 5000.

The next two message commands read and write all 16 words of status and control information in the ICS 5000. The “read” data is stored in processor data file N201 beginning at word 16 while file N200 beginning at word 16 is source of the “write”



data. This combination is valid, but care must be taken to write the appropriate values to control registers (distance and halt for example) to avoid unexpected operation. Consult the command register listing in the Modbus/DF1 Set-up Manual (Art. No. 571 701 291/3) for detailed information of control register actions.

Sequencing of the execution of multiple message commands and error monitoring is critical to proper operation. Use the various status bits mentioned in the previous section to perform the various “house keeping” tasks necessary.

5.4 Modbus® ConfigurationThis section of the ICS 5000 Support Software User Manual deals with the operation of the ICS 5000 when using the ASCII/MODBUS® protocol. It discusses the steps involved with preparing an ICS 5000 for MODBUS operation and the ICS 5000 register assignments. The ICS 5000 operates as an RTU SLAVE device, therefore, a Master device (PLC or computer) must initiate communications.

With the exception of the skew control mode, any of the control algorithms in the ICS 5000 can be configured to use the MODBUS protocol. The ICS 5000 supports MODBUS via its RS-232 and RS-422 serial ports. MODBUS is supported by a 16 bit register.

Note – As with the other optional communication protocols supported by the ICS 5000, MODBUS must be enabled via the ICS 5000 Support Software before it can be used to communicate with the unit.

Configuration of the ICS 5000 for MODBUS communications requires the following steps:

1. Enable the alternate communications protocol (MODBUS)

2. Configure the serial communications parameters to match the PLC or SLC


4. Configure custom data registers (optional)

5. Correctly wire the serial communications

All steps must be configured correctly to enable communication between the ICS 5000 and the PLC or SLC. Once the ICS 5000 has been configured, it should be reset to enable the new communications protocol. Once the unit is communicating via MODBUS, it will need to be reset to communicate using ASCII. To reset the unit, unplug the communications link from the PLC or SLC and cycle power to the ICS 5000.

5.4.1 Software Configuration

There are several steps that must be completed to allow the ICS 5000 to communicate using MODBUS protocol. Poor or no communication may result if any of the steps are completed incorrectly or skipped. The following sections detail each of these steps.



5.18

Enabling the MODBUS Protocol

For ICS 5000 to use the MODBUS protocol, it must first be enabled. You accomplish this by selecting MODBUS from the RS323/422 Protocols group of the Protocols screen ( [Alt] + [M] + [1] ) as shown in the figure that follows.

MODBUS Serial Port Options

Now that the MODBUS protocol has been enabled, you must select the serial port (RS-232 or RS-422) which the ICS 5000 will use to communicate with the PLC or Host Computer. Use the Port Options screen ( [Alt] + [M] + [2] ) of the Communications tab, shown in the image that follows, to configure the operation of both ports. The port that is to be used should be set to 1 Use ASCII protocol until host starts using MODBUS protocol. This way the ICS will always initialize to ASCII for setup then automatically switch to MODBUS once the PCL or SLC starts communicating. Another option is to use choice 3 Switch To MODBUS Protocol Without Waiting For Host. This option allows the port to switch automatically



without the slight delay associated with the first option. However, establishing communications with theICS 5000 Support Software is more difficult with option 3 as power to the unit must be reset any time ASCII communication is used.

Modbus Line Settings

Next you use the Line Settings screen shown in the figure that follows to configure the basic serial communications parameters. Five seconds after boot-up, each serial port (RS232/422) has the option of switching to user-controlled line settings (USER Settings) you define (see MODBUS Serial Port Options on page 5.18). These settings must match the serial port on the PLC or SLC that you are using.

BTip – Shut down any communication port not being used to avoid accidental messages from being received by the ICS 5000.



5.20

MODBUS Address

Each piece of hardware that resides on a MODBUS network must have a “Node” address to uniquely identify the device. Use the Addressing screen ( [Alt] + [M] + [4] ) of the Communications tab, shown in the image that follows, to set this address. If you are also using an ASCII address, the MODBUS address and the first character of the ASCII address are the same. The MODBUS address can be between 1 and 255 and must be unique on the network.

Note – When multi-drop is used, all addresses on the network must be unique.

Custom Read and Write Data Table Definition

While the MODBUS protocol does not require the use of custom data tables, their use, however, may be advantageous for you project. See Custom Read and Write Data Tables on page 5.62 for details on configuring this data.

Communications Cabling

You will need to install a cable between one of the MODBUS compatible serial ports on the PLC and the ICS 5000. See Serial Communications Port Information on page 4.15 for details on wiring the RS-232 or RS-422 ports.

5.5 DeviceNet Configuration

5.5.1 Overview

Configuration of the ICS 5000 for DeviceNet communications requires the following steps:

CWarning – Do not run the ICS 5000 Support Software on one of the ports at the same time as MODBUS or DF1 are running on the other port. If you do, there will be two masters (PC and PLC) that are in control of the ICS 5000 unit (your vehicle).



1. Enable the alternate communications protocol (DeviceNet)

2. Configure the DeviceNet communications parameters to match the PLC or SLC


4. Configure custom data registers

5. Correctly wire the network communications

All steps must be configured correctly to enable communication between the ICS 5000 and the PLC or SLC. Once the ICS 5000 has been configured, it should be reset to enable the new communications protocol. Once the unit is communicating via DeviceNet, it will need to be reset to communicate using ASCII. To reset the unit, unplug the communications link from the PLC or SLC and cycle power to the ICS 5000.

5.5.2 ICS 5000 Software Configuration for DeviceNet

There are several steps that must be completed to allow the ICS 5000 to communicate using the DeviceNet protocol. Poor or no communication may result if any of the steps are completed incorrectly or skipped. The following sections detail each of these steps.

Enabling the DeviceNet Protocol

For ICS 5000 to use the DeviceNet protocol, it must first be enabled. You accomplish this by selecting DeviceNet from the Other Protocols group of the Protocols screen ( [Alt] + [M] + [1] ) as shown in the figure that follows.



5.22

DeviceNet Network Baud Rate

The only Line Settings parameter that is required by DeviceNet is the Baud Rate. You configure the ICS 5000’s DeviceNet Baud Rate from the ICS 5000 Support Software Line Settings screen ( [Alt] + [M] + [3] ) by using the drop down menu in the DeviceNet group (shown below) to select either 125, 250 or 500. The values listed are in kBaud (x1000).

DeviceNet Address

DeviceNet requires a unique Address be applied to each device on the network. The ICS 5000’s address for the DeviceNet Network is configured from the ICS 5000 Support Software Addressing screen ( [Alt] + [M] + [4] ) by using the arrow buttons to select a number between zero and 63.

Read and Write Table Creation

Read and Write data tables must be constructed in the ICS 5000 unit via the ICS 5000 Support Software before the DeviceNet Scanner can communicate with the ICS 5000 unit. For details on configuring the Read and Write data tables, see Custom Read and Write Data Tables on page 5.62.

CWarning – DeviceNet requires that each device on the network use the same baud rate. Introducing a device with a different baud rate will cause a network error.

CWarning – DeviceNet requires that each device on the network use the same baud rate. Introducing a device with a different baud rate will cause a network error.

BTip – Due to the way the DeviceNet scanner module locates nodes on the network, it is desirable to have all node addresses as close to zero as possible.



ICS 5000 Status

The RS-232 port can be used for checking status of the ICS 5000 unit during setup of the DeviceNet network. Connect the RS-232 port to a PC with a terminal program (the HyperTerminal program provided with Windows works well). You can check the status of the ICS 5000 unit by sending the “E” command to the unit.

Note – The BT command resets the ICS 5000 and also the DeviceNet driver inside the ICS unit.

5.5.3 DeviceNet Network Configuration

Network Registration

The following example screens are taken from Rockwell Automation’s RSNetWorx for DeviceNet configuration software. The first step to adding a DeviceNet enabled and configured ICS 5000 to a network is to run the Electronic Data Sheet or EDS Registration Wizard by selecting Tools/EDS Wizard... as shown in the following image.

CWarning – Do not run the Setup software on one of the ports at the same time as DeviceNet is running on the other port. If you do, there will be two masters (PC and PLC) that are in control of the ICS 5000 unit (your vehicle).

CWarning – Do not experiment by sending commands if it is not known which device (PC or PLC) that is in control of the vehicle.



5.24

Note – The EDS Wizard can also be initiated by going Online with the network and using the mouse to right-click on an unregistered device (designated by a question mark) then selecting Register Device from the popup menu.

This displays the EDS Wizard Options dialog box shown in the figure that follows. Choose the first option, Register an EDS file(s), and click Next.

This displays the Register Device screen shown below. This screen allows you to select the EDS file(s) for the device(s) you wish to register. When the ICS 5000 is configured for DeviceNet operation (ICS 5000 Software Configuration for DeviceNet on page 5.21), a custom EDS file is created. This file, called ICS5000.eds, is stored in the working directory along with the .i5k file used to store the configuration of the ICS 5000.

Click Browse to search for the EDS file that was generated for the ICS 5000 that you are working with. The example path is C:\ICS\CRANE1\, you will need to browse to the correct path for your EDS file for the configuration to be successful.



Once the correct file has been located, click Next to continue. At this point the software will run a quick evaluation of the EDS file and display any errors detected as shown in the following image.

Now that the ICS 5000 has been registered, you can pick an icon to use to depict the unit on a graphical representation of the network. From the Change Graphic Image screen shown below make sure that the ICS 5000 unit you are working with is highlighted then click Change Icon.



5.26

This displays the default icon library (shown below), which, unfortunately does not contain an icon for the ICS 5000. An icon in an alternate directory can be selected by clicking Browse at the bottom of the dialog box.

Locate the ICS 5000 icon located in the ICS 5000 Support Software installation directory. Upon opening this directory, the available icons will be displayed as shown below. Select the ICS5K.ico file to choose the closest graphical representation, then click Open.

This returns you to the Change Graphic Image screen, but this time the icon that you choose will be used as shown below.



The Final Task Summary screen, shown in the image that follows, will now be displayed, confirming all devices that you have chosen to register. Click Next to execute the registration process and finish EDS file registration task.

The next step is to add the ICS 5000 to the DeviceNet Scanner’s Scanlist, and insure that the device mapping on the scanlist is correct.

Scanner Configuration

Once the ICS 5000 unit has been successfully registered on the DeviceNet network, it will be correctly displayed when the RSNetWorx software is Online. To go Online, select Network / Online as shown below.



5.28

This will cause the software to attach to the DeviceNet network, and update the graphical representation of the network as shown in the following image.

The graphical display of the network will contain some basic information about the network’s population. Each device registered on the network is displayed in order of it’s node address. The following figure shows that the ICS 5000 has been configured as node 9, the 1747-SDN scanner module is node 0 and the PC interface through which RSNetWorx is accessing the network is node 62.



Even though the ICS 5000 has been successful registered, and it appears on the network graphical display, the system is not yet completely configured to exchange data. The ICS 5000 must be added to the scanner’s Scanlist before useful data can be exchanged over the DeviceNet network.

To configure the scanner’s Scanlist, click on the device on the network graphic (shown in the previous image) then select Device / Properties or right-click on the Scanner icon. This displays the Scanner Module Properties dialog box as shown below.

Select the Scanlist tab to display the devices available for inclusion along with devices already included in the Scanlist. To add the ICS 5000 to the Scanlist, insure that the Automap on Add check box below the Available Devices window is checked, then select the ICS 5000 that you configured and click the right arrow (>). This will add the ICS 5000 to the Scanlist as shown below, and automap the data registers needed as stated in the ICS 5000’s EDS file. Clicking the double right arrow (>>) will add all devices.



5.30

Adding the ICS 5000 to the scanlist with the Automap on Add feature enabled, will automatically configure the data registers specified within the EDS file. It is important that the EDS file that was used to register the ICS 5000 (Network Registration on page 5.23) contain the most current setup information. If you make changes to the ICS 5000’s read or write registers after the unit has been registered on the network, then the unit needs to be removed and then re-register using the new EDS file.

Note – If changes are made to the read or write registers after it has been registered on the DeviceNet network, then the unit must be removed and re-registered with the new EDS file that was created by the Support Software.

The following figures present examples of the automapping results. Click Edit I/O Parameters on the Scanlist tab of the Scanner Properties dialog box to display the details of the ICS 5000 I/O mapping as shown below. This dialog box shows the type of message (Polled) and the transmit (Tx) and receive (Rx) data sizes.

Scanner mapping details can be accessed from the tabs along the top of the Scanner Module Properties dialog box. You use the Input tap to select the Scanner Input mapping is shown in the following figure.



You select the Output tap to select the Scanner Output mapping is shown in the following figure.

This completes the software configuration of both the ICS 5000 and the DeviceNet scanner.

5.5.4 DeviceNet Cable Connections

The DeviceNet port (4 pole screw terminal) on the ICS 5000 is located on the rear panel directly below the Power Connector. The pin configuration for the connector is shown in Figure 5.3 and Table 5.3 that follow.

Figure 5.3 DeviceNet Wiring Overview

Table 5.3 DeviceNet PinoutTerminal Function Wire color Description

1 CAN_High White Not inverted signal.

2 CAN_Low Blue Inverted signal.

3 V- Black DeviceNet networks power.

4 V+ Red DeviceNet networks power.



5.32

The shield or bare wire is connected to the chassis ground using the cable feed-throughs on the rear cover of the unit as described in Grounding And Isolation, page 5.34.

Cable

An ICS 5000 is connected to a DeviceNet network via a drop line. DeviceNet Thin cable with an outside diameter of 6.9 mm (0.27 inch), commonly used for drops, will fit the cable feed-through on the rear cover of the ICS 5000 unit. The cable feed-through is designed to accept cables with a diameter between 5 to 12 mm (0.2 to 0.5 inch).

Note – DeviceNet Thick cable will not fit in to the ICS 5000 cable feed-through.

DeviceNet Wiring

The wires to be connected to the ICS 5000 unit are Can_H (White), Can_L (Blue), V- (Black), V+ (Red) and the shield (Bare). The DeviceNet interface hardware within the ICS 5000 (transceiver) is isolated from the rest of the unit.

Cable Connections

1. Turn off the power supplies for the ICS 5000 unit and the DeviceNet network before beginning.

2. Remove the protective cover on the rear panel.

3. Remove the cable insulation so that the wires (item 1 in Figure 5.4) are slightly longer than the shield (item 2 in Figure 5.4). The shield must come into contact with the metal tongues (item 3 in Figure 5.4) in the hole. Cut the Bare wire so it is as long as the shield.

Figure 5.4 Cable Preparations

4. Slide the strain relief cleat and insulator (stuffing tubes) onto the cable and pass the cable through the hole (item 4 in Figure 5.5).



5. Connect the wires in the DeviceNet network cable to the 4 pole screw terminal (item 5 in Figure 5.5) as listed in DeviceNet Cable Connections, page 5.31. White wire (CAN_High) to terminal number 1. Blue wire (CAN_Low) to terminal number 2. Black wire (V-) to terminal number 3. Red wire (V+) to terminal number 4.

Figure 5.5 DeviceNet Cable Connection.

6. Connect the terminal strip to the block on the ICS rear panel.

7. Attach the strain relief collar (item 6 in Figure 5.6) and tighten the sealing nut (item 7 in Figure 5.6) firmly with a 22 mm ring spanner to avoid leakage. Tighten the sealing nut with 6.25 Nm.

Figure 5.6 Cable Feed-Through Sealing Nut Mounting

Power

It is recommended what the ICS 5000 be powered by a separate 24 VDC regulated power supply and not the DeviceNet networks power supply. This is because the voltage supplied by the DeviceNet network could drop to as low as 11 V DC and the ICS 5000 unit requires at least 18 V DC (24 V DC nom) to operate. The supplied power should be connected to the ICS 5000 power supply port, see Figure 5.2.

4.5.

1 2 3 4



5.34

The DeviceNet networks power should be connected to the V+ and V- terminals on the ICS 5000’s DeviceNet port. After the ICS 5000 has been configured for DeviceNet, ICS 5000 Software Configuration for DeviceNet on page 5.21, the DeviceNet task within the unit will continuously check the DeviceNet networks voltage. If the voltage (V+) goes low, the DeviceNet task in the ICS 5000 shuts down the unit.

Grounding And Isolation

The ICS 5000 grounding philosophy is to ground the unit in only one location. The reason for this is to avoid ground loops. The ICS 5000 unit should only be grounded via the DeviceNet network connection (Figure 5.6 that follows). The ICS 5000 unit is isolated from the vehicle via it’s mounting bracket, and shields around the 24 V cable and I/O cable should only be connected at the ICS 5000. Shields are connected to the Chassis Ground using the specially designed cable feed-throughs on the rear cover of the unit. When terminating the wiring to the ICS 5000 insure that the shields are correctly attached. Consult the ICS 5000 Installation Manual (571 701 451 or 571 701 453) for details on wiring.

Figure 5.7 ICS 5000 Interconnection and Grounding

Note – The ICS 5000 unit should only be grounded via the DeviceNet network, and according to the DeviceNet specification, the DeviceNet network should be grounded in only one location.

BTip – If the DeviceNet network voltage goes low, the ICS 5000 unit will halt any started motion in a controlled way and new commands will be ignored until the voltage is restored.



5.6 PROFIBUS Configuration

5.6.1 General Device description

PROFIBUS-DP is used for data exchange at the field level between industrial controllers (PLC or PC) and distributed field devices such as I/O sensors-actuators, motor starters and operator interfaces.

Regardless of the control algorithm being used, the ICS 5000 can be configured to support the PROFIBUS protocol with the exception of the Advanced Skew Control Version (TCS2). The ICS 5000 is implemented as a slave device on the PROFIBUS network. The supported Profile is General. The unit must be configured correctly before PROFIBUS communication will be possible.

Figure 5.8 Simplified overview of a PROFIBUS network

PNO identification number

The ICS 5000 unit has the PNO identification no. 068A.

PROFIBUS International Certificate

The ICS 5000 unit has the PROFIBUS Certificate No.: Z00791

Profile

The supported PROFIBUS profile in the ICS 5000 unit is of type General.

Station Address

The PROFIBUS Station Address of the ICS 5000 is configured via the ICS 5000 Support Software.



5.36

Bus Termination

A PROFIBUS network must be terminated at the ends of the bus segments. The ICS 5000 unit can be terminated by a built-in termination or by an external active terminator (see PROFIBUS Connections with Internal Termination Jumpers, page 5.50 for details).

Baud Rate

ICS 5000 supports Transmission rates for PROFIBUS between 9.6 kBaud to 12 Mbaud. The Baud rate is automatically detected by the ICS 5000 unit.

GSE File

The ICS 5000’s GSE file name is ICS_068A.gse. A bitmap file named ICS5000n.bmp is also available for the PROFIBUS master configuration tool. The GSE file and bitmap file are included in the ICS 5000 Support Software.

5.6.2 ICS 5000 Configuration

The ICS 5000 supports the PROFIBUS-DP profile General. Read and Write data Modules are built from the various Command Modules available from the GSE file. PROFIBUS-DP communication configuration for the ICS 5000 must be done using the ICS 5000 Support Software provided with the unit.

Use the following steps to configure the ICS 5000 to use the PROFIBUS-DP communication protocol.

1. Enable the PROFIBUS-DP communication protocol.

2. Set the Network address.

3. Build the read and write Modules.

4. Connect (internal or external) termination if required.

5. Print out the text file created from the ICS’s Support Software with the settings and selected communication modules.

The PROFIBUS Master should be configured with the data from the settings in the ICS. The data is available in a printable text file: “Profibus.txt” The text file is stored in the same directory as the data files from the characterization.

Note – Network’s transmission rate is configured in the Master and auto detected by the ICS 5000. Data format (Motorola or Intel) and extended diagnostic functions are configured by the Master.

Note – As with the other optional communication protocols supported by the ICS 5000, PROFIBUS must be enabled via the Support Software before it can be used to communicate with the unit.



Enabling PROFIBUS

PROFIBUS is enabled ICS 5000 Support Software Protocols screen ( [Alt] + [M] + [1] ) by selecting the PROFIBUS option.

PROFIBUS Network ID

PROFIBUS requires a unique Network ID be applied to each device on the network. The ICS 5000’s address for the PROFIBUS Network is configured from the ICS 5000 Support Software Addressing screen ( [Alt] + [M] + [4] ) by using the arrow buttons to select a number between zero and 128.

Read and Write Table Creation

Read and write data tables must be constructed in the ICS 5000 unit via the ICS 5000 Support Software before the PROFIBUS Master can communicate with the ICS 5000 unit. See Custom Read and Write Data Tables on page 5.62.

CWarning – PROFIBUS requires that each device on the network have a unique Node Address. Duplicate Node Addresses will cause a network error.



5.38

ICS 5000 Status

The RS-232 port can be used for checking status of the ICS 5000 unit during setup of the PROFIBUS network. Connect the RS-232 port to a PC with a terminal program. (For example the Hyperterminal program included with Windows can be used.) Check the status of the ICS 5000 unit by sending the “E” command to the unit.

Note – The BT command resets the ICS 5000 and also the PROFIBUS driver inside the ICS unit.

5.6.3 Communications Setup

PROFIBUS Command Listing

Table 5.4 that follows contains the available command modules in the GSE file used to construct the Read and Write tables in the ICS 5000 unit. The commands are separated into 8, 16 and 32 Bits to allow you the flexibility to develop messages that require shorter communication times on the network. In the table, the first and second columns contain the Module function and the ASCII Command Equivalent. The third column contains the Name in the GSE file and describes the Data Size (1 Byte, 1 Word or 2 Word - 8, 16 or 32 Bit). The Last column contains the ID number of the modules in the ICS 5000.

Some of the commands use values that are small enough (< 128 for the 1 Byte (8 bit) and < 32,767 for the 1 Word (16 bit)) that a reduced word size will work. For example: ID# 158 is declared as a 32 bit command, the value returned will never exceed 128 and can thus be accessed as either an 8 or 16 bit value to reduce the message size and conserve bandwidth on the network.

To use the Element ID #’s in the Read or Write Module configuration, simply enter the number corresponding to the 1 Byte, 1 Word or 2 Word values (Right Hand Columns) directly in to the Support Software’s element list. Care must be taken

CWarning – Do not run the Support Software on the RS-232 port at the same time as PROFIBUS is running on the other port. If this is done, there will be two masters (PC and PLC) that are in control of the ICS 5000 unit (your vehicle).

CWarning – Do not experiment by sending commands if it is not known which device (PC or PLC) that is in control of the vehicle.

CWarning – The PROFIBUS-DP Master starts by automatically writing zeroes into all configured Write Modules during the boot-up sequence. This must be anticipated in the PLC program if you, for example, configure Modules like A for acceleration or V for velocity. A wakeup value must be written into the specific registers after they have been zeroed.



when accessing data as smaller (8 or 16 bit) values. If the data value has the possibility of exceeding the limit (128 or 32,767) then it must be treated as a larger value. If not, then the value could be truncated by the PLC and errors could occur.

CWarning – While accessing certain elements as smaller (8 or 16 bit) values will produce correct results, this is not the case with every element. Take care when assigning elements or data truncation may occur.

Table 5.4 PROFIBUS Command Module ListingModule Function ASCII

CharName in GSE file and data size ICS

ID

Read Loop Status E R E Status 1 Byte 0

R E Status 1 Word 64

R E Status 2 Word 158

Read Station Destination S R S Station 1 Byte 11

R S Station 1 Word 65

R S Station 2 Word 159

Write Station Destination W S Station 1 Byte 11

W S Station 1 Word 65

W S Station 2 Word 159

Read Station Location Y R Y Station 1 Byte 22

R Y Station 1 Word 66

R Y Station 2 Word 160

Read Distance Destination D R D Distance Destination 1 Word 972

R S Distance Destination 2 Word 161

Write Distance Destination W D Distance Destination 1 Word 972

W D Distance Destination 2 Word 161

Read Current Distance X R X Current Distance 1 Word 982

R X Current Distance 2 Word 162

Read Return Signal Strength R R R Return Signal Str 1 Byte 7

R R Return Signal Str 1 Word 71

R R Return Signal Str 2 Word 163

Write Return Signal Strength W R Return Signal Str 1 Byte 7

W R Return Signal Str 1 Word 71

W R Return Signal Str 2 Word 163

Write Halt Acceleration H W H Halt Acc 1 Byte 81

W H Halt Acc 1 Word 72

W H Halt Acc 2 Word 164

Read Operating Acceleration A3 R A Op Acceleration 1 Word 73

R A Op Acceleration 2 Word 137

Write Operating Acceleration W A Op Acceleration 1 Word 73

W A Op Acceleration 2 Word 137



5.40

Read Negative Operating Acceleration

A3 R A Neg Op Acceleration 1 Word 101

R A Neg Op Acceleration 2 Word 165

Write Negative Operating Acceleration

W A Neg Op Acc 1 Word 101

W A Neg Op Acc 2 Word 165

Read Positive Operating Acceleration

A3 R A Pos Op Acc 1 Word 102

R A Pos Op Acc 2 Word 166

Write Positive Operating Acceleration

W A Pos Op Acc 1 Word 102

W A Pos Op Acc 2 Word 166

Read Beam Breaks to Ignore I R I Beam Breaks to Ignore 1 Byte 101

R I Beam Breaks to Ignore 1 Word 74

R I Beam Breaks to Ignore 2 Word 167

Write Beam Breaks to Ignore W I Beam Breaks to Ignore 1 Byte 101

W I Beam Breaks to Ignore 1 Word 74

W I Beam Breaks to Ignore 2 Word 167

Read Operating Mode M R M Op Mode 1 Byte 11

R M Op Mode 1 Word 75

R M Op Mode 2 Word 168

Write Operating Mode W M Op Mode 1 Byte 11

W M Op Mode 1 Word 75

W M Op Mode 2 Word 168

Read Measurement Offset O R O Measurement Offset 1 Word 1052

R O Measurement Offset 2 Word 169

Write Measurement Offset W O Measurement Offset 1 Word 1052

W O Measurement Offset 2 Word 169

Read Positioning Tolerance T R T Positioning Tolerance 1 byte 14a

R T Positioning Tolerance 1 Word 78

R T Positioning Tolerance 2 Word 170

Write Positioning Tolerance W T Positioning Tolerance 1 byte 141

W T Positioning Tolerance 1 Word 78

W T Positioning Tolerance 2 Word 170

Read Operating Velocity V3 R V Op Velocity 1 Word 792

R V Op Velocity 2 Word 143

Write Operating Velocity W V Op Velocity1 Word 792

W V Op Velocity 2 Word 143

Read Negative Operating Velocity

V3 R V Neg Op Velocity 1 Word 107

R V Neg Op Velocity 2 Word 171

Write Negative Operating Velocity

W V Neg Op Velocity 1 Word 107

W V Neg Op Velocity 2Word 171

Read Positive Operating Velocity V3 R V Pos Op Velocity 1 Word 108

R V Pos Op Velocity 2 Word 172

Write Positive Operating Velocity W V Pos Op Velocity 1 Word 108

W V Pos Op Velocity 2 Word 172



ID



Read Beam Break Diagnostic Code

U0; J R U0 Beam Break Diag Code 1 Byte

461

R U0 Beam Break Diag Code 1 Word

110

R U0 Beam Break Diag Code 2 Word

174

Write Beam Break Diagnostic Code

W U0 Beam Break Diag Code 1 Byte

46

W U0 Beam Break Diag Code 1 Word

110

W U0 Beam Break Diag Code 2 Word

174

Read Motor Failure Diagnostic Code

U1; J R U1 Motor Failure Diag 1 Word 1112

R U1 Motor Failure Diag 2 Word 175

Write Motor Failure Diagnostic Code

W U1 Motor Failure Diag 1 Word 111

W U1 Motor Failure Diag 2 Word 175

Read Settling Time U2; J R U2 Settling Time 1 Byte 481

R U2 Settling Time 1 Word 112

R U2 Settling Time 2 Word 176

Read Pointing Laser Status/Enable

U3; J R U3 PointingLaser Status 1 Byte 49

R U3 Pointing Laser Status 1 Word 113

R U3 Pointing Laser Status 2 Word 177

Write Pointing Laser Status/Enable

W U3 Pointing Laser Status 1 Byte 49

W U3 Pointing Laser Status 1 Word 113

W U3 Pointing Laser Status 2 Word 177

Read Digital I/O Status Word (Table “Digital I/O Status Word”Below)

U4; J R U4 Digital I/O Status 1 Byte 50

R U4 Digital I/O Status 1 Word 114

R U4 Digital I/O Status 2 Word 178

Read DAC Voltage Digital Value (4095 = 10 V)

U5; J4 R U5 DAC Voltage 1 Word 115

R U5 DAC Voltage 1 Word 179

Read System Self-test Z R Z System Self-test 1 Byte 26

R Z System Self-test 1 Word 90

R Z System Self-test 2 Word 183

Read General Purpose Module R General Purpose 1 Byte

R General Purpose 1 Word

R General Purpose 2 Word

Write General Purpose Module W General Purpose 1 Byte

W General Purpose 1 Word

W General Purpose 2 Word

1This value may exceed the limit for 8 bits (128) - If decided to use this element as an 8 bit value, ensure that your application operates with values within the range of 0 to 128.

2This value may exceed the limit for 16 bits (32,767) - If decided to use this element as an 16 bit value, ensure that your application operates with values within the range of 0 to 32,767.



ID



5.42

PROFIBUS Extended Diagnostic Bit

The ICS 5000 supports diagnostic functions for Beam Break and Motor failures. This information can be utilized in two ways:

1. Use the specific modules for diagnostic (U0;J and U1;J) to be read in every PLC cycle together with the other selected modules.

2. With the Extended Diagnostic Message in PROFIBUS-DP.

The PROFIBIUS-DP Extended Diagnostic Message is configured by the Master. The ICS 5000 will send out a 10 byte diagnostic message. Byte 7, 8 and 9 contains the specific diagnostic data for the ICS 5000 unit.

Note – Length of diagnostic message is always 10 whether extended diagnostic is configured or not. If not the 3 last bytes will always be zero.

The Extended Diagnostic Message is updated once the fault occur and the registers are zeroed again after the ICS 5000 unit has been able to perform a complete measurement. This will take about 3 seconds. When this is done the registers are back to zero, except for the PROFIBUS watchdog time out message.

3This command only applies to the TCS control algorithm.

4The DAC voltage value contained in this register is not appropriate for use in a control circuit. It is only intended for use as an approximate reference of commanded velocity.

Table 5.5 Extended Diagnostic RegisterDiagnostic byte

Function Description

0 Status 1 Standard PROFIBUS-DP diagnostics as specified in EN 501701 Status 2

2 Status 3

3 Master address

4 Ident. no.

5 Ident. no.

6 Header Byte Length of diagnostic (including this byte) is always 4.

7 Beam Break caused by distance meter failure

16-33 = Distance meter error

8 Beam Break caused by measuring problem

0-14 = Measuring problems, could be external or internal.1

1See the chapters of this manual covering the different control algorithms for a complete list of diagnostic codes.

20 = Beam break caused external

21 = Measuring range exceeded

9 Motor Failure 0 = OK

1 = Lagging1

2 = Leading1

3 = DAC failure1

4 = Profibus watchdog time out



Note – If extended diagnostic registers are enabled, the read U0;J and U1;J registers will also be zeroed after the unit has performed a complete measurement.

5.6.4 Parameterization Telegram

The Parameterization Telegram is, in most cases, built by a configuring program for PROFIBUS, such as Siemens Step 7. The data for the Parameterization Telegram is provided in Table 5.6 that follows if you would like to use another method.

5.6.5 Network Configuration

The descriptions contained in this chapter deal with the Siemens Step 7 software for configuring a PROFIBUS-DP network.

GSE file Installation

The ICS 5000’s GSE (or GSD) file must be installed in the Master’s configuration software. In Step 7 the GSE file is installed from the Hardware configuration screen.

Table 5.6 Parameterization TelegramByte Function Description

0 Station Status Standard PROFIBUS-DP Parameterization as specification 1 Watchdog control

2 Watchdog control

3 Min. Station Delay

4 Ident. number of slave

5 Ident. number of slave

6 Group ident.

7 SPC3 specific user parameter byte

Bit 0= Dis_Startbit, The receiver will not monitor the start bit when this bit is turned on (=1).

Bit 1= Dis_Stopbit, The Stop bit is not monitored when this bit is turned on (=1)

Bit 2 = Wd_base, specifies which time base to use for the watchdog.

0 means 10 msec timebase,

1 means 1 msec timebase.

8 ICS specific parametrization byte

Bit 0 = ICS diagnostics (0 means active, 1 means disabled)

Bit 1 = Motorola/Intel output (0 means Intel, 1 means Motorola)



5.44

From the Menu bar select Options/ Install New GSD as shown in the following image.

This will display the Installing new GSE dialog box shown below. Navigate to the folder where the ICS 5000’s GSE file (Ics_068A.gse) is stored. The bitmap file (Ics5000n.bmp) will be located in the same directory.



Once installed, the ICS 5000 module’s folder created from the GSE file is located in the Step 7’s Hardware Catalog under the following path: PROFIBUS-DP/Additional Field Devices/General/ICS 5000.

The ICS 5000 module consist of 1 Byte, 1 Word, and 2 Word (8, 16, and 32 bits) sub-modules with Read or Write functions.



5.46

Basic Rack Configuration

Before communication can be achieved, the Master must be configured for the PROFIBUS network. The first step is to assign a Rack which contains the CPU/PROFIBUS master. The Rack and Modules are selected from the Hardware List as shown in the following image. Select Rail, Power supply (if applicable) and the CPU.

Selecting CPU with PROFIBUS Master will open the window the Properties window for network. Select the Parameters tab. Click New to create a new PROFIBUS Network, then click Properties... to configure the network.



From the subnet Properties window now displaied (see figure that follows), select the Network Settings tab. Use the Transmission Rate list, to select the transmission rate for the network, then click OK to continue.

The selected transmission rate is now provided next to new network as shown in the following figure.



5.48

The module for the configured CPU with the new PROFIBUS network is now located in the rack as shown in the following figure. Open the folder in the Hardware list on the right hand side of the screen that contains the ICS 5000 Module (PROFIBUS-DP/Additional Field Devices/General/ICS 5000). Click on the ICS 5000 folder icon and drag it to the Network.

Inserting the ICS 5000 Module will open the Properties - PROFIBUS interface ICS 5000 window shown below. Use the Parameters tab to configure the ICS 5000’s Address then Click OK.

Note – Make sure this Address matches the one configured with the ICS 5000 Support Software.

Once this has been completed, the ICS 5000 module appears as an icon on the network. Selecting the ICS 5000 will open the configuration list table shown in the following figure. The same modules as in the text file (Profibus.txt) created from the ICS 5000 configuration must be selected. By selecting the sub modules from the ICS 5000 folder on the Hardware list, the Communication Table for the ICS 5000 is programmed in to the PROFIBUS Master.



Note – The selected modules shall be configured in the ICS 5000 using the ICS 5000 Support Software.

Selecting the ICS 5000 Modules Object Properties will open the Properties - DP slave window shown below. Select the Parameter Assignment tab. The Device-specific parameters folder allows you to disable/enable the Extended Diagnostic functions (Ext.diagnostics). The default value is active. The INTEL or Motorola (Swap) data format can also be configured from this window.

5.6.6 PROFIBUS Cable Connections

Cable

The cable fitting sealing on the rear panel is designed to accept cables with a diameter between 5 to 12 mm (0.2 to 0.5 inch).



5.50

Port location

The PROFIBUS-DP, RS-232 and RS-422 ports on the ICS 5000 are located in a 16 pole screw terminal on the rear panel directly below the I/O Connector (see ICS 5000 Communications Port Layout on page 5.2).

PROFIBUS-DP Port Configuration

The pin configuration for the 16 pole screw terminal connector is as follows:

Note – Pin no. 16 (DGND) and 13 (+5V FC) are internally connected to the ICS 5000’s terminating resistors and should only be connected with jumpers to pin no. 14 and 15 if the ICS 5000 internal termination is used. They should not be used in any other way.

Figure 5.9 PROFIBUS Connections with Internal Termination Jumpers

Termination

If the ICS 5000 is the last wired unit in the network, termination must be used. Termination can be achieved with the built-in termination of the ICS 5000 or an external active bus terminator, such as SIEMENS PROFIBUS Terminator (6ES7 972-0DA00-0AA0).

Implementation using the built-in termination on the ICS 5000 requires only the addition of two jumpers on the 16 pin socket. The jumpers should be mounted between pin no. 13 to 14 and 15 to 16. The terminating signals (+5V and DGND) from the ICS on pin 13 and 16 are connected via a voltage divider and should not be used for any other purpose than termination to pin 14 and 15.

Table 5.7 PROFIBUS-DP portTerminal Function Description

13 +5 V FC Power supply voltage. (Should be wired to pin no. 14 if ICS’s internal termination is used.)

14 B Receive/Transmit data - plus (RxD/TxD-P) pin 3 in D-Sub

15 A Receive/Transmit data - minus (RxD/TxD-N) pin 8 in D-Sub.

16 DGND Data reference potential. (Should be wired to pin no. 15 if ICS’s internal termination is used.)



PROFIBUS Grounding and Isolation

The ICS 5000 grounding philosophy is to ground the unit in only one location. The reason for this is to avoid ground loops. The ICS 5000 unit should only be grounded via the PROFIBUS network connection (Figure 5.10 that follows). The ICS 5000 unit is isolated from the vehicle via it’s mounting bracket, and shields around the 24 V cable and I/O cable should only be connected at the ICS 5000. Shields are connected to the Chassis Ground using the specially designed cable feed-throughs on the rear cover of the unit. When terminating the wiring to the ICS 5000 insure that the shields are correctly attached. Consult the ICS 5000 Installation Manual (571 701 451 or 571 701 453) for details on wiring

Figure 5.10 PROFIBUS Interconnection Overview

5.7 Interbus Communications Configuration

5.7.1 General Description

INTERBUS field bus is handling the data communication from a PLC or host computer to one or several ICS 5000 units and other types of sensors or actuators (such as I/O modules, encoders and robots).

INTERBUS field bus is designed as a data ring with a central master-slave access method. The field bus works as a large shift register, where every unit connected to the ring is a part of the shift register, through which the data is clocked. With this ring structure it is possible to send and receive data synchronously (full duplex). The ring system is implemented in one cable. The implemented INTERBUS field bus in the ICS 5000 is of type remote bus supporting the PCP (Peripherals Communication Protocol).



5.52

With the exception of the Skew control mode, all control algorithms in the ICS 5000 can be configured for the INTERBUS fieldbus communications protocol.

Figure 5.11 INTERBUS Interconnection Overview

INTERBUS Wiring

The ICS 5000 INTERBUS communication devices consist of two internal interfaces. Both consisting of RS-485 circuits, one of the interfaces is galvanically isolated from the rest of the unit. The galvanically isolated interface is called DI1 /DO1 and shall be connected to the Master (PLC) or a Slave device what is connected before the ICS 5000 unit in the chain from the Master device.This is shown in Figure 5.12 and Figure 5.13 that follow.

Figure 5.12 INTERBUS Interface Wiring



Figure 5.13 ICS 5000 Internal INTERBUS connections

ICS 5000 INTERBUS Port Pin Configuration

The INTERBUS port on the ICS 5000 is implemented using the two RS-422 ports on the unit. These ports are accessed via the 16 pin Serial Com Ports screw terminal on the back of the unit (see Table 5.1 on page 5.2). The following two tables provide the pin outs for these connections (see Figure 5.14 for more details).

Note – Older style ICS 5000 units may have a Serial Com Ports interface with only 12 terminals.

Note – The polarity on the ICS 5000 units RS-422 interface is switched on the receiver and transmitter pins compared to the INTERBUS DO1 DI1 interface.

Table 5.8 ICS 5000 16 Pin Screw Terminal DI1 / DO1 InterfacePIN NO. FUNCTION DESCRIPTION

10 Isolated COM Tied to the opto-isolated ground of the interface circuit.

6 O (RA) Positive polarity of the DO1 interface.

7 /DO (RB) Negative polarity of the /DO1 interface.

8 DI (TA) Positive polarity of the DI1 interface.

9 /DI (TB) Negative polarity of the /DI1 interface.

Table 5.9 ICS 5000 16 Pin Screw Terminal DI2 / DO2 InterfacePIN NO. FUNCTION DESCRIPTION

5 GND Tied to the ground of the interface circuit.

4 DO (TA) Positive polarity of the DO2 interface.

3 /DO (TB) Negative polarity of the /DO2 interface.

2 /DI(RB) Negative polarity of the /DI2 interface.

1 DI(RA) Positive polarity of the DI2 interface.



5.54

INTERBUS Cabling

Figure 5.14 below shows an example on how to connect an ICS 5000 to an INTERBUS network.

Figure 5.14 Wiring diagram ICS 5000 to INTERBUS

5.7.2 ICS 5000 Configuration

The ICS 5000 is implemented as a slave device in the INTERBUS network. The bus type is REMOTE.

The INTERBUS configuration of ICS 5000 is done with the ICS 5000 Support Software. When the ICS 5000 unit is configured for INTERBUS communication, both RS-422 ports are utilized by INTERBUS once the ICS 5000 has switched to User parameters (five seconds after boot-up).



You configure the ICS 5000 for INTERBUS using the Protocols screen ( [Alt] + [M] + [1] ) of the Communications tab as shown in the figure that follows.

Next you configure the RS-422 port options based upon the position of the ICS 5000 on the INTERBUS chain. Using the Port Options screen ( [Alt] + [M] + [2] ) of the Communications tab select the appropriate setting from the RS422 Port Options group as shown in the figure that follows.

Select option 3 INTERBUS device at END-OF-THE-CHAIN if the ICS 5000 unit is the last device in the INTERBUS chain. Select option 1 INTERBUS device NOT at end-of-the-chain if more devices follow after this unit.



5.56

The RS-232 port can be used for checking status of the ICS 5000 unit during setup of the INTERBUS network. Connect the RS-232 port to a PC with a terminal program. (For example the Hyperterminal program included with Windows can be used.). Check the status of the ICS 5000 unit by sending the E command to the unit.

Note – The BT command resets ICS 5000 and also the INTERBUS circuit inside the ICS 5000 unit.

5.7.3 INTERBUS Network Configuration

INTERBUS communication with ICS 5000 is performed using ASCII characters in strings. End of transmission is indicated with a Carriage Return <CR>.

Note – The following descriptions cover configuring Phoenix Contact's IBS CMD G4 Software to communicate with an ICS 5000 unit on INTERBUS.

Basic Configuration

Before communication can be achieved, the ICS 5000 must be registered on the network. This can be done with the software online. Right Click on the Configuration Frame icon located in the Project window (shown in the figure that follows) and select Read Again. This will cause the ICS 5000 unit to appear as a PCP icon below the Controller Board icon.

CWarning – Do not run the ICS 5000 Support Software on the RS-232 port at the same time as INTERBUS is running on the other ports. (If you do, there will be two masters (PC and PLC) that are in control of the ICS 5000 unit (your vehicle).

CWarning – Do not experiment with sending commands if you do not know which device (PC or PLC) that is in control of the ICS 5000 unit (your vehicle)



The example shows an INTERBUS network with an ICS 5000 unit connected as the end unit. The Status bar in the bottom of the Project window indicates the Status: Bus active and State: Online.

Note – Online configuration with IBS CMD G4 requires the network to be wired and the connected units to be configured for INTERBUS communication.

Write Data to ICS 5000

Communication with the ICS 5000 is performed in the write service (Index 4002) and the read service (Index 4003). The network Operating State must be changed to Monitoring if you wish to use either the write service or read service via the IBS CMD G4 software. Click the F3 State button. Select Monitoring from the Change o ... group of the Operating State window as shown in the figure that follows.

CWarning – Care must be taken prior to switching to the Monitoring state to avoid conflict with the control system.



5.58

As a safety precaution you must confirm that you want to change the operating state to Monitoring. Do this by entering the word MONITOR in the Enable: field (as shown in the image that follows), then Click OK.

The Monitoring State indicated on the Status bar will now be shown as Monitoring.

Right Click on the ICS 5000 unit’s PCP icon to display the menu shown in the following figure. From this menu select Device Parametrization.



The Device Parameterization window with the description: Trimble, ICS 5000 as shown below will be displayed. From the Menu Bar select Device/ Read Parameter List. Four rows with index from 4000 to 40003 will be listed.

Select row 4002 and Click the Change Value button. In the displayed Change Text window, enter the data to be sent to the ICS 5000 using the hex codes for all characters. The first byte is reserved of the number of data bytes in the message. The example in the following figure depicts sending: E;Y <carriage return> (see Table 5.10 that follows for message details). Click OK to close the Change text window.

Click F5 Write Value to send the data. Table 5.10 shows the hex codes for the transmitted message.

Table 5.10 Example Write DataHex Code Commands Description

04 Number of data bytes

45 E Returns the current status of the ICS unit

3B ; Separates multiple commands transmitted with only one carriage return



5.60

Receive Data from ICS 5000

The ICS 5000 status bit changes to 1 if it has new data to be read. This can be viewed from the IBS CMD G4 software using the Address Monitor (shown in the figure that follows). The Address Monitor window is opened from the Controller Board icon.

Note – The status bit is the second bit from the right in the highlighted row for Address 1.

59 Y Reads the current station

0D <CR> Indicates end of transmission

BTip – Null characters (00) can be used in the transmit message if a fixed length of the transmitted message is preferred.

Table 5.10 Example Write DataHex Code Commands Description



Select row 4003 and Click the F4 Read Value button to read the reply from the ICS 5000.

Click the Change Value button to view all 17 bytes in the reply.

Table 5.11 that follows shows the hex code for the received message. The first byte (08) indicates it is 8 bytes in the received message.

Table 5.11 Example Read DataHex Code Commands Description

08 Number of data bytes in received message.

45 E Returns the current status of the ICS unit.

20 Returned command and value are separated with a space character.

31 1 Returned status on ICS.

3B ; Separates multiple commands.

59 Y Returns actual Station.

20 Returned command and value are separated with a space character.

32 8 Returned station number.

0D <Carriage Return>

Indicates end of transmission.



5.62

If no more data exists to be read from the unit, the status bit changes from 1 to 0 as shown in the following figure.

5.8 Custom Read and Write Data TablesLocated under the Communications Tab, the Read Table ( [Alt] + [M] + [5] ) and Write Table ( [Alt] + [M] + [6] ) options allow the user to define the read and write data to be exchanged with a PLC or computer. MODBUS, DFl, DeviceNet and PROFIBUS represent data in integer arrays (e.g. 40001-40006 or N7:0-5 or Element0-Element5). By default, the data in each array element is pre-defined (e.g. Element0 = Status Register) but you can create your own definitions by filling out the Read (ICS 5000-to-host) and Write (host-to-ICS 5000) tables. This approach lets you group important pieces of data together to simplify and speed up the reading/writing process.

Note – You MUST must define Read and Write Tables when using DeviceNet and PROFIBUS.

BTip – If Custom Register Definitions are not used, then the ICS 5000 uses the Default Register Definitions described in Table 5.15 on page 5.69 making it backward compatible with older DF1 and Modbus applications.



5.8.1 Default Register Definitions

When enabling the ICS 5000 with DF1 or MODBUS, the default register definition are as shown in Table 5.12 that follows. This register layout matches the order used in the older TCS 4000 units before custom register definition was available. It is acceptable to skip the custom configuration process and use the default definitions provided as long as the commands you need are contained in the default definitions.

5.8.2 Custom Register Definitions

There are five options to choose from when developing the data registers for an application: 8 Bit, 16 Bit (two byte Integers), 32 Bit (four byte Integers), All Sizes (8 Bit, 16 Bit and 32 Bit) or All Registers. To assist with user selection of elements, a

Table 5.12 Default Command ListingElement Name ASCII Char Read/Write DF1/MODBUS

Address

Status E R 40001/Nff:0

Station Destination S R/W 40002/Nff:1

Station Location Y R 40003/Nff:2

Distance Destination (MSW) D(MSW) R/W 40004/Nff:3

Distance Destination (LSW) D(LSW) R/W 40005/Nff:4

Current Distance (MSW) X(MSW) R 40006/Nff:5

Current Distance (LSW) X(LSW) R 40007/Nff:6

Return Signal Strength R R/W 40008/Nff:7

Halt Acceleration H W 40009/Nff:8

Operating Acceleration A R/W1

1This value is R/W for TCS and BCS control algorithms only. For the PDM algorithm it is R only.

40010/Nff:9

Beam Breaks to Ignore I R/W 40011/Nff:10

Operating Mode M R/W 40012/Nff:11

Measurement Offset (MSW) O(MSW) R/W 40013/Nff:12

Measurement Offset (LSW) O(LSW) R/W 40014/Nff:13

Positioning Tolerance T R/W 40015/Nff:14

Operating Velocity V R/W1 40016/Nff:15

Array Index Variable U R/W2

2Care must be taken when using this register as it can overwrite vital elements of the Calibration, Parameter, or Lookup Table arrays.

40017/Nff:16

Calibration Array C R/W 40018/Nff:17

Diagnostic Array J R/W 40019/Nff:18

Parameter Array (MSW) P(MSW) R/W 40020/Nff:19

Parameter Array (LSW) P(LSW) R/W 40021/Nff:20

Look-up Table Array (MSW) L(MSW) R/W 40022/Nff:21

Look-up Table Array (LSW) L(LSW) R/W 40023/Nff:22



5.64

Filter is provided to control the elements displayed (see figure below). Depending upon the communication protocol selected, some or all of the options will be avalible.

Note – Consult the manufacturer’s literature for the PLC or computer being use to determine the maximum integer file size.

Based upon the filter selection of 8 Bit, 16 Bit, 32 Bit All Sizes, or All Registers, the appropriate Read and Write element list will be displayed. The following sections contain examples of typical 16 bit Read and Write Table screens.

Read Table Configuration

[Alt] + [M] + [5]

The Read Table configuration screen (see figure that follows) is comprised of an element selection list on the left and a listing of the configured chosen elements on the right. The 16 bit Status, for example, is the first element. The Read Table depicted below is from an ICS 5000 configured to use the DF1 protocol.



To construct the message, you simply select the element(s) you would like to use from the left hand column and click the button. You can select multiple elements by holding down the [Cntl] key during the selection process. To remove an element from the Table, simply select that element in the right hand column and click the button. To remove all elements, select any element in the Table (right hand column) and click the button.

To rearrange the order of the elements in the table, select the desired element and click or . To move elements, they must be selected individually.

The PLC register address will be displayed on the right side of the configured data. If you are using DF1 protocol, this address will begin with N7:0, when using MODBUS the first register is 30001. The first register for both DeviceNet and PROFIBUS is Element 0.

If DeviceNet or PROFIBUS are the selected protocols, then the button can be used to view and save the scanner module configuration information. For DeviceNet, the custom EDS file is displayed with the option to save it to disk. For PROFIBUS, a list of the read and write modules use is provided for network configuration.

When you have finished your configuration, proceed to the Write Table configuration.

Write Table Configuration

[Alt] + [M] + [6]

The Write Table configuration screen (see figure that follows) is comprised of an element selection list on the left and a listing of the configured chosen elements on the right. The example shown reads the Destination (high and low words) along with the current settings for Acceleration and Velocity. The Write Table depicted below is from an ICS 5000 configured to use the MODBUS protocol. The Write Table is constructed the same as the Read Table covered in the previous section.

The Write Table configuration screen also has a check box to Ignore Redundant Data. When this is checked, the ICS 5000 will only respond to unique data values sent from the PLC. For example if you command the ICS 5000 to move the vehicle



5.66

to Station 4, and there is a fault stopping the move, another value, such as Station 0, will have to be sent to the unit before the move to Station 4 will be processed. This is designed to reduce network traffic and can be very useful if network is highly populated.

Finishing The Register Configuration

When the configuration of both the Read and the Write Tables is complete the data must be sent to the ICS 5000 by pressing the image of the unit in the lower left corner of the program window or by clicking the button on the Tool Bar.

5.8.3 A Word About Number Conventions

The MODBUS protocol is supported only by a 16 bit register. The DF1, DeviceNet and PROFIBUS protocols are supported by a 16 bit register and a 32 bit register. The 32 bit register is for PLC’s that supports DINT files (AB’s ControlLogix PLC). In addition, the DeviceNet and PROFIBUS protocols also supported by an 8 bit register. With the exception of the Least Significant Word or LSW registers, the ICS 5000 uses 16 bit two’s complement notation. E.g. 0xFFFFH=-1, 0x0001H=+1. The normal range is therefore –32768 (0x8000) to +32767 (0x7FFF). Five of the numbers in the ICS 5000 (D, X, and O commands along with the P and L arrays) can be so large that this range is inadequate. To work around this limit, each of these five numbers has been broken up into two numbers (MSW and LSW). In other words, there are two registers assigned to each numbers instead of one register like the other numbers. These registers are consecutive with the first (lower register address) being the Most Significant Word or MSW. And the next register in the sequence (higher register address) the LSW. The LSW registers are extensions of the MSW registers which carry the sign and are therefore treated as unsigned values. E.g. 0xFFFF=65535, 0x0001=1. The ICS 5000 then combines these two numbers internally to form one 32 bit number according to the following equation:

“ICS 5000 number” = 65536*MSW + LSW

Table 5.13 that follows contains a few examples:

BTip – It can be very useful to utilize the Ignore Redundant Data enabled at the bottom of the Write Table. This feature limits network traffic and can simplify PLC programming code.

Table 5.13 Number Convention ExamplesTest Value Method

Program destination to 65538 mm write 0x0001 (signed +1) to 40004/Nff:3 and

write 0x0001 (signed +1) to 40004/Nff:3 and

(65538 = +1 * 65536 + 2 = 0x00010002)

Program offset to -2 mm write 0xFFFF (signed –1) to 40013/Nff:12 and

write 0xFFFE (unsigned 65534) to 40014/Nff:13

(-2 = -1*65536 + 65534 = 0xFFFFFFFE)



Note – Writing a number to LSW of the Destination register causes the control loop to activate and move the machine to a destination in millimeters specified by combining 65536*MSW and LSW. To insure that the position is interpreted correctly, write data to the MSW register first.

The following table contains some additional examples of 32 bit numbers supported by the ICS 5000 as two 16 bit numbers.

This complexity can be avoided in two possible ways:

1. Use stations instead of millimeter destinations.

2. If the near and far limits are less than 65.535 meters apart, the wake-up offset can be adjusted so near travel limit is 0. Then only MSW register needs to be used.

5.8.4 Advanced Communications Command Listing

The following tables contain all command elements available for use when building Custom Read and Write Tables for the ICS 5000. Detailed descriptions of all commands can be found in Appendix A, Commands and Diagnostics. The first table, 16 Bit Commands, contains a listing of the 16 Bit command set. The second table, 32 Bit Commands, contains information about the expanded 32 Bit command set. The commands are separated into two groups to allow compatibility with a wider range of PLC and computer hardware. In each table, the first and second columns contain the elements name and the ASCII Command Equivalent, the third column contains the Element type (Read or Write or Both) and the last columns contain the various (16 and 32 Bit) ID #’s.

While the two tables contain 16 and 32 bit commands respectively, some of the commands use values that are small enough (< 32,767) that a reduced word size will work. For example: Element # 158 is declared as a 32 bit command, the value returned will never exceed 128 and can thus be accessed as a 16 bit value to conserve space. An ID # placed in the 16 ID column indicates that the value can be safely treated as a 16 bit value

The 16 Bit compatible command listing contains 16 bit ID #’s while the 32 Bit Command listing contains both 16 and 32 bit ID #’s. This is done to present the option of accessing the smaller 16 bit values when using a PLC that supports 32 bit registers. While this is a more efficient way to transfer data, care must be taken when accessing data as smaller 16 bit values. If the value has the possibility of exceeding the limit (32,767) then it must be treated as a larger value. If not, then the value could be truncated by the PLC.

Table 5.14 32 Bit Number ExamplesDecimal Hex =MSW & LSW

0 (0x00000000) = 0 (0x0000) & 0 (0x0000)

-1 (0xFFFFFFFF) = -1 (0xFFFF) & -1 (0xFFFF)

-2 (0xFFFFFFFE) = -1 (0xFFFF) & -2 (0xFFFE)

32767 (0x00007FFF) = 0 (0x0000) & 32767 (0x7FFF)

65535 (0x0000FFFF) = 0 (0x0000) & -1 (0xFFFF)

65536 (0x00010000) = 1 (0x0001) & 0 (0x0000)



5.68

The ICS 5000 defaults to handling only 16 Bit integer values. 32 Bit values are only enabled once a 32 Bit Write has been received from the PLC or SLC.

Note – The DF1 protocol selection in the ICS 5000 disables the use of 8 Bit integers. 16 Bit integers read with 32 Bit integer files will be padded with zeros once a 32 Bit Write has been preformed to switch the ICS 5000 to 32 Bit Mode. 32 Bit integers read with 16 Bit integer files will be truncated which may alter the data.



16 Bit Commands.

32 Bit Commands

Note – When using 32 Bit Commands, a 32 Bit Write must be completed before a 32 Bit Read. The 32 Bit Write switches the ICS 5000 operating mode from the default of 16 Bits to 32 Bits. The switch is accomplished automatically when a Write from a

CWarning – While accessing certain elements as smaller (16 bit) values will produce correct results, this is not the case with every element. Take care when assigning elements or data truncation may occur

Table 5.15 16 Bit CommandsElement Name ASCII Char Read/Write 16 ID

Status E R 64

Station Destination S R/W 65

Station Location Y R 66

Distance Destination (MSW) D(MSW) R/W 67

Distance Destination (LSW) D(LSW) R/W 68

Current Distance (MSW) X(MSW) R 69

Current Distance (LSW) X(LSW) R 70

Return Signal Strength R R/W 71

Halt Acceleration H W 72

Operating Acceleration A R/W1

1This value is R/W for TCS and BCS control algorithms only. For the PDM algorithm it is R only.

73

Beam Breaks to Ignore I R/W 74

Operating Mode M R/W 75

Measurement Offset (MSW) O(MSW) R/W 76

Measurement Offset (LSW) O(LSW) R/W 77

Positioning Tolerance T R/W 78

Operating Velocity V R/W1 79

Array Index Variable U R/W 80

Calibration Array C R/W 81

Diagnostic Array J R/W 82

Parameter Array (MSW) P(MSW) R/W 83

Parameter Array (LSW) P(LSW) R/W 84

Look-up Table Array (MSW) L(MSW) R/W 85

Look-up Table Array (LSW) L(LSW) R/W 86

Debug Array (MSW) B(MSW)2

2This command should only be used by experienced personnel. If used incorrectly, it can result in unexpected operation, vehicle damage and personnel injury.

R/W 87

Debug Array (LSW) B(LSW)2 R/W 88

Key to Activate Special Routine G2 R/W 89

System Self-test Z R 90



5.70

Dint file is received by the ICS 5000.

Table 5.16 32 Bit CommandsElement Name ASCII Char Read/Write 16 ID 32 ID

Status E R 94 158

Station Destination S R/W 95 159

Station Location Y R 96 160

Distance Destination D R/W 971

1This value may exceed the limit for 16 bits (32,767) - If you decide to use this element as an 16 bit value, insure that your application operates with values within the range of 0 to 32,767.

161

Current Distance X R 981 162

Return Signal Strength R R/W 99 163

Halt Acceleration H W 100 164

Negative Operating Acceleration A2

2This command only applies to the TCS control algorithm.

R/W 101 165

Positive Operating Acceleration A2 R/W 102 166

Beam Breaks to Ignore I R/W 102 167

Operating Mode M R/W 104 168

Measurement Offset O R/W 1052 169

Positioning Tolerance T R/W 106 170

Negative Operating Velocity V2 R/W 107 171

Positive Operating Velocity V2 R/W 108 172

Memory Protect Status U-1; J R 109 173

Beam Break Diagnostic Code U0; J R 110 174

Motor Failure Diagnostic Code U1; J R 1112 175

Settling Time U2; J R 112 176

Pointing Laser Status/Enable U3; J R/W 113 177

Digital I/O Status Word (See Table 5.17 that follows)

U4; J R 114 178

DAC Voltage Digital Value (4095 = 10 V)

U5; J3

3The DAC voltage value contained in this register is not appropriate for use in a control circuit. It is only intended for use as an approximate reference of commanded velocity.

R 115 179

Spare 116 180

Spare 117 181

Array Index Variable U R/W 118 182

System Self-test Z R 119 183

Calibration Constant Array Value 0 U0; C4

4This command should only be used by experienced personnel. If used incorrectly, it can result in unexpected operation, vehicle damage and personnel injury.

R/W 120 184

Calibration Constant Array Value 1 U1; C4 R/W 121 185

Calibration Constant Array Value 2 U2; C4 R/W 122 186

Spare 123 187



Digital I/O Status Word

The Digital I/O Status Word is shown in Table 5.17 below.

Combinations of multiple outputs or inputs will result in a sum of the values. For example: When the Brake Output and the FWD/REV Output are both closed the value of this element will be 10.

Note – For a detailed description or the function of the listed commands, status codes and diagnostic codes, see Appendix A, Commands and Diagnostics.

Table 5.17 Digital I/O Status WordBit I/O Element Value

0 Synchronization Output 1

1 Brake Output 2

2 Safety Output 4

3 FWD/REV Output 8

4 Spare Output 16

5 Synchronization Input 32

6 DAC Voltage is Positive 64

7 DAC Voltage is Negative 128



5.72

C H A P T E R

6
Station Configuration 6
In this chapter:

• Introduction

• Stations Configuration Tab


6 Station Configuration

6.2 IC

6.1 IntroductionThis chapter covers the configuration of the Station Look-up Table stored in the ICS 5000. The use of the Stations varies between the different control algorithms, so be sure you check you application before beginning. In general, Stations can be used by the ICS 5000 to represent distances in millimeters. The ICS 5000 can hold up to 2000 stations, and they can be numbered in any order desired. Remember though that skipped station numbers still count toward the total.

Note – Try not to skip stations or assign them out of order, this wastes stations as even skipped ones count against the total number, and decreases the efficiency of the Y command.

6.2 Stations Configuration TabThere are only two different aspects to configure before using Stations - Station Setup and Modify Stations.

6.2.1 Station Setup

[Alt] + [S] + [1]

Use the Station Setup screen picture below to configure the Station Location (Y command) Format and the Starting Station Number.

Station Location (Y command) Format

You must select one of the two available formats for the Station Location (Y command) Format. The Y command returns the station number that matches the current position if in tolerance. When out of tolerance, there are two formatting options for the response:


Station Configuration 6

Format 0

The station location will be negative when out-of-tolerance regardless of direction. For example, Y -5 means the machine is close to Station 5 (Y 5 means it is at Station 5).

Format 1

10000 will be added to the station location when out-of-tolerance and the sign implies the direction. For example, Y -10005 means the machine's distance is less than Station 5, Y 10005 means it is greater than station 5 (Y 5 means it is at Station 5).

Starting Station Number

This is the first or lowest numbered station. For example, if there are 5 stations numbered 10, 11, 12, 13, and 14 then 10 would be the Starting Station Number.

6.2.2 Modify Stations

[Alt] + [S] + [2]

Reached from the Stations tab, the Modify Stations screen allows you to define/redefine station locations. This screen displays the length of travel as it is defined by the Travel Limits using a scale in millimeters positioned above the control buttons as shown in the following image. Stations are depicted as vertical rectangles with the current active station shaded in green. If a station is defined outside of the Travel Limits, then it will be shaded red when selected. The default view is scaled such that each side of the display is a travel limit. Finally, when ON Line with an ICS 5000 unit, the current position is indicated by the arrow ( ) and the status is displayed in the center of the screen.

Making Modifications

To add or change stations, enter the number of the station in the Station field, then position the axis at the desired location and click . Alternatively, you can change the millimeter value for any station by dragging the icon (if Dragging has


6 Station Configuration

6.4 IC

first been enabled by checking the Enable Drawing option) to the desired location or by entering a numeric value in the mm Value field. To remove a station, select the station or enter the number in the Station field, then click . Deleting a station will renumber any existing stations that were greater than the number of the station deleted. For example if you delete station six out of ten consecutive stations beginning with one, then everything above six will be shifted down (e.g. 7 to 6, 8 to 7, 9 to 8, and 10 to 9). To avoid this, you can delete the value in the mm Value field to make the station undefined.

Click Undo to undo edits made to the Stations from this screen. Each time you select Undo, the last change made (up to five) will be undone. The Undo button is disabled if no edits exist. All edit Undo information is deleted once a Save has been completed.

Enabling Motion

Checking the Go to Station option on the Modify Stations screen will enable you to move the vehicle to any station simply by selecting that station. Before motion is enabled however, the warning screen in the following image is displayed to confirm your choice. Click Yes to continue and enable motion. If Enable Drawing is also selected, then you will be able to move the vehicle by drawing the station. This can be helpful for fine tuning a location.

Interpolate Feature

To assign a specific amount of evenly spaced stations to an axis use the Interpolate feature. To use Interpolate you must define the first and last stations then click

to calculate millimeter values of undefined stations in between. For example if you want to set up ten stations equidistant apart, setup the first station then the tenth station leaving the middle eight undefined. Then click to assign values to the eight undefined stations.

Note – When On Line with an ICS 5000 unit and a modification is preformed, the ICS 5000 icon located at the bottom left of the screen will be displayed with a yellow arrow indicating that the parameters need to be sent to the unit before any updates will be applied. This is accomplished by clicking on the icon .


C H A P T E R

7
Motion Control Overview 7
In this chapter:

• Introduction

• TCS Algorithm - Closed Loop Control

• BCS Algorithm - Open Loop Control

• PDM Algorithm - Feedback Only and Collision Avoidance

• ICS Integrated Approach


7 Motion Control Overview

7.2 IC

7.1 IntroductionThis chapter provides a brief background on motion control as implemented in the ICS 5000. The ICS 5000 is available with three different control algorithms:

• TCS Algorithm - Closed Loop Control

• BCS Algorithm - Open Loop Control

• PDM Algorithm - Feedback Only and Collision Avoidance

Before Selecting which method to implement, it is important that you understand the benefits and limitations of each approach. The following sections give a detailed description of each control approach along with some helpful integration advice.

7.2 TCS Algorithm - Closed Loop ControlThe theory of operation behind the Total Control System (TCS) control algorithm and the Self Learning part of the ICS 5000 Support Software is really quite simple. In fact, anyone that has adjusted their driving style to that of an unfamiliar car has performed many of the same tasks the software performs when “learning” the characteristics of a vehicle.

• How hard do you press on the gas peddle to make the car go?

• How fast does the car accelerate?

• How fast does the car Brake?

• How does the car respond to changing speed – passing or slowing to exit a highway?

Once all of these variables have been tested and you are comfortable with the response of the car, tasks such as deciding when to begin braking at a traffic light or accelerating to a specific velocity become quite easy. This same concept is applied to allow the TCS to position vehicles. The key is to insure that the actual response of the system does not change once the learned response is established. Minor loading deviations such as changing from fully loaded to empty can be easily dealt with, but drastic changes such as modifying the motor drives characteristics require that the TCS control algorithm re-learn the response profile of the vehicle.

7.2.1 PID Closed Loop Control

The PID control loop that the ICS uses is a modified version of one of the most popular industrial control algorithms. When it is desired to set an output to a specific value, such as the temperature of a tank of water, a PID loop will improve the controllers ability to accurately follow the set-point. The way a PID controller works is that each gain acts upon any error present in the system differently. When the error is zero the gains are effectively non-existent, but as the error becomes larger the gains have more effect. The following is a listing of the individual gains, and how they react with errors:

• Proportional Gain - Acts on errors based upon size.

• Integral Gain - Acts on errors based upon duration.



• Differential Gain - Acts on rate of change of the errors.

As the temperature in the tank just mentioned starts to cool and deviates from the desired value or Set Point, the difference between the Set Point and the Temperature feedback increases. The larger this value becomes, the greater the effect of the PID loop on the output or in this case the heat supply. The goal being to drive the temperature back to the desired level with a minimal amount of correcting or settling at the end. This type of configuration should keep the temperature within a reasonable tolerance.

Figure 7.1 PID Temperature Control Example

The same approach is used in motion control applications, except that the Set Point is a desired destination; the Feedback is position; and the Output is power to the motor. The way the Feedback and the Output are integrated with the PID loop is the secret to successful control, and one of the things that sets the ICS 5000 using TCS control apart from other controllers.

7.2.2 System Modeling

A PID control loop is only as good as it’s gains, and selecting the right gains is not an easy task. That is why Trimble has developed the Self Learning feature of the ICS 5000 Support Software. This feature allows the ICS 5000 to learn (or model) the characteristics of the system it is controlling. This model is then used to choose the optimal control loop gains for the system. Gains that will result in the shortest move time independent of velocity, acceleration, length of move or starting point of the move.

Using predictable, predetermined stimulus patterns, the ICS 5000 Support Software instructs the ICS 5000 to output a voltage waveform to the axis motor controller. While the axis is in motion, the Electronic Distance Meter (EDM) and the Controller Interface accurately record the resulting response of the vehicle (see Figure 7.2 that follows. By testing the vehicle with enough different sets of stimuli,



7.4 IC

the ICS 5000 Support Software can accurately develop a mathematical model of the system’s response. In addition to being used to develop the loop gains, the model is also used by the TCS control algorithm to calculate move profiles and monitor system performance problems.

Figure 7.2 “Black Box” Modeling Example

Figure 7.3 that follows depicts a TCS algorithm controlled system. As the analog output (velocity reference) is increased from zero, the velocity of the vehicle (velocity feedback) follows. The amount of “lag” that the system demonstrates is depended upon the responsiveness of the system and will vary. The system model is formed to exactly profile the response of the vehicle thus minimizing lag errors and over corrections. Errors between the analogue control set-point and the velocity feedback still do exist but are quickly dealt with by the TCS algorithm’s PID loop. If the velocity feedback falls below the theoretical response then the error causes the control signal to oppose or correct the error by increasing the voltage above the theoretical set-point.

Figure 7.3 Typical TCS Algorithm Response Curves

The amount of undershoot and overshoot present during a move factors into the systems settling time. A correctly matched TCS algorithm will minimize a systems settling time resulting in moves that appear to ramp directly down to the final position. Changes in the system’s theoretical response by increasing/decreasing the rolling resistance or changing the drive to motor horsepower ratio, can cause an increase in settling time. Correcting these problems could require a re-modeling or re-characterization of the system.

Note – Remember that if the systems response changes drastically the TCS’ theoretical profile of the system will require updating



7.3 BCS Algorithm - Open Loop ControlThe Brake Controlled System (BCS) algorithm developed by Trimble utilizes a simple open loop positioning algorithm coupled with a state of the art Electronic Distance Meter to close the positioning loop around even the poorest responding mechanical systems. The BCS algorithm allows the user to configure from a two to a seven speed positioning algorithm. The algorithm uses the distance feedback to implement a set of velocities and minimum distances. As the distance measured approaches the distance commanded to travel to, the BCS causes the motor drive to change speed.

For example: At 5 meters from the final distance, the speed will be reduced from speed 4 to speed 3 causing the vehicle to slow. At 3 meters, the velocity is again reduced to that relating to speed 2. The final speed is used to jog the vehicle for a short distance prior to using the mechanical brake for final positioning. The resulting move profile, if tuned correctly, can be very effective at positioning all sizes of vehicles.

Figure 7.4 BCS Algorithm Positioning Overview

The BCS algorithm is used when the TCS algorithm is unable to the control the axis. This is typically caused by the control configuration (two speed contactor for example), or poor mechanical performance. Because the BCS algorithm does not model the performance of the system, it is much more flexible when it comes to poor performance. The trade off is that the BCS algorithm can not compete with the TCS algorithm with respect to settling time or quality of control.

7.4 PDM Algorithm - Feedback Only and Collision AvoidanceThe Programmable Distance Meter (PDM) algorithm developed by Trimble - is a fast monitoring device for Distance, Velocity and Acceleration. with a state of the art Industrial Distance Meter. The PDM can also be configured for an Advanced Collision Avoidance function. While the PDM is equipped with the analog and digital controls as the TCS and BCS, the PDM is configured to use this I/O for



7.6 IC

control. The PDM is strictly for position monitoring and collision avoidance applications were an external control loop will be developed in the PCL or host controller.

Figure 7.5 Collision Avoidance Overview

7.5 ICS Integrated ApproachUnlike traditional positioning solutions, where the feedback device is monitored by the main vehicle controller, the ICS 5000 combines an infrared distance meter whit a dedicated positioning microprocessor. In essence, the ICS 5000 acts as a positioning co-processor to the vehicle controller. This approach frees up the vehicle controller for supervisory tasks and insures that optimal control is always achieved independent of vehicle controller make or model. This distributed approach also greatly reduces the complexity of the overall system design while implementing a vastly superior control algorithm.

7.5.1 Advanced Position Control - In Search of the Trapezoidal Response

In theory, a trapezoidal response is the perfect move profile. After taking into account the mechanical and electrical limitations of a vehicle, the tightest profile one can achieve resembles a trapezoidal pattern. There will be a slight amount of rounding at the corners, depending upon the responsiveness of the system, but basically it is still a trapezoid. Over time, various control methods have been developed to approach this level of performance, but rarely, if ever, do they achieve their goal - Trapezoidal Control.

More often than not, the performance of a controller falls prey to the limitations of it’s integration without even approaching the engineered design limits of the system. This is understandable, because without the right tools (an advanced PID loop with a Model Predictor for example) approaching the optimal Trapezoidal Control level is not possible. Factors such as creep speed at the end of the move or speed changes



during deceleration eat away at the efficiency of a control system. Trimble’s ICS 5000 distance meter based positioning system successfully overcomes the limitations of common controllers by integrating the hardware in a rather uncommon manner.

By moving the control loop out of the PLC and into the position feedback device were modeling and other advanced control approaches can be utilized enabling vehicle control to approach the elusive Trapezoidal level. This configuration also allows the control loop to function independent of PLC scan time limitations. The result is a control system that gives the designer the flexibility to modify performance characteristics for the vehicle such as velocity and acceleration without “tweaking” the control loop gains each time. Performance gains from the implementation of the ICS 5000 positioning system are realized in two ways:

Short term - The drastically reduced move times (typically 25% and as much as 50% for some moves) result in improved cycle times and more throughput.

Long term - The smooth transitions between velocity extremes places less stress on the vehicle potentially reducing maintenance worries and extending the operational life of the vehicle.

7.5.2 System Integration with the ICS 5000

Integration of an ICS 5000 to an industrial vehicle control scheme is simple once it’s operation is understood. Unlike every other feedback device, the ICS 5000 is also a motion controller. It interfaces directly with the PLC and the Motor Drive acting as a “Positioning Co-Processor”. All motion control tasks must be directed by the ICS 5000 including fault handling (with the exception of emergency stops of course). The ICS 5000 has been designed to function as a distributed controller that will respond to move requests from the PLC, but require no other interaction to complete the positioning of the vehicle.

The ICS 5000 has digital I/O designed to sequence the vehicle’s mechanical brake and drive enable. These are typically passed through the PLC so that it can monitor the status of these signals and take control during manual operation when the ICS 5000 is “out of the loop”. In addition to the digital I/O, the ICS 5000 uses an analog signal (-10 to +10VDC or 0 to +10VDC) to direct the motor drives operation. The Speed Reference is used by the motor drive to turn the motor at the desired RPM’s which moves and eventually positions the vehicle. It is imperative that this signal be routed directly to the motor drive using shielded cable to reduce electrical interference.

7.5.3 Motor Drives

Motor Drives (or Motor Controllers) come in two basic types - AC or DC. DC motor drives convert the AC supply voltage to a DC supply that drives a DC motor. DC drives and motors typically cost less than AC, but require substantial maintenance to insure proper operation. AC motor drives also convert the AC supply voltage to a DC supply, but then recreate an AC waveform that powers an AC motor. This extra voltage conversion, along with new technology to improve performance, is what elevates the price of AC drives with respect to DC. The trade-off comes with the virtually maintenance free operation of the system.



7.8 IC

Since we deal primarily with AC motors and drives, that is all that will be covered here. Just remember that in general, DC is the standard of operation that AC tries to emulate. Therefore, as we discuss the operation of AC drives, it is assumed that the performance of a DC drive meets or exceeds AC in every way.

Different Types of AC Drives

There are basically three different types of AC drives:

• Open Loop Volts/Hertz

• Open Loop Vector

• Closed Loop Vector

Open Loop indicates that there is no encoder feedback from the motor to the drive to indicate the position of the rotor. Closed Loop utilizes encoder feedback to greatly improve speed regulation by closely monitoring rotor movement.

Volts/Hertz or constant volts per hertz Mode describes the basic method of control used by an AC drive. It is the simplest drive configuration that changes the voltage and frequency of the AC supplied to the motor to achieve a desired speed. While this is an efficient way to control speed, there is no way to control torque and thus, precise control is not possible.

Vector or Field-Oriented Control uses a complex series of control algorithms to manipulate the torque in addition the speed. Closed Loop Vector drives come extremely close to DC drive performance and are a suitable substitution in almost every application including vertical applications.

The ICS 5000 will work very well with either Volts/Hertz or Open Loop Vector drives. On a few instances, a Closed Loop Vector drive should be used to improve torque control at zero speed (vertical applications for example), but in general Closed Loop Vector is “over kill” as the ICS 5000 already provides position feedback for the drive.

7.5.4 PLC or Host Controllers

The PLC or PC Controllers that reside in almost every vehicle are the heart and soul of the system. They contain the control logic which enables the vehicle to do whatever it is supposed to do. The PLC or PC may also be the link between the vehicle and an upper level controller (PLC or PC) responsible for synchronizing multiple vehicles or operations.

What is a PLC

A PLC or Programmable Logic Controller consists of a Processor, a Rack and multiple I/O Cards. The processor executes a program that coordinates all activities of the vehicle.

How do PLCs Differ from PCs

PLCs user proprietary hardware and are specifically designed for industrial applications. The operating systems are real-time and rarely fail.



7.10

C H A P T E R

8
Tools & Utilities 8
In this chapter:

• Introduction

• Tools Tab

• Utilities Menu


8 Tools & Utilities

8.2 IC

8.1 IntroductionThis chapter covers the various tools and utilities provided with the ICS 5000 Support Software. You may find these helpful for setting up and troubleshooting an ICS 5000 installation.

8.2 Tools TabThe Tools tab of the ICS 5000 Support Software contains the following six screens:

• Terminal

• Over-/Undershoot

• Motor Tuning Aid

• Random Moves

• Output Test

• Chart Recorder

Depending upon the control algorithm you are using, some of the options will be made unavailable (see figure that follows). The PDM algorithm, for example, does not utilize the Over-/Undershoot, Motor Tuning Aid, Random Moves, or Output Test screens. As a result, these options are greyed out to indicate inactivity.

8.2.1 Terminal

[Alt] + [T] + [1]

Use the Terminal screen to communicate directly to an ICS 5000 using ASCII commands. A list of these commands along with a brief description of each is located in Appendix A, Commands and Diagnostics. You type the command in the


Tools & Utilities 8

field below the Message to ICS label and press Enter to send a command to the ICS 5000. The response will appear in the terminal window as shown in the following figure.

Click Settings to display the PC Communications Settings dialog box which allows you to reconfigure the communications parameters as described in User Communication Parameters on page 4.2. If your configuration’s communications parameters use an address character, then the Other Devices button will also be available. Click Other Devices to launch a second Terminal screen, as shown below, which uses a separate set of communication parameters. Use this window to communicate to a second addressed ICS 5000 without having to re-load parameters.

Once the second Terminal screen is open, click Settings to display the PC Communications Settings dialog box. The communications parameters configured from this Terminal screen are only active until the screen is closed. The ICS 5000

BTip – The second Terminal screen is very helpful when communicating with the two units while setting up or troubleshooting an ASC system.


8 Tools & Utilities

8.4 IC

Support Software stores the original set of communication parameters, allowing you to switch communications between two ICS 5000 with little effort. This is especially useful when working with skew control systems or multi-drop. Use the X in the upper right hand corner to close the window when finished.

8.2.2 Over-/Undershoot

[Alt] + [T] + [2]

Use the Over-/Undershoot Control screen, shown below, to make minor adjustments to the position control loop gains. Clicking the Start button on this screen causes the axis being controlled to cycle back and forth (current position is indicated by the top arrow icon ) between the left and right turn around points ( ). Use your mouse to drag the turn around points to any location or enter new values in the Left Point and Right Point fields. The goal of this screen is to make it easier for you to observe the over/undershoot of the system. The Pause Time, Velocity and Acceleration can all be changed to see how the axis reacts under different conditions.

Once the axis is in motion, monitor the screen at the turn around points. If necessary, click Zoom In to increase the magnification of the display. Undo magnification by clicking Zoom Out or Normalize. As the axis approaches on of the turn around points, it should decelerate directly to that arrow (keep in mind the working tolerance), stop and accelerate in the opposite direction. If overshooting or undershooting is observed, insure that it is occurring the same at both turn around points. Overshooting at one point and undershooting at the other is the symptom of an other problem and can not be corrected with this screen.

Once you have determined that the over/undershooting is symmetrical, us either the Overshoot or Undershoot buttons to begin correcting the problem. Click Overshoot to add more overshoot to an undershooting condition, or click

BTip – Remember that the ICS 5000 only responds to CAPITAL letters. Also, you can string multiple commands together by using a semicolon (;) between each command (e.g. X;D).


Tools & Utilities 8

Undershoot to add more undershoot to an overshooting condition. Remember that the Overshoot and Undershoot buttons slightly change the way the axis stops and should be used sparingly. The percentage of Gain Change is displayed above the move axis along with the current status of the control loop in the ICS 5000. As you make changes to the Under/Overshoot, the percentage will change. After five consecutive button clicks, the field changes to yellow, and after ten it changes to red. The colors are used to inform you of excessive changes to the control loop gains.

If you are having trouble detecting if the axis is undershooting or overshooting, click Graph to display a Position vs. Time Graph (shown below) of the motion. This free running plot of the motion contains a set of target lines that are switched from top to bottom depending upon the turn around point destination. These lines indicate the destination of the move +/- the Positioning Tolerance. Each move should complete the turn around between the lines. Add a second or two of Pause Time to separate the moves and help clarify the positioning.

Alternatively, you can move the axis by dragging the top arrow ( ) to any point between the systems End of Travel Limits. All motion can be stopped by clicking either Halt or . Turn the Pointing Laser on to check system alignment.

8.2.3 Motor Tuning Aid

[Alt] + [T] + [3]

The Motor Tuning Aid screen is provided to assist you with the proper configuration of you motor controller. This screen turns the ICS 5000 into a signal generator. It will generate the waveform selected (Square, Triangle, or Trapezoid) once you click Start. Use the Settings group to adjust the properties of each waveform. Use Voltage #1 and Voltage #2 to adjust the maximum output voltages for each direction for the Square and Triangle waveforms, and use Time Interval to adjust the duration which


8 Tools & Utilities

8.6 IC

the Square Wave is applied. Finally, use the Ramp Rate to control the ramping of the Triangle and Trapezoid waveforms. All motion can be stopped by clicking either Halt or .

Note – The final test that should be completed with this screen is to determine the maximum Ramp Rate your system can handle. Using the Trapezoid Wave, click Start to begin motion. After the axis has begun moving back and forth, gradually adjust the Ramp Rate until the acceleration and deceleration is acceptable. Remember that the ICS 5000 uses a 10 VDC control signal. Therefore, the acceleration time will equal 10 v / Ramp Rate v/s.

Square Wave

Use the Square Wave selection for tuning over/under-shoot and current limit if the motor rotor is locked down. Because no ramping is used, you must select a low enough values for Voltage #1 and Voltage #2 to prevent slippage or over current. Start with a value of one volt for each. When you click Start, the axis will start moving back and forth following the square wave output to the analog reference. Watch the motion of the axis to insure that it follows the signal as closely as possible with limited under and overshoot. Tune the motor drive, if possible, to get the correct response before continuing to the next waveform.

CWarning – Items in this menu can cause vehicle motion and possible damage!!! It is important that you consult a Trimble representative prior to using the Motor Tuning Aid so that you can fully understand what will happen with each test.

BTip – Spend as much time as needed to insure that the motor drive is tuned correctly. This can save hours in lost time and may be the only way to successfully complete a Characterization with usable data.


Tools & Utilities 8

Triangle Wave

Use the Triangle Wave selection for tuning current stability (if locked rotor) and linearity around zero speed. Select a median setting for Voltage #1 and Voltage #2, such as three volts, and use a reduced Ramp Rate so you may more easily observe the performance around zero speed. Watch for a smooth transition around each turn around point with minimal deadband. Proceed to the next waveform when satisfied.

Trapezoid Wave

Finally, use the Trapezoid Wave for determining maximum velocity and current limit (acceleration) if motor rotor is NOT locked. Begin by entering an estimated Speed Goal in mm/sec. If you do not know what your top speed will be guess and adjust it as the readings begin appearing (see image that follows). Use the Ramp Rate field to adjust the acceleration/deceleration of the system. Increase this value until you reach a maximum value with which you are satisfied. Record the value and enter this as the Ramp Rate during the Characterization (see Ramp Rate on page 9.34).

8.2.4 Random Moves

[Alt] + [T] + [4]

Use Random Moves screen which follows to test the machine for marginal operation and to measure the settling time. Destinations (either millimeters or stations) are chosen at random so a variety of move lengths are tested automatically. The status of the control loop is monitored continuously, with any warnings (such as Beam Break or Motor Warning) displayed in the field in the center of the screen. Marginal control settings (gains) are reported as Motor Warning or are implied if the Average


8 Tools & Utilities

8.8 IC

Settling Time is much larger than the Typical Settling Time. The Random Moves screen is particularly useful during setup or when trying to verify the operation of the ICS 5000’s control loop.

In the Number of Moves field enter the number of moves you want the vehicle to complete. A minimum of 20 moves is recommended. Use the Start Delay and Pause Time fields to enter a delay time in seconds before motion begins and to enter a pause time in seconds between each move. The Minimum Distance field is used to enter a minimum distance to insure per move, and the Ending Position option allows you to select the final positioning of the vehicle. Selecting the Stations option will cause the routine to select random station locations instead of distances in millimeters. If no stations are defined, then this option is not available.

8.2.5 Output Test

[Alt] + [T] + [5]

Use the Output Test screen to directly control the ICS 5000’s digital and analog outputs. This is useful when testing the ICS 5000 and the wiring to other devices. A voltmeter may also be useful. It is important to note that when the outputs are manipulated using this screen they ignore the selected output format and always use


Tools & Utilities 8

format A (see Control Options on page 3.3). Also, when the Analog Output is selected all the Relay Outputs will be open and when the Relay Outputs are selected, the Analog Output will be set to zero.

8.2.6 Chart Recorder

[Alt] + [T] + [6]

Use the Chart Recorder Screen to graphically display the output of the ICS 5000 vs. time. When you enter this screen, the chart recorder is already capturing data at the rate dictated by the Seconds of Data setting at the bottom of the screen. Seconds of Data also represents the horizontal display scaling in seconds.

CWarning – Disconnect the ICS 5000 from the motor drive or disable the motor drive. Failure to do so can result in uncontrolled high speed motion of the machine

CWarning – Items in this menu can cause vehicle motion and possible damage!!! It is important that you consult a Trimble representative prior to using the Output Test screen so that you can fully understand what will happen with each test.


8 Tools & Utilities

8.10

If you are using an ICS 5000 with the TCS or BCS control algorithms, then the Message to ICS field can be used to issue move (S or D) commands. Once the message is received, the move will commence.

This screen is particularly useful when setting up an axis that is difficult to see or configuring an ICS 5000 using the BCS algorithm. Because of the configuration process required with setting up the BCS algorithm, the Strip Chart Recorder offers a detailed look at the profile of a move as shown in the image that follows.

Right clicking on the graph gives you the option to Save, Copy or Print a bitmap image file of the data displayed.

8.3 Utilities Menu

8.3.1 Flash Loader

Use the Flash Loader screen to download a new firmware revision to an ICS 5000 when an upgrade is needed. Firmware files can be obtained at the Trimble web site or can be e-mailed to you by a Trimble representative. Firmware in the ICS is like the operating system and application program in a computer.

Downloading firmware does NOT affect parameters, stations and other settings that customize the ICS 5000 to match your application. A new firmware should only be downloaded with a short, direct cable using the RS-232 port (do NOT download


Tools & Utilities 8

through an ASC system, MODEM, multi-drop network or wires over 50 meters). Do not disturb a download in progress. If a download is interrupted, first cycle power on the ICS 5000 and try to start the download again without going on-line. If that doesn't work, the ICS 5000 will need to be sent in for service.

CWarning – Contact Trimble support personnel prior to performing a firmware upgrade. Downloading an incorrect firmware revision to your ICS 5000 could result in undesired operation, and may even require that the unit be returned for service.

CWarning – Do NOT download through an ASC system, MODEM, multi-drop network or wires over 50 meters.


8 Tools & Utilities

8.12

8.3.2 Hardware Configuration

Use the Hardware Configuration screen shown below to determine which features your ICS 5000 can support. If you are trying to use a feature that is unavailable on this ICS 5000, it will be marked in RED. Features may be added via hardware upgrades or possibly by entering a new configuration number. Please contact Trimble support personnel before attempting to modify this screen.

Note – The New Serial Number field is inactive unless you have entered the master password for the software.


Tools & Utilities 8

8.3.3 Analog Output Calibration

Use the Analog Output Calibration screen to calibrate the zero point of the ICS 5000’s analog output. The analog output is calibrated in production to perfectly match each ICS 5000. If this setting is changed, any different ICS 5000 unit used in place of the original will not be an exact match. This procedure should only be attempted by experienced Trimble service personnel.

Note – The Analog Output Calibration screen is inactive unless you have entered the master password for the software.

CWarning – Disconnect the ICS 5000 from the motor drive or disable the motor drive. Failure to do so can result in uncontrolled high speed motion of the machine


8 Tools & Utilities

8.14

C H A P T E R

9
TCS Control Algorithm Configuration 9
In this chapter:

• Introduction

• System Integration Principles

• System Configurations

• Hardware Output Status

• TCS Parameters Tab

• Characterize Tab

• Software Error Messages


9 TCS Control Algorithm Configuration

9.2 IC

9.1 IntroductionThis chapter covers the configuration of the TCS (closed loop) control algorithm for the ICS 5000. See Chapter 7.2, TCS Algorithm - Closed Loop Control on page 7.2 for information on the theory of operation of this algorithm.

9.2 System Integration PrinciplesThe integration of the ICS 5000 as a motion controller should be approached with a modular state of mind. Think of the ICS 5000 as a positioning co-processor that is wholly responsible for motion related tasks including error detection and reaction. The ICS 5000 works together with the PLC to control motion instead of simply providing a position feedback signal. No attempt should be made to anticipate the safe shut down of the control loop during an error by removing control from the ICS 5000. Instead, the PLC should take advantage of the resources that this distributed control approach frees up by enhancing the communication driver used with the ICS 5000. Thorough support of the status codes and some choice diagnostic registers could save hours of down time spent troubleshooting problems. The exception is when a motor drive faults or safety condition is not satisfied. In this case, the PLC should assume immediate control and stop the machine.

Figure 9.1 TCS Algorithm Integration Overview

9.2.1 Safe Shutdown of System Operations

The fail-safe design of the ICS 5000 requires little PLC interaction. Once a move command has been initiated the ICS 5000 is capable of controlling every aspect of the move. While the move is in progress, the control loop is constantly monitoring the relationship between the system model and the position feedback. This allows



the ICS 5000 to react to performance related deviations before problems develop. When the ICS 5000 determines that action is necessary, the response is generated automatically without assistance from the PLC.

Below is a brief summary of the ICS 5000 TCS Algorithm error handling responses. Also included in this listing is a suggestion as to how the PLC should react once the system has been shut down and an error reported. For more detailed information on error generation see Hardware Output Status, page 9.12 and Commands and Diagnostics, page A.I.

9.2.2 Status Interrogation and Response

Every move initiated by the ICS 5000 will result in a change in status. The PLC must query the ICS 5000 at the completion of each move to determine if the move was a success or failure. The transmission of this query at the end of a move can be triggered by monitoring the ICS 5000’s Brake output. This relay will open to set the mechanical brake when motion has ceased or a fault has occurred. The following text details basic logic that the PLC should possess to deal with possible fault situations reported by the TCS algorithm:

Table 9.1 TCS Algorithm Error Handling ResponsesFAULT ICS 5000 ACTIONS PLC RESPONSE

Loss of Data

(Beam Break declared). Automatic Retries not enabled. (RETRY = 0)

• Ramps vehicle down to zero speed and then opens Safety contact and Brake contact.

• Reports status of E 2 when polled by PLC.

Retry move. If data loss continues then check alignment of unit.

Loss of Data

(Beam Break declared). Automatic Retries enabled. (RETRY > 0)

• Ramps vehicle down to zero speed but keeps the Safety contact and Brake contact closed while redetermining absolute position. Then resumes the move. If Beam Break is permanent, same action as above.

• Reports status of E 2 during the stop when polled by PLC.

No action necessary if ICS 5000 succeeds to complete the move. Otherwise same as above.

Faster than theoretical model (Motor Failure)

• Immediately opens Safety contact and Brake contact. This is a “runaway” situation.


PLC should not retry the move because error could be mechanically related.

Slower than theoretical model (Motor Failure)

• Ramps vehicle down to zero speed and then opens Safety contact and Brake contact.

• Reports status of E 4 when polled by PLC

The PLC should not retry the move because error could be mechanically related.

Warming Up • Will not initiate any motion. Both Safety relay and Brake relay are open.

Retry command for up to 10 seconds upon first power up.

Selftest Failure • Reports status of E 128 when polled by he PLC.

Reboot unit using BT command then check for status to change.



9.4 IC

Send move command (D or S) to ICS 5000

If ACK received from ICS 5000 then

Data received successfully, move in progress.

If NAK is received from ICS 5000 then

Data needs to be re-transmitted.

Wait for Brake Relay to open

Send E command to ICS 5000

Read Status response E ###

If ### = 2 then retry move command 2 times before reporting Beam Break Fault.

If ### = 4 then report Motor Failure Fault.

If ### = 8 then retry E command, still positioning.

If ### = 16 then Move Complete in Position.

If ### = 32 then retry E command for 30 seconds before reporting Warming Up.

If ### = 128 then send BT command to reboot ICS 5000 and retry E command.

9.3 System ConfigurationsThe ICS 5000 system can be configured for three main algorithm versions. Available algorithms are:

• TCS (Total Control System)

• BCS (Brake Control System)

• PDM (Programmable Distance Meter)



Each of these can be set to different sub versions, with different I/O formats, aimed at their specific applications. These various I/O formats are selected from the Control Options screen ( [Alt] + [G] + [2] ) shown in the figure that follows.

To configure the ICS 5000 to use the TCS algorithm, select TCS from the Algorithm section of the Control Options screen. The Output Format section allows you to configure the ICS 5000’s I/O to match the requirements of your system. The following sections provide information on the I/O configurations available with the TCS algorithm.

If you attempt to change the Algorithm type of a configured ICS 5000 unit the following warning will be displayed.

For information on the different control algorithms, see Chapter 7, Motion Control Overview on page 7.1.

9.3.1 Configuration Overview

The TCS algorithm has two main sub versions TCS1 and TCS2. TCS1 is a closed loop single axis control with internal ramp generation. It can be hardware synchronized to other ICS 5000 units for collision avoidance. Two ICS 5000 units




9.6 IC

using the TCS2 algorithm together with the Advanced Skew Controller form a closed loop Advanced Skew Control system. The different sub versions for the TCS algorithm, are shown in Table 9.2 which follows.

Note – All relay outputs on the ICS 5000 are 24 Volt DC/AC reed style contacts. The relay input used for system synchronization is a 12 - 24 Volt DC/AC coil. See the ICS 5000 Installation Manual for more information on output specifications. Despite minor output differences, the units function identically. The various configurations are explained in detail in the following paragraphs.

Note – The TCS1 sub-versions support all communication protocols. TCS2 sub-versions are only available with the ASCII protocol.

9.3.2 Format “A” Configuration - Bi-Polar Output versions (–10 to + 10 VDC)

The bi-polar output configuration of the TCS algorithm is the most commonly used. The analog control signal, used by the motor controller for speed reference, varies from 0 VDC to -10 VDC for one direction and from 0 VDC to +10 VDC for the other.

The control I/O perform the following functions:

Table 9.2 TCS System Configuration OverviewSub Version Control Format I/O Functions

TCS1 A Bi-Polar Output version (-10 to +10 VDC)

B Uni-Polar Output version (0 to +10 VDC with one direction contact)

C Uni-Polar Output version (0 to +10 VDC with two direction contacts)

TCS2 A Bi-Polar Output version (-10 to +10 VDC)

B Uni-Polar Output version (0 to +10 VDC with one direction contact)

C Uni-Polar Output version (0 to +10 VDC with two direction contacts)

Table 9.3 TCS Format “A” I/O ConfigurationI/O NAME DESCRIPTION

13 & 14 Analog Output – 10 (pin 14) to +10 (pin 13) V DC speed reference to the motor drive.

7 & 8 Safety Contact Normally open contact (OUT 3) that opens to indicate a fault. OUT 3 also interrupts the Analog Output signal.

5 & 6 Brake Contact Normally open contact (OUT 2) that closes to release the mechanical Brake on the motor.

3 & 4 TCS Status Output for Synchronization

Normally open contact (OUT 1) used to indicated when the TCS has begun to ramp to a stop after a fault.

1 & 2 TCS Status Input for Synchronization

Coil for a normally open contact (IN) used to indicated when another TCS in the system has begun to ramp to a stop after a fault.



TCS configuration codes for control Format “A”

The listed configuration codes below are retrieved by sending the Self Test (Z) command to the unit. The configuration codes only show the communication protocols using the RS-232 and RS-422 ports. PROFIBUS-DP and DeviceNet communication protocols use their own communication port and are not included in the configuration code.

50001 – Configured for the basic serial communications protocol with ASCII character set.

50101 – Configured for the basic serial communications protocol (default settings) with ASCII character set and the Gould Modicon Modbus® protocol in RTU mode.

50201 – Configured for the basic serial communications protocol (default settings) with ASCII character set and the Rockwell Automation DF1 protocol used in Allen Bradley PLC-5 series and SLC 500 series PLC’s.

50301 – Configured for INTERBUS with the PCP protocol.

50008 – Advanced Skew Control version. Supports the basic serial communications protocol with ASCII character set. Two units are used to control the skew of a bridge or gantry crane. This version is covered in depth in the Advanced Skew Controller Installation Manual.

For information on product code and the Self test message, see Commands and Diagnostics, page A.I.

9.3.3 Format “B” Configuration - Uni-Polar Output versions (0 to +10 VDC)

The analog control signal, used by the motor controller for speed reference, varies only from 0 VDC to +10 VDC. Direction is indicated by the state of one relay contact, OPEN for one direction CLOSED for the opposite.


Table 9.4 TCS Format “B” I/O ConfigurationI/O NAME DESCRIPTION

13 & 14 Analog Output 0 (pin 14) to +10 (pin 13) V DC speed reference to the motor drive.

9 & 10 Direction Contact Normally open contact (OUT4) that indicates direction. Open for one direction, closed for the other.









9.8 IC

TCS configuration codes for control Format “B”




50211 – Configured for the basic serial communications protocol (default settings) with ASCII character set and the Rockwell Automation DF1 protocol used in Allen Bradley PLC-5 series and SCL 500 series PLC’s.




9.3.4 Format C Configuration - Uni-Polar Output versions (0 to +10 VDC)

The analog control signal, used by the motor controller for speed reference, varies only from 0 VDC to +10 VDC. Direction is indicated by the state of two relays, one for reverse direction and one for forward direction. A CLOSED relay indicates the direction. If both reverse and forward direction contacts are opened, then the mechanical brake on your system should be set (de-energized).


Table 9.5 TCS Format “C” I/O ConfigurationI/O NAME DESCRIPTION


9 & 10 Reverse Direction Contact

Normally open contact (OUT4) that indicates direction. Closed to run in the reversed direction.


5 & 6 Forward Direction Contact

Normally open contact (OUT 2) that indicates direction. Closed to run in the forward direction.



Note – Forward and reverse are arbitrary, no physical direction is implied. The ICS will determine polarity during the characterization process.

TCS configuration codes for control Format “C”








9.3.5 Sampling Frequency Configuration

The sampling frequency (samples/sec. or Hz) used in the IDM (Industrial Distance Meter) inside the ICS 5000 can be configured during the set up. The available sampling frequencies are: 19.35, 30.58, 49.32 and 69.50 Hz with the default being 30.58 Hz (the TCS/BCS/PDM system 4000 uses 30 Hz). If ICS 5000 is used as a replacement unit for an old system, 30.58 Hz should be used to avoid having to re-characterize.

For information on configuring sampling frequency in the ICS 5000 Support Software, see Chapter 3.4, Sample Rate on page 3.5.





Table 9.5 TCS Format “C” I/O ConfigurationI/O NAME DESCRIPTION



9.10

9.3.6 Continuously Self Adaptive Function (Auto Gain Limit)

During setup, you can fine tune the control loop from the Over-/Undershoot screen by typing the ‘O’ and ‘U’ keys. Once the setup is finalized, changes in temperature, load, friction and line voltage may de-optimize this tuning. This either slows down positioning or requires the operator to re-tune. Alternatively, the TCS algorithm can be configured to automatically and continuously adapt to these changes within user defined limits. With this continuously self adaptive function (Self tuning) the TCS algorithm will be able to handle most normal changes in the response of the vehicle by itself. A Characterization would still needed to do the initial tuning required to adapt to large changes. For information on configuring the Auto Gain Limit in the ICS 5000 Support Software, see Auto Gain Limit on page 9.17.

9.3.7 Operational Modes

The TCS algorithm supports the Modes listed in Table 9.6 and Table 9.7. The Mode codes are bit mapped. This means that each unique mode has it’s own bit. If two or more different modes are desired, send the summation of the individual modes. For information on configuring the modes in the ICS 5000 Support Software, see Wake Up Mode, page 9.22.

Holding Modes

The TCS algorithm can be configured for four different types of holding modes.

Table 9.6 TCS Algorithm Holding Modes

M Number Mode

0 Full servo without Integration during beam breaks.

The control loop is always trying to make the position error equal to zero. If, however, the ICS 5000 is performing an internal auto-calibration or a Beam Break occurs, then the integrator is zeroed and a new DC bias must be re-established once the measurement is restored. Halt commands also remove the integrator. This has the advantage of being as close to the desired position as possible even with disturbances.

The disadvantage are that phase meter noise may cause the load to flinch and twitch. Also, if the motor is lifting something it will falter during a beam breaks and auto-calibrations. This mode is recommended on horizontal applications without a brake.

4 Zero DAC (reference) voltage when within tolerance at destination.

Once the control loop gets the load within tolerance it turns the integrator and control loop off. In this mode the brake can be configured to be released if the position is out of tolerance.

This mode is recommended on horizontal applications with or without a brake.



Other Modes are:

8 Full servo.

The integrator is always on for bias, even during data loss where it remains “frozen” at the last value. The integrator is zeroed after a Beam Break fault, Motor Failure fault or a return signal strength measurement (R) command.

This mode is recommended for vertical applications without a brake.

12 Zero DAC (reference) voltage and integrator.

This mode is like mode 4 but the integrator is always on except after a Beam Break fault, Motor Failure fault or a return signal strength measurement (R) command. In this mode the load will remain levitated once the brake is released since the DAC is outputting a voltage.

This mode is recommended for vertical applications with a brake.

Table 9.7 TCS Algorithm Modes

M Number Mode

1 Enable warning code to be sent with the status information “E”.

The TCS algorithm can send a warning for motor failure when motor warning level is exceeded. The warning code for beam breaks will be sent when half the I value is exceeded.

• With ASCII protocol, the warning (E 8, #) where #=2 mean almost beam break. #=4 mean almost motor failure, # =0 mean no warning.

• With PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocols the warning code is multiplied by 256 and added to the status. For example: The total status on a travelling vehicle (status 8) with a motor failure warning will be: 4 * 256 + 8 = 1032 The total status on a positioned on destination vehicle (status 16) with a beam break warning will be: 2 * 256 + 16 = 528

2 Enable reporting status on auto-calibration (E 64) to be sent with the status information.

If mode two is enabled and not mode one the E status will be 64 when an auto-calibration is performed. If mode one and mode two are enabled a warning will be send when half the time to the next auto-calibration has passed.

• With ASCII protocol, the warning (E 16, #) where # = 64 means half the time to next auto-calibration has passed.

• With PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocols the warning is multiplied by 256 and added to the status. For example if the status is 16 and the time is less than half to next auto-calibration, the status will be: 64 * 256 + 16 = 16400.

16 Hold the response of position readings and station locations (X & Y).

If beam is broken position data (X & Y) responses will be withheld until the beam is re-established or the I-number is exceeded.

• With ASCII protocol, the reply on X and Y commands is delayed for as long as the beam break ignore time.

• With PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocols, the last known position is returned during the beam break.

Table 9.6 TCS Algorithm Holding Modes

M Number Mode



9.12

For information on ASCII protocol status, see Commands and Diagnostics, page A.I. For PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocol information, see Chapter 5, Advanced Communications Configuration on page 5.1.

9.4 Hardware Output StatusThe table below shows how the different output relay contacts act during different situations. The functions are the same for all TCS algorithm versions except for the following:

• TCS2 is the Advanced Skew Control version. Therefore the SYNC. Output is directly connected to the dedicated input on the Advanced Skew Control unit and it’s function adapted for this purpose.

• TCS Format C uses the forward relay and reverse relay as a brake function. The brake should be set when both relays are open and released when either is closed.

32 Disable the Ramp Retardation feature.

Ramp Retardation limits the acceleration ramp output to the system in an effort to zero position error, thereby also avoiding the drive to enter current limit condition.

64 Disable reverse directions.

Some applications, like elevators, require the TCS to ignore destinations that would cause the machine to stop and reverse directions.

128 Simple Halt

The response on the Halt command can be slow if high noise filter values and or low P and D gains are used. With Mode 128 enabled a simple ramp down will be used instead.

Table 9.8 TCS Algorithm Output StatusStatus Code Safety Brake Sync

Warming up E32 Open Open Open

Just out of warm-up or halted with H-command.

E1 Closed Open Open

Moving to a destination or station. (D# or S# command sent to TCS.)

E8 Closed Closed Closed

At Destination or Station. (Will not change during auto-calibration unless a new D# or S# command is sent.)

E16 Closed Open Closed

After a prolonged Beam Break (I-number exceeded) at Destination or Station.

E2 Open Open Closed

Table 9.7 TCS Algorithm Modes

M Number Mode



For information on status and diagnostic codes, see Commands and Diagnostics, page A.I.

After a prolonged Beam Break during a move and while decelerating.

E2 Closed Closed Open

When stopped after a prolonged Beam Break during a move. No RETRYs enabled.

E2 Open Open Open

When stopped after a prolonged Beam Break during a move. With RETRYs enabled.


After a lagging motor failure and while decelerating.


After a leading motor failure warning and while decelerating with RAMP RETARDATION active.

E4 Open Closed Open

After a leading motor failure and while decelerating with RAMP RETARDATION disabled (M32).

E4 Open Closed Open

When stopped after a motor failure. E4 Open Open Open

Sync input configured as normal and stopped after the sync. input been opened.

E8 Closed Closed Closed

Sync input configured as halt and stopped after the sync. input been opened.

E1 Closed Open Open

During auto-calibration and when a D# or S# is sent to the TCS. (Before the move starts.)

E16 orE64 if in M2

Closed Open Open

During auto-calibration just before final positioning. (Will happen if calibration time interval has run out during the move.)

E8 orE64 if in M2

Closed Closed Open

Table 9.8 TCS Algorithm Output StatusStatus Code Safety Brake Sync



9.14

9.5 TCS Parameters Tab[Alt] + [P]

When the TCS control algorithm has been selected, the TCS Parameters and Characterize tabs are shown. The TCS Parameters tab (shown below) displays all the values for the control loop with the exception of the tolerance. Use this tab to view the wake-up values for the TCS algorithm and to make changes to meet the specific needs of the vehicle being controlled.

Note – If this is a new installation the table and fields in the TCS Parameters tab will be empty and a characterization of the vehicle must be performed before control is possible.

The TCS Parameters tab contains links to the following screens:

• Common Control Parameters

• Acceleration and Velocity

• Noise and Filter

• Beam Breaks

• Wake Up Mode

• Sync Input Definition

BTip – Wake-up values are the values the ICS 5000 starts with after a boot up. For example: Once Characterized, the ICS 5000 unit has a maximum value for Velocity. A lower Wake-up value for velocity can be configured so the ICS 5000 uses this value as default.



The function of each of these screens will be discussed in detail in the following sections. The shortcut key combinations for reach each screen are also provided in each section.

For information on how to perform a characterization on a ICS 5000 unit, see Characterize Tab, page 9.27.

9.5.1 Common Control Parameters

[Alt] + [P] + [1]

Use the Control Parameters screen to configure the Common TCS algorithm control parameters. These parameters modify certain aspects of how the TCS control algorithm will react. An Advanced column displays the control loop gains and model information. Values in the Advanced column are accessible only with the Master password active.

Restore the old settings from when the file was last saved by clicking .

In the Common parameters column the following parameters can be configured.

Warning Level

Motor Warning means deviations in your machines performance have exceeded the Warning limit entered. If you have the warning byte enabled (see Operational Modes on page 9.10), the ICS 5000 will send E #, 4 or W #, 4 when this occurs. It is also the point at which Ramp Retardation is activated. Enter a percentage of deviation at which the Motor Warning should occur in the field.

Failure Level

Motor Failure means deviations in performance have exceeded the Failure limit entered. The TCS algorithm shuts down the machine and reports E 4 or W 4. Setting this value too small leads to nuisance shutdowns; setting it too high will cover up a real problem. Normally the default setting of 40% is adequate for most situations. Enter a percentage of deviation at which the Motor Failure should occur in the field.



9.16

Windup Limit

The Windup Limit limits the PID loop’s integrator action. A good rule-of-thumb is to make it double that of the worst non-linearity in the drive (reported during the Characterization). For example, if the drive slows down 3% when fully loaded, set the windup limit to 6%. This number affects the disturbance response.

Start Delay

Start Delay controls the time between closing the Brake contact and ramping up the Analog output. It gives the mechanical brake time to release before the drive is asked to accelerate. If the ICS 5000’s Brake output is used to enable the motor drive, set this value to the time it takes for the drive to enable.

Stop Delay

The Stop Delay is the time between opening the ICS 5000’s Brake contact and indicating On Station is controlled by this number. It gives the load time to stop swinging or it helps when the mechanical brake sets slowly. Also, if the brake sets slowly, the re-release time will probably need to be non-zero.

Re-release Delay

A non-zero value in the Re-release Delay parameter permits the ICS 5000’s Brake contact to re-release if the machine gets out of tolerance while the brake is setting. The larger the value, the longer the machine must be out of tolerance before the brakes will release again. A recommended starting value is 0.15 seconds.

Creep Distance

Creep Distance tells the TCS algorithm how much of the remaining distance to travel at a creep speed. One use for this is to give the payload some extra time to stop swinging before being delivered. Another use is to guarantee there will never be any overshoot by slowing down prematurely then creeping to the final destination. A value of zero disables this feature.

Creep Speed

Creep Speed tells the TCS algorithm how fast to travel the defined Creep Distance. Creep time will be approximately equal to Creep Distance/Creep Speed. Because this normally increases the travel time, it should only be used when benefit is greater than the time penalty. A value of zero disables this feature.

Braking Distance

Braking Distance tells the TCS algorithm how far from the destination to open the Brake contact, thus using the mechanical brake for final positioning. This can improve the positioning time if the following are true:

a. The brake reacts quickly and stops the machine quickly

b. The positioning tolerance is more than 4 mm or counts



c. The drive is not very responsive

Auto Gain Limit

Auto Gain Limit is used to control how much the feed forward gain can adapt. A non-zero value lets the feed forward gain try to adjust itself in response to changes in temperature, load, friction and line-voltage. A value of zero disables it. 5% is normally adequate. At times, this feature may need to be disabled. For more information, see Continuously Self Adaptive Function (Auto Gain Limit) on page 9.10.

Velocity Flat Time

The Velocity Flat Time is the minimum time between acceleration and deceleration phases of any move. This option inserts a consistent top velocity in an otherwise triangular shaped velocity profile. This feature helps avoid the whiplash effect common on short moves by giving the vehicle time to stabilize at a constant speed before starting to decelerate.

9.5.2 Advanced Control Parameters

The Advanced parameters column contains parameters such as the PID gains, these parameters are automatically tuned from the Characterization and it is not recommend that they be changed.

Disturbance P Gain

This number tunes the proportional response to disturbances. It changes the way the machine returns to a set point after being pushed away. The easiest way to create disturbances is to add a voltage source (e.g. 1.5 v battery) in series with the TCS analog output and remove it.

Disturbance I Gain

This number tunes the integral response to disturbances. Increasing can very easily lead to oscillations, especially when there is backlash in the drive. This gain will have little or no effect if the windup limit is small. Like the P gain above, it will normally only change the disturbance response.

Disturbance D Gain

This number tunes the derivative response to disturbances. Increasing tends to dampen or stabilize the system but amplify feedback noise.

CWarning – The values contained in the Advanced parameters column are very sensitive. Changing any of these values could cause the crane to become un-controllable. Do not modify these values unless you know exactly what the response will be. Trimble relinquishes all responsibility for system damage if these values have been changed.



9.18

Transient P Gain

This number tunes the proportional response to transients. It affects the over/undershoot. Increasing it too much will cause instability. It is easier to experiment with this gain if the disturbance PID gains are reduced e.g. P=D=0, I=original value/4.

Transient D Gain

This number tunes the derivative response to transients. It affects damping, stability, and over/undershoot. Too much will cause instability. Like the transient P gain, it is easier to tune if the disturbance gains have been reduced. There is much less noise penalty if this gain is high.

Negative Deadband

Negative Deadband is the largest negative voltage that will NOT move the machine. It helps save time when trying to move the machine small distances. Sometimes, additional time can be saved by making it slightly bigger. Sometimes, smoother low speed operation can be achieved by reducing it.

Positive Deadband

Positive Deadband is the largest positive voltage that will NOT move the machine. It helps save time when trying to move the machine small distances. Sometimes, additional time can be saved by making it slightly bigger. Sometimes, smoother low speed operation can be achieved by reducing it.



9.5.3 Acceleration and Velocity

[Alt] +[P] + [2]

The Acceleration and Velocity screen allows you to modify the Acceleration and Velocity values which the TCS will “wake up” with upon power up or reset. These values can also be referred to as the default values. Even if a value has been changed using the “A” or “V” command, the unit will reset to the “wake up” value if the unit is reset. A value entered cannot exceed the maximum value listed.

Click to restore your settings to its original values. The result of a change of values for acceleration and velocity is depicted on the graph shown on the figure above. Changes in the positive and negative direction are also indicated.

Acceleration

The maximum value for the Acceleration is determined from the “Slew rate” entered during the Characterization or the current limit of the motor drive. The wake-up value for Acceleration can be configured for positive direction and negative direction.

Velocity

The maximum value for the Velocity is determined by the setup of the motor drive. Remember that a closed loop positioning algorithm reduces the top speed by 5% to allow for positioning adjustments during moves (also called “head room”). The wake-up value for the Velocity can be configured for positive and negative direction.

BTip – Positive and negative values for acceleration can be used to maximize the performance of a stacker crane.



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9.5.4 Noise and Filter

[Alt] + [P] + [3]

Use the Noise and Filter screen to re-configure the values for Noise Limit and Low Pass Filter settings after a Characterization.

Noise Limit

This choice allows you to limit the Noise Limit which will make the load position smoother but slower. The noise limit is expressed in volts and limits the peak voltage noise from the D/A converter output. Range is from 1/32 to four Volts. Enter a value of four to disable the noise limitation.

For information on tuning the Noise Limit, see Manual Controls on page 9.47.

Low Pass Filter

This choice also allows you to gradually add a Low Pass Filter into the control loop which has the same affect as adding mass to your load. This will cause the load to position smoother but slower. The filter is expressed in terms of a number where one, for example, adds a small filter, while ten adds a much larger one (note that adding filters can also increase the velocity limit). Most situations that add filters use about five. Sometimes, with loads (such as hoists and elevators) driven by wires, the spring action causes the control loop to create a response where the load backs up before it takes off. By selecting an appropriate filter value this “back-up”

BTip – Before you start experimenting with different settings of Noise and Filter values make a back-up of your parameter file.



can be minimized or eliminated. Optimum filter values are mostly between four and eight. The filter calculation routine will help you pick the best value in case there is a back-up problem.

Click for a calculation of the new parameters. A graphical presentation of the result from the changes are shown in the Characterization Program window. If you are satisfied with the result click the Done button, if not satisfied with the result, change the values and watch the result on the graphs. For information on tuning the Low Pass Filter, see Manual Controls on page 9.47.

Click for a graphical view on the existing parameters Transient and Disturbance Response. Click Done to get back to the Noise and Filter screen.

9.5.5 Beam Breaks

[Alt] + [P] + [4]

The Beam Break Parameters screen (image that follows) allows you to modify the methods which the TCS algorithm uses to deal with Beam Breaks (data losses). The first parameter is the wake up or default number of Beam Breaks to ignore which controls the fault tolerance. The next parameter Number of Automatic Retries allows you to enable automatic recovery from a Beam Break fault. Finally, the Number of Beam Breaks to Skip allows the TCS algorithm to delay ramping down the velocity when data is first lost. More details on these parameters are provided in the following sections.

For information on Beam Break diagnostics, see Commands and Diagnostics, page A.I.



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Number of Beam Breaks to Ignore

The I number for maximum consecutive bad data samples to Ignore is determined during the characterization by the time it takes the vehicle to travel 2.4 meters at full speed. When this number is exceeded, the TCS algorithm will perform a controlled stop and issue a Beam Break error message. Even if the value has been changed using the I command, the ICS 5000 unit will return to the wake up value declared here once reset. The value entered cannot exceed the maximum value listed. During normal operation there is no benefit to lowering this value from the maximum.

Number of Automatic Retries

Use this field to enable one or more Automatic Retries after a Beam Break fault has occurred. The automatic retry feature is useful in situations where Beam Breaks occur frequently due to environment or system mechanical problems. The retries are preformed independent of the PLC code, and without issuing the Beam Break fault status.

Number of Beam Breaks to Skip

During a move, a Beam Break normally causes the vehicle to immediately begin ramping down. If the Beam Break goes away before the Ignore level is exceeded, the machine speeds back up and finishes the move. The slight loss of time caused by this slow down and recovery can be avoided by setting the number of Beam Breaks to Skip to a value greater than zero. With Skip enabled, the vehicle will only begin slowing down after the Beam Breaks to Skip value of bad samples has been exceeded.

9.5.6 Wake Up Mode

[Alt] + [P] + [5]

The Wake-up Mode screen allows the user to modify the basic operational modes of the TCS algorithm including: Holding Modes, Enable Warning Codes, report Auto-Calibration, Wait for Good Data, Disable Ramp Retardation and Disable Reverse



Direction on an ongoing move. For information on the different holding modes and algorithm modes, see Table 9.6 on page 9.10 and Table 9.7 on page 9.11. The following screen descriptions.

Mode 1 Warnings

Enables a Warning code that is sent with the status information. This lets the host controller know when a Beam Break and/or a Motor Failure warning has occurred (this is a rarely used feature). Adds 1 to the Mode sum. For protocol information, see Table 9.7 on page 9.11.

Mode 2 Calibration

Enables reporting of the Auto-Calibration within the status so the host controller can know when an Auto-Calibration is occurring (this is a rarely used feature). Adds 2 to the Mode sum. For protocol information, see Table 9.7 on page 9.11.

Mode 4 Deadband

Enables Deadband Holding mode where the speed reference signal is set to zero when on station. Highly desirable in most applications and is required if a parking brake is used. Adds 4 to the Mode sum. For information, see Table 9.6 on page 9.10.

BTip – By default after a characterization Mode 4 is used. (Deadband when positioned on destination.) Mode 4 is the most common used mode and will fit to the most of the installations.



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Mode 8 Integrator

Prevents the integrator from being zeroed at the beginning and end of a move and when a beam break occurs. This characteristic may be desirable for vertical applications but is usually turned off for horizontal applications. Adds 8 to the Mode sum. For information, see Table 9.6 on page 9.10.

Mode 16 Wait

Delays the response of the On Position and Station Location readings if the measurement beam is broken. Adds 16 to the Mode sum. For protocol information, see Table 9.7 on page 9.11.

Mode 32 Retardation

Ramp Retardation limits the acceleration ramp output to the system if the machine is unable to accelerate quickly enough. If the machine is lagging because it cannot match the commanded acceleration then the TCS reduces the ramp to 1/3 of the Wake-up value until the error has dropped back below the Warning Limit. Nuisance motor failure reports are eliminated but vector accuracy for X-Y coordinated moves is degraded. Adds 32 to the Mode sum. For information, see Table 9.6 on page 9.10.

Mode 64 Reversals

Some applications, like elevators, require the TCS algorithm to ignore destinations that would cause the machine to stop and reverse directions. This selection adds 64 to the Mode sum. For information, see Table 9.6 on page 9.10.

Mode 128 Halt

The response on the Halt command can be slow if high noise filter values and or low P and D gains are used. With the Simple Halt mode enabled a simple ramp down will be used instead. For information, see Table 9.6 on page 9.10.

9.5.7 Sync Input Definition

[Alt] + [P] + [6]



The Sync (roniztion) Input relay is typically used in coordination with Sync Output relay. The function of the Sync Input relay can be configured in three different options:

• Normal - De-energizing the SYNC input programs the velocity to zero while keeping the control loop active. This is good when there are multiple machines on the same runway that need to avoid collisions but is basically an unused input for all other applications.

• Halt - The SYNC input can be programmed to perform a HALT when de-energized. This adds a redundant shutdown path when safety is important.

• Ignore - The SYNC input is ignored. This is the default choice after a Characterization.

For information on Synchronization wiring, see the ICS 5000 Installation Manual.

BTip – Sync input is by default configured to Ignore. If no Synchronization wiring between several ICS 5000 units exists, this section can be ignored.



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9.5.8 ASC Parameters

[Alt] + [P] + [7]

The ASC Parameters screen is only available for the Skew Control TCS format. It allows the user to configure the Skew Limit and the Skew Distance for the Advanced Skew Controller.

For information on how to setup and configure ICS 5000 in the Skew Control format, see the Advanced Skew Controller Installation Manual.

Note – Using the ICS 5000 Support Software with the Advanced Skew Controller requires the set of the Connection/Direct Connection item on the Menu bar to be unselected.

Skew Limit

This choice allows you to limit the maximum Skew between the two ends in an Advanced Skew Control System. The default wakeup value is 400 mm. When the skew limit is exceeded, the ASC performs a controlled halt and the Skew Limit exceeded status is reported. This error must be corrected before the ASC will be allowed to move the vehicle. The Skew Limit can also temporary be changed using the N command.

CWarning – Do not set the Skew Limit to a higher value than mechanically allowable. Make sure there is mechanical skew limits on the vehicle before starting to configure this value.



Skew Distance

In some situations it can be beneficial to have an intentionally skew on the vehicle. The Skew Distance option allows you to configure the distance from which the vehicle shall start to square before it is finally postponed on the destination. The Skew between the axis can be controlled in two ways:

• By using stations in both TCS units with different values for position.

• By sending the O command to the Advanced Skew Controller with a squaring value in mm and use the go to a destination in mm command for positioning.

Note – A non-zero Skew Distance also disables the collision avoidance outputs.

9.6 Characterize Tab[Alt] + [Z]

The Characterization is the method that the ICS 5000 Support Software uses to learn the characteristics of the system that it is going to control. By executing a series of movements and recording the change in position feedback, the ICS 5000 Support Software is able to develop an accurate model of the vehicle’s performance. It then uses this model to determine the optimal control loop gains.

The Characterization process is broken down into two phases. First comes the data gathering phase. This phase involves the Support Software exciting the system with known waveforms and recording the response. Much like a person who is driving an unfamiliar car for the first time, the Support Software begins with slow predictable movements and builds to full speed, full acceleration moves as the program becomes more comfortable with the vehicle’s performance.

Once the data has been collected the Support Software finishes the Characterization by reducing the collected data into a theoretical system model. This model is used by one of the tuning procedures (Brown or ITAE) to select the optimal control loop gains for the system. The model is also used to develop the move profiles used



9.28

during positioning, to compensate for data loss, and to monitor for possible performance deviations. If performance deviations are too great, the ICS 5000 will alert the PLC of possible mechanical problems in the form of a Motor Failure status.

Navigation through the settings screens for the Characterization is achieved by using the and buttons. Once all settings are correct, click the

button to begin the process.



9.6.1 Preparation

[Alt] + [Z]

The first screen in the Characterization is the Preparation screen. This screen briefly explains what is necessary to begin a characterization. In some cases it is not necessary to use a load when Characterizing, but this is something that will have to be determined on a case-by-case basis. As a rule of thumb, if the load is small with respect to the total weight of the vehicle it is not necessary during Characterization.

If this is the first characterization, it is recommend that you spend some time adjusting the motor drive settings and determining the maximum slew rate usable with the crane. The final outcome of the characterization depends greatly on the proper tuning of the motor drive. To perform the drive tuning tests click the

button. For Motor Tuning information, see Motor Tuning Aid, page 8.5.

Click to continue to the next screen.

9.6.2 Characterization Menu

If a prior Characterization has been successfully completed using this software, then the Characterization Menu screen will be displayed. This is dependent upon data saved in the .i5k file in the working directory. The .i5k file contains the results of the various tests performed during the last Characterization so that they do not need to be performed every time. For example, the results of the Deadband test will not change just because the top speed of the motor controller has been reduced. Therefore there is no reason to perform that test again.

BTip – After finalizing the Motor Drive Tuning, make sure the vehicle is positioned in the middle of the track before the characterization starts.



9.30

The Characterization Menu, shown in the screen that follows, allows you to complete only the steps of the Characterization that are necessary.

Select the desired test from the menu and click the button to go to the first screen in the selected test. If the selected test is not number 5 or 6, the program will return to this menu after completion of the test.

More information on the different choices can be found at:

• 1. Define Characterization Parameters - Settling Time on page 9.30.

• 2. Polarity, Deadband and Sticky Test - Deadband and Polarity Test, page 9.40 and Speed Regulation or Bias Test on page 9.41.

• 3. Acceleration and Velocity Test - Acceleration and Velocity Test on page 9.41.

• 4. Pink Noise Test - Pink Noise Test on page 9.43.

• 5. Calculate the model parameters and tuning constants - Transient Response on page 9.46 and Manual Controls on page 9.47.

9.6.3 Settling Time

The Settling Time screen asks you to provide some basic information about the performance of the vehicle. If final positioning takes a long time, as with some stacker cranes and vertical applications, then the excitation ramps used during the Pink Noise test are modified to take this into account. The alternate set of Pink Noise ramps are extended to allow any unwanted response characteristics to decay before beginning the next ramp. The default set of ramps is a series of quick steps



suitable for short settling times. Choose from the settling time options provided, see following figure, to more closely match the Characterization routine to your application.

Click to go to the next screen.

9.6.4 Gear Box

The measurements for modeling during the Pink Noise test can be configured to be performed in one of two ways:

1. Only measure the acceleration mass

2. Measure both acceleration mass and deceleration mass.

Normally, to avoid back-lash induced errors, only the acceleration mass is measured (acceleration and deceleration mass are assumed to be the same) during the Characterization. A minority of drive systems decelerate much differently than they accelerate. Certain gear boxes, older worm-gears in particular, have much different characteristics for acceleration and deceleration. This is because power flow efficiency through the gear box is so different in the two directions. It has the effect of making the mass appear to decrease during deceleration and increase during acceleration. If not taken into account, this characteristic could cause severe undershoot in a tuned system.

BTip – Normal vehicles with short settling times can use the set of quick “steps”.



9.32

Use the Gear Box Considerations screen to tell the Characterization what type of system you are using by selecting one of the options from the screen that follows.

Click the button to go to the next screen.

9.6.5 Accuracy/Time Trade -off

The type of motor drive that you select is really not related to the quality of the drive itself. It has been found that non-ideal machine characteristics are usually second order effects and can be handled better by hiding them in the measurement noise. The simplest way to get more noise is to reduce the number of samples averaged. So

BTip – Try with the NORMAL/SYMETRICAL choice if its the first time or if you don’t know which to choose.



in effect this question controls the number of samples taken during the Pink Noise test. If you choose SHORT model, the samples are reduced and it takes less time. If you choose LONG, the samples are increased and it takes more time.


9.6.6 Horizontal vs. Vertical

If the axis of a vehicle or the vehicle itself moves vertically or carries loads in excess of it’s own weigh then the Horizontal vs. Vertical screen selection, shown below, should be answered Vertical Application. By selecting Vertical Application an alternate setup is used during the Acceleration and Velocity Test. Before the Acceleration and Velocity test is begun, you will be prompted to put a full load on the machine. This way the Acceleration and Velocity test will be conducted under

BTip – AVERAGE choice will work for most applications.



9.34

the worst case scenario, and determine a more accurate top acceleration. At the conclusion of this test you will be prompted to remove the full load from the machine.


9.6.7 Ramp Rate

The Ramp Rate screen is necessary to establish the appropriate ramps for the vehicle. If torque produced by your vehicle can overcome the friction of the wheel, (spinning or skidding) then it is important to use a low enough ramp rate to avoid this. The ramp rate is setup in volts/seconds using the following screen. This will determine the maximum working acceleration of the vehicle.

The Ramp Rate value is configured by clicking on the to increase or decrees the volts/sec. value or click on the button to use the value observed during the Motor Drive tuning. For Motor Drive Tuning information, see Motor Tuning Aid on page 8.5.



The ICS 5000 unit’s ramp generator can be bypassed by clicking on the button. This will cause the unit to use a step function when

accelerating or decelerating. On most vehicles this is unacceptable, so select this option with care.

Alternatively, the Ramp Rate value can also be configured by entering the Acceleration Time of the vehicle in the Acceleration Time field.

Note – If the option is selected the following Warning will POP up.


9.6.8 Ending Position

The Ending Position screen allows you to specify where the vehicle should be positioned at the end of the gathering data portion of the Characterization. Once the vehicle is positioned at the selected position, all motion is complete.

Three Ending Position choices are available:

• Near the middle

• Near Limit - Shortest distance between reflector and ICS 5000

• Far Limit - Farthest distance between reflector and ICS 5000


BTip – The common way configuring the Ramp Rate is to use the results from the Trapezoid test in the Motor drive tuning and with the calculated Acceleration Time in mind.



9.36

9.6.9 Automatic Pause

The Automatic Pause option instructs the Support Software to pause the Characterization periodically and prompt for the user to press a key when the Characterization should resume. The Support Software will pause before each move, and can be suspended as long as required. This choice is primarily intended for Characterizing bridge cranes with the Advanced Skew Control System. You then have the possibility to square up the bridge between moves

Note – The characterization can also be temporary paused by clicking on a pause button.


9.6.10 Delayed Start

If it is necessary to start the Characterization and move away from the vehicle before motion begins, a Start Delay can be configured.

Configure a Start Delay by enter a time in sec. in the Start Delay field or use the to configure the delay time.



Note – If a Start Delay is used and the prior screen has been used to insert a pause prior to the move, the start delay will be incorporated each time before motion resumed.

Click the button to start the data gathering portion of the Characterization. The vehicle will begin travelling back and forth within the configured Travel Limits.

If a Start Delay is configured the following screen appears before the tests starts as the delay is counted down.

9.6.11 Characterization Program

After the initial configuration process, the Characterization moves to the data gathering phase and the following screen id displayed. It will automatically perform the tests required of the vehicle without switching from the Static Data tab.

At any time during the Characterization, motion can be paused by using the button.

CWarning – The next action will initiate vehicle motion over the entire area to travel. Be sure that you anticipate this by taking any precautionary measures necessary. If you are unsure of what will happen, stop and contact a Trimble engineer before proceeding.



9.38

Click OK to get back to the tests, click cancel to abort the characterization.

The characterization can also be aborted by clicking the button.

Click Yes to abort the Characterization procedure, click No to return to the tests.

The following Status appears if the Characterization routine is aborted.

To exit the Characterization, click the button. This will restore the original parameters to the ICS 5000 if the Characterization was not completed successfully.

Positioned Near the End Limits

If the characterization is started with the vehicle too close to one of the end limits then the following message appears. Reposition the vehicle to the middle of the track and click OK to continue,

CWarning – Clicking on the Pause button will stop the tests first after it has finished the ongoing test. For Emergency STOP use the Vehicles Emergency STOP function.



Show Log

Create a log on the Characterization by clicking the button. If a log is created the following window opens.

Save the log file as a text file by clicking the button, exit the Log window by clicking .

Note – The Log file data must be saved before exiting the characterization program, else the log data will be lost.

9.6.12 Offset Test

When the Characterization Program first starts to determine the polarity and deadband, it first checks to make sure that there is no position drift. If a drift is present, the program automatically determines what offset will compensate for the drift. This offset will become a permanent part of the TCS algorithm output until the next time polarity and dead-band are determined. As with all ICS 5000 output signals, the offset will only be delivered to the motor drive when the Safety output is closed. Therefore, the offset is not in effect during warm-up, Beam Breaks, Motor Failures or Signal Strength readings.

The offset is also used to compensate for a non-symmetrical deadband. This has the negative effect of causing a small non-zero output when you would normally expect a zero output but greatly improves the symmetry of the Over/Undershoot characteristics

The first test of the gathering data tests is the Offset test

BTip – Creating a log file can help troubleshoot a failed Characterization.



9.40

The Offset test begins by checking if there is any drift in the system. The Support Software starts by outputting a zero VDC signal and measuring any position drift. If there is no drift in the system, then the Deadband and Polarity test starts.

If drift is detected, the Support Software tries to compensate for the drift by changing the Output voltage offset and re-measuring the response of the vehicle. This test continues until an acceptable voltage is found that stops the drift in the system, or if the value is to high to compensate for using the TCS algorithm.

9.6.13 Deadband and Polarity Test

The next test that the Characterization performs determines the Deadband and direction of motion (Polarity) of the system. This test starts by exciting the motor drive with 1 VDC.

If motion is recorded then the voltage is decreased by half. This process continues until no motion is observed. At this point the test increases the voltage and watches for motion.

A series of eight tests are conducted to determine the deadband in both directions. The result of the Offset, Polarity and Deadband tests are shown in the Upper part of the Static Data screen.

If the vehicle can’t be moved on the track in a predictable manner during these tests, error or warning messages will be displayed. For information, see Not Moving, page 9.51, High Deadband, page 9.52 or Change Direction Error, page 9.52.

BTip – If the drift is to high for the TCS algorithm to compensate, adjust the drift on the Motor drive.



9.6.14 Speed Regulation or Bias Test

If the deadband voltage level is above 0.078 volts or below -0.078 then the Speed Regulation test is automatically initiated.

The Speed Regulation or Sticky test moves the vehicle up and down half the length of travel using a 5% reference signal (0.5 volts). Once this test has been performed it is not required again and can be skipped by click on the button.

If the vehicle cannot be moved on the track with 0.5volt then a message is displayed. For information, see Bad Track, page 9.52.

9.6.15 Acceleration and Velocity Test

The Acceleration and Velocity test executes a series of step outputs using the pre-defined ramp rate. The steps are conducted in each direction followed by a display of the results of the test. This test will determine the maximum working velocity and acceleration for the vehicle. The velocity that the vehicle reaches during the 10 volt step should match the top speed for which the drive and motor have been configured. To allow for regulation margins, the actual closed loop top speed will be 95% of this speed. Therefore it is important to set up the drive so the final top speed matches the performance specification of the vehicle.

Steps Outputs

The Acceleration and Velocity test starts by positioning the vehicle at one of the end of travel limits.

BTip – If its not possible to control the vehicle with 0.5 Volt reference over the whole track its strongly recommended to stop the characterization and fix the problem causing this error.

CWarning – During the next series of tests the vehicle will be moving very fast and using all of the area of travel. Notify individuals working near the vehicle that it could approach them very quickly. At no time however will the area of travel exceeded the end of travel limits.



9.42

The TCS puts out 2.5 volt to the vehicle and measures the response.

The measured response is uploaded to the Support Software.

This test is performed using 2.5 Volt, 5 Volt and 10 Volt steps in both directions. The results are then shown in the Static Data field (shown in the figure that follows). The corrected velocity and acceleration values have been recalculated to correct for the dynamics of the machine. The more non-linear the acceleration profile, the more of a change will be made by this correction. For motors that work against current limit this change should be minimal.

Vertical Application

If the choice Vertical Application was selected in the Horizontal vs. Vertical, page 9.33 screen, you will be prompted to put a full load on the vehicle before the Acceleration and Velocity test starts.

After the Acceleration and Velocity test is finalized you will be prompted to the load to half back on the vehicle.

Note – Changing load is only required if its a varietal installation or if using loads exceeding the weight of the vehicle.

BTip – During this test its a good idea to check the relationship between acceleration and velocity data for each step by using the Log file.



Troubleshooting with the Characterization Log

Possible system problems can be observed during this test. The best way to monitor the Characterization for problems is to use the Characterization Log. Look for a linear relationship between the velocities printed for each step. The value should double from step to step. The acceleration values should remain somewhat constant, look for drastic changes from step to step to indicate problems.

For information on error message and solutions go to the section: Not Moving, page 9.51 or Track or Acceleration, page 9.53.

9.6.16 Pink Noise Test

The Pink Noise ramps are a series of 3 or 9 step ramps (depending on the answer to the Settling Time question - see Settling Time on page 9.30) used to gather the response data required to model the system. The previous tests were required only to collect the maximum and minimum performance data.

This test is used to develop the actual model of the system.

BTip – This test can take a long time so be prepared. Selection of a high sampling frequency results in a large amount of passes while a low sampling frequency results in less passes.



9.44

The ramps that are executed are very slow and deliberate with the vehicle appearing to just “wander” back and forth on the track.

The Static Data field above the Status field shows the settings used in this test.

9.6.17 Pink Noise Data

The program reduces the data collected during the Pink Noise ramps to a workable system model. This process also, referred to as the Curve Fitting routine, is graphical displayed in the Pink Noise Data tab shown below. The red line is the theoretical model being “fitted” to the data which is the green line. As the process proceeds the model will gradually conform to the data.

BTip – If the number of passes appears to be excessive the Skip button can be used to exit the program early. While this is not always recommended, it can be required if many Characterizations need to be run to optimize the systems settings. It is always recommended that at least half of the required passes be completed before exiting.



This process can also be displayed numerically by viewing the Log file.

The Curve Fitting is done in the sampled data or Z domain. As with all sampled systems, it is difficult to predict what goes on in between samples. In the screen below, where the proportional and derivative gains are chosen, it becomes possible to accidentally find gains that look good at the sampled times but bad in between. To avoid this problem, the sampled data is converted to the continuous data or Laplace domain. This not only keeps the behavior between samples under control, it also acts like an additional filter to improve the noise rejecting capabilities of the Support Software.

For information on error, warning messages and solutions, go to the section: Non-Linearity, page 9.53 or Speed Overshoot, page 9.54.

9.6.18 Step Response

The graph viewed on the Step Response tab shows how the machine, which is everything except the ICS 5000, responds to a small change in the velocity set point. The more square-like or sharp it is, the better. Some motor drives can be tuned so as



9.46

to affect this curve; if the curve is very, rounded indicative of a slow or sluggish response, or if the curve overshoots, then re-tuning the drive to sharpen the step response would be wise.

9.6.19 Transient Response

The graph viewed using the Transient Response tab shows how the system, which does include the ICS 5000, responds to a small change in the position set point. Like the velocity step response, the more square-like or sharp it is, the faster the system will position or get on-station. However, faster is not always better. Stress on the vehicle and load sway can be reduced by rounding the curve.

The tuning program handles two calculations, one for Transient Response and one for Disturbance Response. The Transient Response mainly affects the Over/Undershoot, while the Disturbance Response affects stability and how the



vehicle returns to set point after being pushed away. The red line in the graph is the calculated Transient Response. (How the system responds to a change of setpoint). The green line is the calculated Disturbance Response.

1. Increase the Low Pass Filter.

2. Decrease the Noise Limit. This de-tunes or reduces the system loop gain which will also cause the curve to be more rounded.

3. Manipulate the Transient Response PD gain manually. This is not a common solution and should not be necessary in the most cases therefore access to this requires a password.

Note – Test the performance of the system before starting with manual tuning.

Manual Controls

Manual Controls group contains the selection of the Tuning Algorithm and Tuning Strength. It also contains the functions for tuning the Low Pass Filter and Noise Limit values.

Two tuning algorithms for the gain parameters are supported:

BTip – Manual tuning to reduce stress on the machine and load sway (rounding the curve) after a Characterization can be accomplished in several ways:



9.48

• Brown tuning will select gains that provide a smoother “machine friendly” final positioning result in gain parameters

• ITAE tuning is designed to provide a “hotter” final positioning profile.

The Tuning Strength for Brown and ITAE tuning can be set to: Gentle, 2..8 and Aggressive.

Note – The default configuration after a new characterization is Brown tuning and Gentle strength.

Tuning Noise Limit allows you to limit the noise gain which will make the load position smoother but slower. The noise limit is expressed in volts and limits the peak voltage noise from the D/A converter output. Range is from 1/32 to 4 Volts. Enter 4 to disconnect the noise limitation.

Tune the Noise limit by select Noise Limit in the Manual Controls group and enter a value in the Control Value field or move the slider to the left. The result of changing Noise Limit is showed directly on screen as a change in the graph for Transient and Disturbance response.

BTip – The Default choice of Tuning Algorithm (Brown) and Tuning Strength (Gentle) will suit the most of the applications. For a normal installation it is no need to experiment with these settings. Testing with different settings for the Noise Limit and Low Past Filter can however be necessary for optimal performance.



Tune the Low Pass Filter by select Low Pass Filter in the Manual Controls group and enter a value in the Control Value field or move the slider to the left. The result of changing the Low Pass Filter is showed directly on screen as a change in the graph for Transient and Disturbance response.

9.6.20 Disturbance Response

This graph shows how the Disturbance gains are tuned to response on a force function. Tuning the Disturbance Response is performed in the Transient Response tab. See Manual Controls, page 9.47 for tuning information.



9.50

9.6.21 Finalizing the Characterization

Exit the Characterization part of the Support Software with the button. The new settings of parameters are written to the ICS 5000 unit.

Finishing a Characterization will return you back to the Characterization Menu. From the Characterization Menu its possible to re-do the entire Characterization or portions of the Characterization.

For information on using the Characterization Menu, see Characterization Menu on page 9.29.

From the Characterization tab go to the Tools tab [Alt] + [T] + [1] and test the result of the Characterization in the Terminal.

For more information on using the Terminal, see Terminal on page 8.2. For information on commands, see Commands and Diagnostics, page A.I

Start with a short moves and then increase the distance if the results seams ok.

BTip – The Log file data must be saved before exiting the characterization program, else the log data will be lost.

CWarning – Be prepared with the Emergency STOP on this tests. Bad gain-parameters if tuned wrong can cause a dangerous behavior of the vehicle.



After making sure the vehicle can travel in both directions without any strange behaviors. Save the new parameters to file and use the Over/Undershoot test to observe how well the vehicle is stopped at destination (see Over-/Undershoot on page 8.4). Finally, use the Random Moves test to measure the settling time and move times and the Chart Recorder to watch the behavior of the analog output. For information, see Random Moves on page 8.7 and Chart Recorder on page 8.9.

Note – Make sure a back-up of the original parameters from the Characterization has been saved prior to fine tuning or experimenting with different settings.

9.7 Software Error MessagesThe following is a list of warning and disaster messages that can be issued by the ICS 5000 Support Software during the Characterization. A warning is triggered by less than optimal performance and allows the user to continue if no changes to the system are possible. A warning will give several suggestions on how to improve the problem, but sometimes it is just not possible to improve the situation.

Disaster messages indicate that fatal error has occurred and completion of the Characterization is not possible at this point. The problem must be rectified before the Characterization can be completed successfully.

9.7.1 Not Moving

This problem can be detected during the different tests with the exception of the Pink Noise test, but it will of course be detected on the first test, the Deadband and Polarity test. It means the ICS is trying to move the vehicle but can not see any response in motion on the output signal to the drive.

Suggestions are for the deadband and Polarity test if its during:

• Check if the drive is enabled.

• Check the wirings from the ICS to the drive. (Deadband and Polarity test)

• The ICS puts out 1 volt to the drive in the deadband test. Click Retry and check the voltage.

• Check so the drive did not get into its current limit. (Acceleration and Velocity test)

Note – No Motion during the Pink Noise test is detected as a Beam Break. This is due to the fact that the software is now measuring the response on the vehicle of different test signals.



9.52

9.7.2 High Deadband

This problem can be detected during the Deadband and Polarity test. It means what the deadband is very high.

Suggestions are:

• The IR-compensation is turned down to low or there is too much resistance in the wires between the motor and drive.

• The track has a detente or bump which should be smoothed out.

• The motor may be undersized for the application.

9.7.3 Change Direction Error

This problem can be detected during the Deadband and Polarity test. It means what the vehicle can only travel in one direction.

Suggestions are:

• The direction control of the drive may not match the selected ICS Output format in the Control Options screen.

• The wirings can be wrong if the direction is controlled with relays (format B and C).

• The drive is not a 4 quadrant or regenerative drive. In this case must the drive be replaced.

9.7.4 Bad Track

This problem can be detected during the Speed Regulation or Bias test. It means what it was not possible to move the vehicle with 0.5V on this position.

Suggestions are:

• Check the track for mechanical damage.



9.7.5 Track or Acceleration

This problem can be detected during the Acceleration and Velocity test. It means what the near and far limits are too close or the acceleration is not high enough to get the vehicle up to speed within the defined position limits.

Suggestions are:

• Modify the near limit and far limit to give the vehicle more room.

• Turn up the current limit or get a larger motor.

• Lower the top speed somehow.

• The acceleration test was interrupted somehow (motor drive stopped) and restarted with to short track left to travel. Retry the test.

9.7.6 Non-Linearity

This problem can be detected during the curve fitting process. It means what the drive using to control the vehicle is not very linear. Overshoot and undershoot will vary depending on the velocity, acceleration and direction.

Suggestions are:

• Use tach feedback instead of EMF.

• Use Pulse Width Modulated instead of SCR drives.

• Reduce the friction



9.54

Figure 9.2 Linearity

9.7.7 Speed Overshoot

This problem can be detected during the curve fit process. It means that the drive has more than 20% speed overshoot. This increases the positioning time.

Common sources are:

• Undersized VF drive and AC motor combinations.

• Too much integral gain in tunable drives.

• Poorly tuned DC drives

• Any spring-like thing in the drive train (drive shaft, rubber coupling, wire rope, pulley/timing belt)

• Even mounting the sensor far from the drive wheel in large structures can cause it

Velocity

Voltage



Note – If you can make the system look more like the ideal velocity step response below, you should abort, fix and re-characterize.

Figure 9.3 Velocity step response

Time

Velocity



9.56

C H A P T E R

10
BCS Control Algorithm Configuration 10
In this chapter:

• Introduction



• Hardware Output Status

• BCS Parameters Tab

• Control Parameters Setup


10 BCS Control Algorithm Configuration

10.2

10.1IntroductionThis chapter covers the configuration of the BCS (open loop) control algorithm in the ICS 5000. See Chapter 7.3, BCS Algorithm - Open Loop Control on page 7.5 for information on the theory of operation of this algorithm.

10.2System Integration PrinciplesThe integration of the ICS 5000 as a motion controller should be approached with a modular state of mind. Think of the ICS 5000 as a positioning co-processor that is wholly responsible for motion related tasks including error detection and reaction. The ICS 5000 works together with the PLC to control motion instead of simply providing a position feedback signal. No attempt should be made to anticipate the safe shut down of the control loop during an error by removing control from the ICS 5000. Instead, the PLC should take advantage of the resources that this distributed control approach frees up by enhancing the communication driver used with the ICS 5000. Thorough support of the status codes and some choice diagnostic registers could save hours of down time spent troubleshooting problems. The exception is when a motor drive faults or safety condition is not satisfied. In this case, the PLC should assume immediate control and stop the machine.

10.2.1 Safe Shutdown of System Operations

The fail-safe design of the ICS 5000 requires little PLC interaction. Once a move command has been initiated the ICS 5000 is capable of controlling every aspect of the move. While the move is in progress, the system controller is constantly monitoring the relationship between the distance to the target and the speed levels. When the ICS 5000 determines that action is necessary, the response is generated automatically without assistance from the PLC.

Following is a brief summary of the ICS 5000 BCS algorithm error handling responses. Also included in this listing is a suggestion as to how the PLC should react once the system has been shut down and the error reported. For more detailed information on error generation please see Hardware Output Status, page 10.11 and Commands and Diagnostics, page A.I.

Table 10.1 BCS Algorithm Error Handling ResponsesFault BCS Algorithm Action PLC Response

Loss of Data

(Beam Break declared). Automatic

Retries not enabled. (RETRY = 0)

• Ramps vehicle down to zero speed and then opens Brake contact.


Retry move. If data loss continues

then check alignment of unit.

Loss of Data (Beam Break declared). Automatic Retries enabled. (RETRY > 0)

• Ramps vehicle down to zero speed but keeps the Brake contact closed while re-determining absolute position. Then resumes the move. If Beam Break is permanent, same action as above.

• Reports status of E 2 during the stop when polled by PLC.

No action necessary if ICS 5000 succeeds to complete the move. Otherwise same as above.



10.2.2 Status Interrogation and Response

Every move initiated by the ICS 5000 will result in a change in status. The PLC must query the ICS 5000 at the completion of each move to determine if the move was a success or failure. The transmission of this query at the end of a move can be triggered by monitoring the ICS 5000’s Brake output. This relay will open to set the mechanical brake when motion has ceased or a fault has occurred. The following text details basic logic that the PLC should possess to deal with possible fault situations reported by the BCS algorithm:

Send move command (D or S) to ICS 5000

If ACK (ª) received from ICS 5000 then

Data received successfully move in progress.

If NAK (§) is received from ICS 5000 then

Data needs to be resent.

Wait for Brake Relay to open

Send E command to ICS 5000

Read Status response E ###

If ### = 2 then retry move command 2 times before reporting Beam Break Fault

If ### = 4 then report Motor Failure Fault

If ### = 8 then retry E command - still positioning

If ### = 16 then Move Complete In Position

If ### = 32 then retry E command for 10 minutes before reporting Warming Up

Slower than theoretical model

(Motor Failure)



PLC should not retry the move

because error could be mechanically related.

Faster than theoretical model

(Motor Failure)



The PLC should not retry the move because error could be mechanically related.

Warming Up • Will not initiate any motion. Brake relay are open.

• Reports status of E 32 when polled by the PLC.




Table 10.1 BCS Algorithm Error Handling ResponsesFault BCS Algorithm Action PLC Response



10.4

If ### = 128 then send BT command to reboot BCS and retry E command

10.3System ConfigurationsThe ICS 5000 system can be configured for three main algorithm versions. Available algorithms are:





To configure the ICS 5000 to use the BCS algorithm, select BCS from the Algorithm section of the Control Options screen. The Output Format section allows you to configure the ICS 5000’s I/O to match the requirements of your system. The following sections provide information on the I/O configurations available with the BCS algorithm.







The BCS algorithm has two main sub versions BCS1 and BCS2. BCS1 is an open loop single axis control with programmable speed plateaus. BCS2 is an open loop single axis control system with a two speed function (digital output for speed changes). The different sub versions for the BCS, are shown in Table 10.2 which follows.

Note – All relay outputs on the ICS 5000 are 24 Volt DC/AC reed style contacts. The relay input used for system synchronization is a 12 - 24 Volt DC/AC coil. See the ICS 5000 Installation Manual for more information on output specifications. Despite minor output differences, the units function identically. The various configurations are explained in detail in the following paragraphs.

10.3.2 Format A Configuration: Bi-Polar Output versions (-10 to +10VDC)

The analog control signal, used by the motor controller for speed reference, varies from 0 VDC to -10 VDC for one direction and from 0 VDC to +10 VDC for the other.

Figure 10.1 System integration BCS format A

Table 10.2 BCS System Configuration OverviewSub Version Control Format I/O Functions

BCS1 A Bi-Polar Output version

( -10 to +10 VDC)

B Uni-Polar Output version (0 to +10 VDC with one direction contact).

C Uni-Polar Output version (0 to +10 VDC with two direction contacts).

BCS2 D Two speed Output version (Fast / slow speed indicated with relay contact).



10.6

The control I/O performs the following functions:

10.3.3 BCS1 Configuration Codes for Control Format A

The listed configuration codes below are retrieved by sending the Self Test (Z) command to the unit. The configuration codes only shows the communication protocols using the RS-232 and RS-422 ports. PROFIBUS-DP and DeviceNet communication protocols use their own communication port and are not included in the configuration code.






10.3.4 Format B Configuration: Uni-Polar Output Version (0 to +10 VDC)

The analog control signal used as a speed reference by the motor drive varies only from 0 VDC to +10 VDC. Direction is indicated by the state of one relay contact, OPEN for one direction CLOSED for the opposite.

Table 10.3 BCS Format “A” I/O ConfigurationI/O NAME DESCRIPTION

13 & 14 Analog Output – 10 (pin 14) to +10 (pin 13) VDC speed reference to the motor drive.



3 & 4 BCS Status Output for Synchronization


1 & 2 BCS Status Input for Synchronization

Coil for a normally open contact (IN) used to indicated when another BCS in the system has begun to ramp to a stop after a fault.




10.3.5 BCS1 Configuration Codes for Control Format B







Table 10.4 TCS Format “B” I/O ConfigurationI/O NAME DESCRIPTION


9 & 10 Direction Contact Normally open contact (OUT4) that indicates direction. Open for one direction, closed for the other.




Normally open contact (OUT 1) used to indicated when the BCS has begun to ramp to a stop after a fault.





10.8

10.3.6 Format C Configuration: Uni-Polar Output Version (0 to +10 VDC)

The analog control signal used as a speed reference by the motor drive varies only from 0 VDC to +10 VDC. Direction is indicated by the state of two relays, one for reverse direction and one for forward direction. A closed relay indicates the direction. If both reverse and forward direction contacts are opened the brake on your drive should be enabled.

Figure 10.2 System integration BCS format C


Table 10.5 BCS Format “C” I/O ConfigurationI/O NAME DESCRIPTION


9 & 10 Reverse Direction Contact

Normally open contact (OUT4) that indicates reverse direction. Closed for reversed direction. Open for forward direction or applying the brake.


5 & 6 Forward Direction Contact

Normally open contact (OUT 2) that indicates forward direction. Closed for forward direction. Open for reverse direction or applying the brake.


Normally open contact (OUT 1) used to indicated when the BCS has begun to ramp to a stop after a fault.





10.3.7 BCS1 Configuration Codes for Control Format C







10.3.8 Format D Configuration: Two Speed Output Version

Speed is indicated by the state of a relay contact, OPEN for low speed and CLOSED for the high speed. Direction is indicated by the state of one relay contact, OPEN for one direction CLOSED for the opposite.

Figure 10.3 System integration BCS format D



10.10


10.3.9 BCS2 Configuration Codes for Control Format D








The sampling frequency (samples/sec. or Hz) used in the IDM (Industrial Distance Meter) inside the ICS 5000 can be configured during the set up. The available sampling frequencies are: 19.35, 30.58, 49.32 and 69.50 Hz with the default being 30.58 Hz (the TCS/BCS/PDM system 4000 uses 30 Hz). If ICS 5000 is used as a replacement unit for an old system, 30.58 Hz should be used to avoid having to re-characterize.

For information on configuring sampling frequency in Support Software, see Chapter 3.4, Sample Rate on page 3.5.

Table 10.6 BCS Format “D” I/O ConfigurationI/O NAME DESCRIPTION

9 & 10 Direction Contact Normally open contact (OUT 4) that indicates direction. Open for one direction, closed for the other.

7 & 8 Safety Contact Normally open contact (OUT 3) that opens to indicate a fault.


3 & 4 High / Low speed contact

Normally open contact (OUT 1) indicated low speed and closed contact indicate high speed.




The BCS algorithm supports the modes listed in Table 10.7. The Mode codes are bit mapped. This means that each unique mode has it’s own bit. If two or more different modes are desired, send the summation of the individual modes. For information on configuring the modes using the ICS 5000 Support Software, see Wakeup Mode, page 10.20.

For information on ASCII protocol status, see Commands and Diagnostics, page A.I. For PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocol information, see Chapter 5, Advanced Communications Configuration on page 5.1.

10.4Hardware Output StatusThe table below shows how the different output relay contacts act at different situations. The functions are the same for all BCS versions except for the following:

Table 10.7 BCS Algorithm Modes

M Number Mode


The BCS can send a warning for motor failure when motor warning level is exceeded. The warning code for beam breaks will be sent when half the I value is exceeded.

• With ASCII protocol, the warning (E 8, #) where #=2 mean almost beam break. #=4 mean almost motor failure, # =0 mean no warning.

• With PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocols the warning code is multiplied by 256 and added to the status. For example: The total status on a travelling vehicle (status 8) with a motor failure warning will be: 4 * 256 + 8 = 1032 The total status on a positioned on destination vehicle (status 16) with a beam break warning will be: 2 * 256 + 16 = 528






If beam is broken position data (X & Y) responses will be withheld until the beam is re-established or the I-number is exceeded.





10.12

• BCS algorithm format D (Two speed version) does not support the Sync output.

For information on status and diagnostic codes, see Commands and Diagnostics, page A.I.

Table 10.8 BCS Algorithm Output StatusStatus Code Brake Sync BCS1 Only

Warming up E 32 Open Open

Just out of warm-up or halted with H-command.

E1 Open Open

Moving to a destination or station. (D# or S# command sent to BCS.)

E8 Closed Closed

At Destination or Station. (Will not change during auto-calibration unless a new D# or S# command is sent.)

E16 Open Closed

After a prolonged Beam Break (I-number exceeded) at Destination or Station.

E2 Open Closed

After a prolonged Beam Break during a move and while decelerating.

E2 Closed Open

When stopped after a prolonged Beam Break during a move. No Retries enabled.

E2 Open Open

When stopped after a prolonged Beam Break during a move. With Retries enabled.

E2 Open Open

After a lagging motor failure and while decelerating.

E4 Closed Open

After a leading motor failure and while decelerating.

E4 Closed Open

When stopped after a motor failure. E4 Open Open

Sync input configured as normal and stopped after the sync. input been opened.

E8 Open Closed

Sync input configured as halt and stopped after the sync. input been opened.

E1 Open Open

During auto-calibration and when a D# or S# is sent to the BCS. (Before the move starts.)

E16 or E64 if in M2

Open Closed

During auto-calibration just before final positioning. (Will happen if calibration time interval has run out during the move.)

E8 or E64 if in M2

Closed Closed



10.5BCS Parameters Tab[Alt] +[P]

When the BCS control algorithm has been selected, the BCS Parameters tab is shown. The BCS Parameters tab (shown below) displays all the values for the control loop with the exception of the tolerance. Use this tab to view the wake-up values for the BCS algorithm and to make changes to meet the specific needs of the vehicle being controlled.

Note – If this is a new installation, the table and fields in the BCS Parameters tab will be empty and a configuration of the vehicle to control shall first be performed.

The BCS Parameters tab contains links to the following screens:

• Control Parameters

• Top Speed

• Beam Breaks

• Wakeup Mode

• Sync Input Definition

The function of each of these screens will be discussed in detail in the following sections. The shortcut key combinations for reach each screen are also provided in each section.

For information on how to perform a configuration on a BCS algorithm, see Control Parameters Setup, page 10.22.



10.14

10.5.1 Control Parameters

[Alt] + [P] + [1]

The Speed and Distance parameters that enable the BCS to control a vehicle are entered using the fields of the Control Parameters screen shown below.

For information on how to configure this screen, see Control Parameters Setup, page 10.22. The following is a short description on each field, this descriptions are also shown in the Support Software by selecting the fields. For a detailed information, see the link in the end of each field’s description.

Number of Speeds

This field controls the number of speeds. If set for two, the analog output goes to 10v for high and 0v for low speed. If 3-7, the analog output ramps up and down to the values determined by the various Speed # Voltage fields. See also: Selecting the Number of Speeds, page 10.23

Failure Level

If the measured velocity differs from theoretical speed by this percentage or more, a Motor Failure fault will be declared. See also: Optimizing Velocity Failure Level, page 10.33

Top Speed

The velocity in millimeters the vehicle will reach with 10 V reference. This is used to calculate a Theoretical Speed which is compared with the Actual Speed for Motor Failure detection. See also: Multi-Speed Algorithm, page 10.24

Brake/Start Delay

The time between closing the Brake relay and ramping up the analog output. It gives the mechanical brake time to release before the drive is asked to accelerate. If the ICS 5000’s Brake output is used to enable the motor drive, set this value to the time it takes for the drive to enable. See also: Brake/Start Delay, page 10.33



Speed 1 min. Distance

This is the distance at which the Brake is applied. This number controls whether the load stops short of or beyond the target destination. See also: Speed 1 Setup, page 10.28

Speed 1 Voltage

The voltage reference supplied to the motor drive for Speed 1. Too high of a value causes violent stops when the brake is applied and makes positioning inconsistent. Too low of a value can cause the machine to stall or get stuck. This value is also used for the Jog pulses. See also: Multi-Speed Algorithm, page 10.24

Speed 2 min. Distance

The distance to transition from Speed 2 to Speed 1. If this is too large, you will waste time at low speed. If this is too small, you will overshoot the target destination. See also: Adding Multiple Speeds, page 10.30

Speed 2 Voltage

The voltage reference supplied to the motor drive for Speed 2. See also: Multi-Speed Algorithm, page 10.24

Speed 3 - 7 min. Distance

The distance to transition to the next lower SPEED #. If too large, you will waste time at the current speed. If too small, you will not see a clean transition to the next speed. See also: Adding Multiple Speeds, page 10.30

Speed 3 - 7 Voltage

The voltage reference supplied to the motor drive for the corresponding Speed #. See also: Multi-Speed Algorithm, page 10.24

Fine Pos. Jog Time

Some Fine Positioning parameters are available to configure how the BCS algorithm corrects small position errors. The first one, Fine Pos. Jog Time, determines the time period to apply the Speed 1 reference to the motor drive. If this is too large the machine may cycle back and forth without finding final position. If this is too small, too many tries will be required resulting in a fault. See also: Fine Pos. Jog Time, page 10.26

Fine Pos. Wait Time

The next Fine Positioning parameter is the Fine Pos. Wait Time. This is the time to wait after applying the Speed 1 reference to the motor drive. Start with twice the time required to stop after pulsing. See also: Fine Pos. Wait Time, page 10.27



10.16

Fine Pos. Fail Limit

The final Fine Positioning parameter is Fine Pos. Fail Limit. This determines the maximum number of times the Speed 1 reference will be applied to the motor drive before declaring a Motor Failure fault. See also: Fine Pos. Fail Limit, page 10.27

Normal Accel Time

For 2 speed AC motors, enter your estimate of the time to reach top speed. For variable speed drives, enter the desired time to reach top speed. See also: Normal Accel Time, page 10.27

Normal Decel Time

For 2 speed AC motors, enter your estimate of the stopping time from top speed. For variable speed drives, enter the desired stopping time from top speed. See also: Normal Decel Time, page 10.27

Emergency Decel Time

For emergencies like Beam Breaks, Motor Failures and halts enter the time you would like to see the machine stop within. See also: Emergency Decel Time, page 10.27

Reversed Polarity

This check box lets you reverse the polarity of the BCS algorithm’s reference voltage output. If the machine goes in the wrong direction, select or unselect this box to reverse the polarity. See also: Reversed Polarity, page 10.28



10.5.2 Top Speed

[Alt] + [P] + [2]

The Top Speed Determination screen displays a filtered velocity feedback that should be used to complete the Top Speed field of the Control Parameters screen. Once the estimated top velocity has been selected and tuned to work with the system, the actual top velocity should be recorded using this step.

The Speed # field’s default value is the configured number of speeds and the Top Speed field’s default value is the entered Top Speed from the Control Parameters screen. Click the button to initiate movement of the vehicle. The vehicle will travel back and forth approaching the two endpoints. If desired, you can configure a Pause Time in seconds between each move by entering a value in the Pause Time field or using the arrow keys. The slider can be used for adjusting the estimated top speed. Try to adjust the Top Speed to the average of the actual measured top speed. The adjusted value for Top Speed is automatically recorded in the Top Speed field on the Control Parameters screen.

All motion can be stopped by clicking either Halt or .

Note – It is important that this step be completed to enable the BCS algorithm to more accurately detect performance related error (Motor Failures) via the Failure Level parameter.

For information on how to use the Top Speed Determination when implementing the speed steps, see also: Testing Top Speed, page 10.32.

CWarning – The velocity verification section of the Support Software will cause the vehicle to move. Be sure that you anticipate this by taking any precautionary measures necessary. If you are unsure of what will happen, stop and contact a Trimble engineer before proceeding.



10.18

10.5.3 Beam Breaks

[Alt] + [P] + [3]

The Beam Break Parameters screen (image that follows) allows you to modify the methods which the BCS algorithm uses to deal with Beam Breaks (data losses). The first parameter is the wake up or default number of Beam Breaks to Ignore which controls the fault tolerance. The next parameter, Number of Automatic Retries, allows you to enable automatic recovery from a Beam Break fault. Finally, the Number of Beam Breaks to Skip allows the TCS algorithm to delay ramping down the velocity when data is first lost. More details on these parameters are provided in the following sections.



The I number for maximum consecutive bad data samples to Ignore is determined during the characterization by the time it takes the vehicle to travel 2.4 meters at full speed. When this number is exceeded, the BCS algorithm will perform a controlled stop and issue a Beam Break error message. Even if the value has been changed using the I command, the ICS 5000 unit will return to the wake up value declared here once reset. The value entered cannot exceed the maximum value listed. During normal operation there is no benefit to lowering this value from the maximum.



Number of Automatic Retries

Use this field to enable one or more Automatic Retries after a Beam Break fault has occurred. The automatic retry feature is useful in situations where Beam Breaks occur frequently due to environment or system mechanical problems. The retries are preformed independent of the PLC code, and without issuing the Beam Break fault status.

Number of Beam Breaks to Skip

During a move, a Beam Break normally causes the vehicle to immediately begin ramping down. If the Beam Break goes away before the Ignore level is exceeded, the machine speeds back up and finishes the move. The slight loss of time caused by this slow down and recovery can be avoided by setting the number of Beam Breaks to Skip to a value greater than zero. With Skip enabled, the vehicle will only begin slowing down after the Beam Breaks to Skip value of bad samples has been exceeded.

CWarning – Using the Skip function with the BCS control algorithm can cause the vehicle to exceed its end of travel limits, if a Beam Break occurs during slow down to final position.



10.20

10.5.4 Wakeup Mode

[Alt] + [P] + [4]

The Wake-up Mode screen allows you to modify the basic operational modes of the BCS algorithm including: enable Warning Codes, report Auto-Calibration and Wait for Good Data. For information on the different algorithm modes, see Table 10.7 on page 10.11 or the following screen descriptions.

Mode 1 Warnings

Enables a Warning code that is sent with the status information. This lets the host controller know when a Beam Break and/or a Motor Failure warning has occurred (this is a rarely used feature). Adds 1 to the Mode sum. For protocol information, see Table 10.7 on page 10.11.

Mode 2 Calibration

Enables reporting of the Auto-Calibration within the status so the host controller can know when an Auto-Calibration is occurring (this is a rarely used feature). Adds 2 to the MODE sum. For protocol information, see Table 10.7 on page 10.11.

BTip – By default, Mode 0 is used after the initial configuration. Mode 0 is the most common mode used with the BCS algorithm and will fit to the most of the installations.



Mode 16 Wait

Delays the response of the On Position and Station Location readings if the measurement beam is broken. Adds 16 to the Mode sum. For protocol information, see Table 10.7 on page 10.11

10.5.5 Sync Input Definition

[Alt] + [P] + [5]

The Sync (roniztion) Input relay is typically used in coordination with Sync Output relay. The function of the Sync Input relay can be configured in three different options:

• Normal - De-energizing the SYNC input programs the velocity to zero while keeping the control loop active. This is good when there are multiple machines on the same runway that need to avoid collisions but is basically an unused input for all other applications.

• Halt - The SYNC input can be programmed to perform a HALT when de-energized. This adds a redundant shutdown path when safety is important.

• Ignore - The SYNC input is ignored. This is the default choice after a Characterization.

For information on Synchronization wiring, see ICS 5000 Installation Manual.

BTip – Sync input is by default configured to Ignore. If no Synchronization wiring between several ICS 5000 units exists, this section can be ignored.



10.22

10.6Control Parameters SetupThe Speed and Distance parameters that enable the BCS algorithm to control a vehicle are entered via the Control Parameters screen selected from BCS Parameters tab of the ICS 5000 Support Software (shown below).

10.6.1 Choosing Control Parameter Values

The fields in the Control Parameters screen must be completed correctly before the BCS algorithm can be used to control a vehicle. Filling out the table is a three step process:

1. Estimate the correct values for the speeds and distances.

2. Tune the performance of the vehicle so that the control is acceptable.

3. Use the Support Software to determine the actual value for the Top Speed.

The table is filled out with Speeds (voltages), Distances and various control parameters. Isolate the lowest speed first and tune the distance until the vehicle positions repeatability without under or overshooting. Then gradually add the remaining speeds one at a time, tuning each to provide only the slightest hesitation when the unit shifts from one speed down to another. Once a comfort level is developed with the performance of the control algorithm, the actual speed should be determined using the Top Speed Determination, see Top Speed, page 10.17.

BTip – Because the BCS algorithm is “open loop” it can not compensate for load and performance changes. Therefore, it is best to preform the Control Parameter tuning with a maximum load on the vehicle.



The software performs some basic validity checks to insure the accuracy of the data entered. Incorrect data is identified as a red field as shown in the following image.

The following sections describe the setup process in greater detail and give some suggestions to guide you to a successful setup.

Selecting the Number of Speeds

Enter the Number of Speeds that the BCS algorithm will be using for the positioning algorithm. This is dependent upon how fast the vehicle moves at full speed and how smooth you need the deceleration portion of the move to be. Multi-speed algorithms use the analog output to ramp the motor drive down from one speed to the next. The reaction time of this ramp is determined by the Normal Decel. Time parameter entered on the Control Parameters screen.

The BCS algorithm can also implement a simple two speed algorithm using only high speed and creep speed. Depending upon the type of interface used by the motor controller to which you are integrating the ICS 5000 there are two ways of developing the two speed profile:

• The BCS algorithm format D uses a digital output.

• The BCS algorithm format A, B or C uses an analog output.

The first option uses contacts to interface with a High Speed/Low Speed contactor, while the second configuration uses the analog reference signal to drive the motor at either full speed or creep speed.

For information on Pin configuration, see:

• Format D Configuration: Two Speed Output Version, page 10.9.

• Format A Configuration: Bi-Polar Output versions (-10 to +10VDC), page 10.5

• Format B Configuration: Uni-Polar Output Version (0 to +10 VDC), page 10.6

• Format C Configuration: Uni-Polar Output Version (0 to +10 VDC), page 10.8.



10.24

Analog Voltage Levels

The relationship between the entered voltages and the velocity setpoint is really quite simple. The entered voltages for the different speeds are supplied to the motor drive as the velocity signal from the ICS 5000. The highest entered voltage will be supplied to the motor drive as the highest velocity signal. Even though the maximum output from the ICS 5000 is 10VDC, there is no problem with configuring a lower voltage for the maximum velocity.

Note – The vehicle’s final velocity depends on the motor drive’s velocity related settings.

In the example presented in Table 10.9 that follows, Speed 3 in is one half of speed 4 (the highest speed). Therefore the voltage output when speed 3 is active will be one half the maximum or 5VDC.

Using this information, a two speed algorithm using the analog output could be setup with the following parameters:.

Multi-Speed Algorithm

The same approach used to setup the two speed algorithm can be carried over to a multi-speed system. Enter the Speed 1 Voltage to Speed n Voltage in the table where N is the highest number of speeds to incorporate into the system. The selected voltages are the voltage the ICS 5000 supplies to the motor drive at each speed.

This data relates to how fast (in millimeters per second) the load will be traveling at different speeds. The Speed 1 Voltage should be slow enough to insure that the positioning tolerance of your system is satisfied while preventing the vehicle from stalling under full load. This voltage may have to be found by trial and error if this data is not readily available.

Table 10.9 Velocity/Analog Output

Speed Number Velocity (mm/sec.) Analog Output (VDC)

1 50 0.5

2 200 2.0

3 500 5.0

4 1000 10.0



The illustration in Figure 10.4 depicts the layout of a four speed algorithm. The graph of Velocity vs. Distance in the top half of the figure shows the relationship between Speed Voltage and Distance settings and the final positioning point. The bottom half of the figure shows the theoretical response of a vehicle when it is exposed to this positioning algorithm.

Figure 10.4 BCS Positioning theory

If the various Speed Voltages are not known, Trimble suggests a formula that uses Speed 1 and the maximum velocity of your system to calculate the remaining Speed variables. For example, for a 7 Speed algorithm, we may know that the Speed 1 Voltage (LO SPEED) should be 0.30 volts to insure positioning accuracy and that the Speed 7 Voltage is 10.00 volts. For a geometric progression from Speed 1 to Speed 7, we can assume the following:

Speed 1 Velocity = 0.30 volts

Speed 2 Velocity = 0.30 * N volts

Speed 3 Velocity = 0.30 * N^2 volts




Speed 7 Velocity = 0.30 * N^6 = 10.00 volts



10.26

Solving for n gives:

0.30* N^6 = 10.00

N^6 = 10.00/0.30

N^6 = 33

N = 33^(1/6)

N = 1.79

Therefore, substituting 1.79 for n in our original formula results in the following reference voltages:








Trimble only suggests this solution and the design engineer for your application may have his or her own speed algorithm implementation. Trimble recommends designing the speed profile base upon the particular performance attributes of your application.

10.6.2 Selecting Other Parameters

Once the Speeds and Distances have been correctly tuned and recorded it is time to finish setting up the remaining control parameters. These values are responsible for everything from detecting performance related errors to adjusting the fine positioning attributes.

Fine Pos. Jog Time

The Fine Pos. Jog Time (in seconds) determines the number of seconds that the motor will be energized too get back into position if the load ever misses (under or over-shoots) its destination. A correctly functioning positioning system should not encounter this problem, but this is an added feature to insure that positioning is successful on every move sequence. Try setting this value to around 1 second. The key with this setting is not to have the value too large. If the value will move the vehicle more that the length of the positioning tolerance then it is too big.



Fine Pos. Wait Time

The Fine Pos.Wait Time determines the amount of time to wait after pulsing the motor to see if the load is on position. Typically this should be twice the Fine Pos. Jog Time. This value is required to let the vehicle settle after jog pulses so that the location may be determined accurately. If this value is too small then the vehicle could never actually come to a complete stop before trying to jog again.

Fine Pos. Fail Limit

The Fine Pos. Fail Limit determines the number of times the BCS algorithm will attempt to jog your load before it shuts down operation. During the set-up stage for the BCS algorithm, this figure should probably be quite high (> 10 tries). During normal operation this number should be quite low (< 5 tries).

Ramp Parameters

The Acceleration Time parameters (Normal Accel Time, Normal Decel Time and Emergency Decel Time) are vital in instructing the BCS algorithm which ramp rates to use while accelerating up to speed or decelerating from Speed to Speed. The time is roughly converted into a slew rate which limits changes in the analog signal. Without this feature, some vehicles would spin there wheels during acceleration and deceleration. It is important that these values be determined prior to setting up the Speed and Distance relationship table as the ramp rate will effect the time it takes the vehicle to change speeds. Thus, changes made to the normal deceleration value after setup has been completed, could result in changes to the various Speed Distance values.

Normal Accel Time

Set the Normal Accel Time to the time it should take the load to get from a dead stop to high speed. The acceleration rate that the vehicle can safely withstand mechanically should determine this parameter. This acceleration time will control how quickly the D/A CONVERTER ramps up to 10 VDC.

Normal Decel Time

Set the Normal Decel Time to the time it takes the load to stop from Top Speed. This Decel Time controls the ramp rate of the D/A Converter output as the analog control signal changes from Speed to Speed. Once this time is set and experimentation begins on the Speed Distances, the Normal Decel Time should not be adjusted. Modifying this value will cause the Speed Distance relationships to change.

Emergency Decel Time

Emergency Decel Time is the time it will take the load to come to a stop in the event of a beam obstruction (Beam Break) or Motor Failure in the ICS 5000. The H or halt command also uses this time to decelerate. An Emergency Deceleration is done in an open loop fashion and does not use the various Speed Distances to shift speeds, but simply ramps down to 0 V when the Emergency Decel Time is implemented. Typically setting this time to your Normal Decel Time is satisfactory.



10.28

Reversed Polarity

If your are using format B or C, ignore this check box, because it pertains only to the bi-polar analog signal in format A. Select or clear this to change the polarity of the analog signal reversing the direction of the drive.

10.6.3 Tuning The Speed Profile

Begin setting up the Control Parameter table with Speed 1 Distance. Once Speed 1 has been successfully setup, the other Speeds will be added one by one and meshed with the previously setup Speeds to insure that there ability to position is not altered.

Note – While Setting up speed 1, there is no need for setting Speed2 to Speed7 to a default value. Just select the speed to be tested from the Over/Undershoot screen.

Speed 1 Setup

Set Speed 1 Distance to the distance from the final destination that the brake will be set and make a mental note of this distance for future use.

Figure 10.5 Speed 1 Setup

Testing Speed 1

Testing of various Speed Distances requires movement of the vehicle. Because the control loop has not yet been verified, it is imperative that someone be prepared to press an Emergency Stop button if something unexpected should happen.

Manually position the vehicle to the center of the length of travel and enable it for automatic control.

BTip – If one of the fields in the table is red, a value was not entered correctly.

CWarning – Next action will initate motion of the vehicle and using all of the area to travel. Be sure that you anticipate this by taking any precautionary measures necessary. If you are unsure of what will happen, stop and contact a Trimble engineer before proceeding.



Speed 1 Undershoot/Overshoot Adjustment

Go to the Over/Undershoot test. [Alt] + [T] + [2]

For information on using the Over/Undershoot test, see Over-/Undershoot on page 8.4.

Move the two turn-around points until they are slightly further apart than the value for the Speed 1 Distance. Zoom in until the scale are showing the two turn around points with a scale of mm resolution. In the Velocity field select Speed 1 or the speed to be tested. Click the button to initiate motion.

Monitor the turn-around points and see if vehicle is undershooting or overshooting the target..

Undershoots are characterized by the load stopping short of destination. Overshoots are characterized by the load passing over target destination. Use either the Overshoot or Undershoot button once to compensate for positioning error. Clicking on Overshoot compensates for undershoots by adding more overshoot, and clicking on Undershoot corrects for overshoots by adding more undershoot. Once

BTip – If the vehicle can’t move, check the wiring, motor drive enable or the analog signal to the motor drive.

CWarning – If the vehicle moves over the turn-around point without stopping and changing direction. The direction control is wrongly set up. Stop the motion and fix the problem, else the vehicle will ultimately pass over the end limit.

BTip – If the vehicle pass over the turn-around point without stopping and change direction.-If format A -change the polarity of the signal in the Reversed Polarity check box or change the polarity on the wiring for the analog signal. -If format B, C or D check the direction controls wirings.



10.30

the vehicle starts moving again continue to check for overshoots and undershoots. Repeat this process as many times as necessary to insure that the vehicle skids exactly into position.

One of three things should have occurred:

1. The vehicle oscillated several times before it finally positioned itself. If this occurred, decrease the Fine Position Jog Time and Wait Time from Control Parameter screen. Repeat the previous test after you have corrected the problem. Remember, the wait time should be approximately twice the jog time.

2. The vehicle did not move. Increase the Fine Position Jog time from Control Parameter and repeat the previous test. Repeat until the problem is corrected.

3. The vehicle positioned itself correctly. Decrease the Fine Position Fail Limit using the Control Parameter and continue to the next procedure.

Save to disk and write to the unit.

10.6.4 Adding Multiple Speeds

At this point you are ready to begin implementing the higher speeds (speeds 2-7). Go to the Control Parameter screen and enter in the Speed 2 Distance. Using the Under/Overshoot test, spread the endpoints apart such that they are positioned at a distance greater than the Speed 2 min. Distance. Select Velocity 2 and initiate vehicle motion by using the Start button. If the vehicle appears to be spending too much time at Speed 1 (creeping), decrease the Speed 2 Distance value from Control Parameter screen.

Never use the Overshoot or Undershoot buttons to adjust overshoot or undershoot of Speeds 2-7. These buttons only effect the minimum distance for Speed 1.

If the vehicle appears to be overshooting, increase the Speed 2 Distance. Once you are satisfied with the 2 speed position control, add the Speed 3 Distance and repeat the same procedure that you used for speed 2.

Note – Remember, you add speeds by entering values in the Speed n Distance and Speed N Voltage fields of the Control Parameter screen. Never hit the Overshoot or Undershoot buttons to tweak on the 2-7 speed control and make sure that your turn around points are further apart than the Distance for the Speed you are trying to adjust.

The analog output performance of the speed settings can be checked in the Chart Recorder tool, [Alt] + [T] + [6]

BTip – If your Speed 1 Distance is less than your tolerance, you may temporarily set it higher than your tolerance for experimentation purposes.

BTip – If the brake can’t release in time before the analog output starts ramping up, configure a delay time. For details, see Brake/Start Delay, page 10.33.



For information on using the Chart Recorder, see Chapter 8.2.6, Chart Recorder on page 8.9.

Test the performance by sending the vehicle to a position, if the distance to travel is long enough for all speeds to be used, all speed steps will be shown on the graph.

Note – Its important to understand what the Chart recorder only shows the analog output from the BCS and not the actual velocity (performance) of the vehicle being controlled.

Note – It can be difficult to view all the different steps if the lowest voltage is very low.

Optimizing the Deceleration Phase of the BCS Algorithm

It is important that the Speed 1 Distance to Speed 7 Distance steps are long enough so that the vehicle will not overshoot the destination when it is carrying maximum load.

Figure 10.6 Deceleration from top speed with the Speed # Distance correctly adjusted.



10.32

Figure 10.7 Deceleration from top speed with the Speed # Distance set too short.

Testing Top Speed

After the speed steps have been implemented it is time to determine the Top Speed.

Go to the Top Speed Determination screen, [Alt] + [P] + [2]

For information on using the Top Speed Determination, see Top Speed on page 10.17.

From the Top Speed Determination screen, adjust the top speed in mm/s that the vehicle travels. This is done by selecting the maximum speed level, estimate the actual Top speed and adjust the actual Top Speed value to the estimated.

Remember that this is a filtered value and takes a few seconds to stabilize.



10.6.5 Optimizing Velocity Failure Level

It is now time to adjust the Failure Level from the Control Parameter screen. This data controls when the system shuts down because of Motor Failures. Once your system is operational, it should consistently travel at the same velocities. It is often fair to assume that if the vehicle’s velocity deviates at different speeds from what it attained at start up, the system has in some way degraded. You may wish to have the BCS algorithm stop the vehicle’s motion at this point, and in some manner indicate to an operator that there is something wrong with the system he or she is working with.

The Failure Level is the point of deviation from any of the vehicles different velocities that the BCS algorithm shuts down your system. For example, if top speed is found to be 1000 mm/s and the Failure Level is set to 10% of Top Speed, the BCS algorithm will shut down operation at either 900 mm/s or 1100 mm/s. The same would hold true for any other speed operation. Previously, this value has been set quite high so that BCS algorithm operation may be initialized. Once the system has been configured this safety and system performance feature should be implemented.

From Control Parameter setup slightly lower the Failure Limit. Use the Over/Undershoot test to cycle the vehicle back and forth. If a Motor Failure appears on the screen, raise the Failure Level in Control Parameter setup. If a Motor Failure does not appear, lower the Failure Level in Control Parameter setup menu until a Motor Failure is detected. At this point raise the limit by approximately 20%.

This should be done for no load and full load situations. If motor failure problems become a nuisance during normal BCS algorithm operation, raise this limit until the problem goes away. Caution should be taken that this limit is not set so high as to cause risk of injury to any plant workers, or to damage the equipment that the ICS 5000 is controlling.

For information on Motor failure diagnostic, see Appendix A, Commands and Diagnostics.

Brake/Start Delay

If the previous tests have shown problems with the brake releasing before the acceleration starts, then the Brake/Start Delay field can be used to configure a delay time between releasing the brake and the ramping of the analog output.

10.6.6 Finalizing the Configuration

After making sure the vehicle can travel properly according to the previously described procedure. Save the parameters and use the use the Random Moves Test to measure the settling time and move times, verifying they are meeting the design requirements of the installation. For information on using the Random Move test, see Random Moves on page 8.7.

CWarning – The Velocity Failure Level is incorporated into the BCS algorithm as a safety feature and should not be ignored.



10.34

C H A P T E R

11
PDM Control Algorithm Configuration 11
In this chapter:

• Introduction



• PDM Parameters Tab


11 PDM Control Algorithm Configuration

11.2 I

11.1IntroductionThis chapter covers the configuration of the PDM (feedback only) control algorithm in the ICS 5000. See Chapter 7.4, PDM Algorithm - Feedback Only and Collision Avoidance on page 7.5 for information on the theory of operation of this algorithm.

11.2System Integration PrinciplesThe integration of the ICS 5000 as a Programmable Distance Meter (PDM) should be approached with a more traditional state of mind. The PDM algorithm turns the ICS 5000 into a pure positioning sensor that is primarily responsible for keeping track of the absolute position of the vehicle. Some additional features have been integrated to extend this scope of operation of the PDM algorithm (such as Collision Avoidance support and Velocity and Acceleration monitoring), however the basic application is still position feedback.

Figure 11.1 System Integration

Following table contains a brief summary of the ICS 5000 PDM algorithm error handling responses. Also included in this listing is a suggestion as to how the PLC should react once the error reported. For more detailed information on error generation please see Commands and Diagnostics, page A.I.

Table 11.1 PDM Algorithm Error Handling ResponsesFault PDM Actions PLC Response

Loss of Data

(Beam Break declared).


Ramps vehicle down to zero speed and then opens Brake contact. Retry move. If data loss continues then check alignment of unit.

CS 5000 Support Software User Manual


11.3System ConfigurationsThe ICS 5000 system can be configured for three main algorithm versions. Available algorithms are:





To configure the ICS 5000 to use the PDM algorithm, select PDM from the Algorithm section of the Control Options screen. The following sections provide information on the I/O pin configuration for the PDM algorithm.

Warming Up • Reports status of E 32 when polled by he PLC.




CWarning – Changing the Algorithm type used by the ICS 5000 will require that the ICS 5000 Support Softwareerase the current setup.

Table 11.1 PDM Algorithm Error Handling ResponsesFault PDM Actions PLC Response



11.4 I




The different main functions supported in the PDM algorithm are shown in Table 11.2. The PDM algorithm does not support any sub versions as the other control algorithms.

Note – All relay outputs on the ICS 5000 are 24 Volt DC/AC reed style contacts. The relay input used for system synchronization is a 24 Volt DC/AC coil. See the ICS 5000 Installation Manual for more information on output specifications.

Despite minor output differences, the units function identically. The various configurations are explained in detail in the following paragraphs. The control I/O performs the following functions:

PDM Configuration Codes


Table 11.2 PDM System Configuration OverviewSub Version Selected Option I/O Functions

PDM Collision Avoidance System

Controlled slowdown, controlled halt and controlled emergency stop relay functions.

Monitoring Not applicable

Monitoring output via Analog signal

Analog output (configure signal from -10 to +10VDC). with one relay for status indication.

Table 11.3 PDM Collision Avoidance I/O ConfigurationI/O Name Description I/O Functions

3 & 4 Controlled Slow Down

Normally closed contact (OUT1) that opens to indicate a controlled slow down.

Controlled slowdown and controlled halt relay functions.

9 & 10 Controlled Halt Normally closed contact (OUT4) that opens to indicate a controlled halt.


5 & 6 Emergency Stop Normally closed contact (OUT2) that opens to indicate an emergency stop










The sampling frequency (samples/sec. or Hz) in the IDM (Industrial Distance Meter) inside the ICS can be configured during the set up. The available sampling frequencies are: 19.35, 30.58, 49.32 and 69.50 Hz with the default being 30.58 Hz (the old TCS/BCS/PDM system 4000 uses 30 Hz). If ICS 5000 is used as a replacement unit for an old system, 30.58 Hz should be used to avoid having to re-configure the parameters.

For information on configuring sampling frequency in Support Software, see Sample Rate on page 3.5.

11.3.3 Filter Selection

The default Digital Filter values use by the PDM algorithm can be fully user configured. There are three standard filters and one user defined filter to select between.

• Small Filter - Standard filter with a smoothing by 4 samples for position, velocity and acceleration.

• Medium Filter - Standard filter with a smoothing by 12 samples for position, velocity and acceleration.

• Large Filter - Standard filter with a smoothing by 36 samples for positioning, velocity and acceleration.

• User Defined Filter - Allows individual configuration for positioning, velocity and acceleration filter parameters.

All filters are of the smoothing by N type. This means they are non-recursive with all coefficients of equal magnitude. This type of filter has the best noise performance of any non-recursive design. This filter is chosen by specifying n the averaging window.



11.6 I

A large N implies much filtering; an N of one implies no filtering. Table 11.4 shows the N values for the standard filters. It’s important to keep N as small as possible to avoid unnecessary time delays in the data.

When N is the same for Position, Velocity and Acceleration, the delays introduced by the individual filters match. This means Position, Velocity and Acceleration measurements coincide with each other in time. However, the peak-to-peak noise increases from Position to Velocity and Velocity to Acceleration.

The Velocity filtering is similar to the Position filtering except that the averaging window is divided in half. Two running averages (one on the first half and one on the second half) are used to compute Velocity. The Acceleration filtering makes four running averages and computes Acceleration from the four positions.

For example: If the Position filter is smoothing by four samples, every X value (for distance) you get will be the average of the four most recent readings. Velocity and acceleration work the same way but are scaled to make the units come out in mm/sec. and mm/sec2.

For information on selecting filter in the Support Software, see Digital Filters on page 11.21.

User Filter

The User Filter is configured by specifying N individually for Position, Velocity and Acceleration. If this is done, the time lag between Position, Velocity and Acceleration readings must be considered as they will depend upon the individual n value and could be different.

For example: a common user filter has N=10 for Position, 20 for Velocity and 40 for Acceleration. The peak-to-peak noise is about the same but the delays are very different. For this example, the filtered Position is five samples old by the time its received. The Velocity data is 10 samples old and the Acceleration data is 20 samples old. If you would like the readings to coincide in time like the standard sets then Position must be measured, wait five samples, measure Velocity, wait 10 samples and then measure Acceleration. For information on configuring user filter in the Support Software, see User Filter on page 11.22.

Table 11.4 PDM Standard FiltersType Smoothing by ‘n’ value Operating Mode

Small 4 samples 4 4

Medium 12 samples 12 8

Large 36 samples 36 12



11.3.4 Collision Avoidance

The PDM algorithm can also be configured to work as a collision avoidance system. It can be used between different vehicles working on the same aisle, see Figure 11.2, or on manually controlled vehicles to avoid running outside an allowed travel zone.

Figure 11.2 Collision Avoidance Overview

The PDM algorithm’s Collision Avoidance system is unique in that it uses relative velocity along with vehicle proximity to determine if a collision is possible. The allowable minimum distance between vehicles based upon the velocity at which they approach each other. This permits correctly operating vehicles to ramp down to within a few feet of each other without causing a fault. Output relays are configured to insure that the approaching vehicles that exceed the velocity at a given distance are forced to first Slowdown to correct the problem. If this does not succeed, a second relay will instruct the vehicle to preform a controlled Halt. Finally, if all else fails, a third relay will drop out the emergency stop circuit disabling the drive.

Collision Avoidance Operation Description

The Collision Avoidance system uses the first six stations in the look-up table for configuring the Collision Avoidance outputs, see Figure 11.3. Stations 3 & 4 control the Controlled Slowdown Zone output, stations 2 & 5 control the Controlled Halt Zone output and stations 1 & 6 control the Emergency Stop Zone output. The stations are configured as minimum and maximum distances using the Support Software. Configuring the stations for the zones in the Support Software is simple, just enter the minimum and maximum distance for the zones, or move the vehicle to one of the distances and register it. For more information, see Minimum Distance and Stopping Acceleration, page 11.17.



11.8 I

Note – More than six stations may be defined, however the first six will be used for Collision Avoidance.

Figure 11.3 Collision Avoidance Zone Overview

The layout of the six stations in Figure 11.3 depicts the algorithm’s use on one vehicle moving between two fixed objects, such as walls, with operation based purely on distance (all Acceleration values set at the max value of 999,999). The End of Travel distance at each end is a point just inside the wall that is still safe to travel to with the vehicle. As the vehicle approaches each End of Travel (or wall in this example) it will pass through the various zones. If the algorithm is applied to two vehicles, then only the first three stations are really used as the distance between the vehicles is always relative to their position, thus the far End of Travel point is not clearly defined.

Once the estimated stopping position exceeds the safe operating zone (less than Station 3 or more than Station 4) the Controlled Slowdown contact will open. If it exceeds the Controlled Slowdown Zone (less than station2 or more than station5) the Controlled Halt contact will also open. If it exceeds the Controlled Halt Zone (less than station 1 or more than station 6) the Emergency Stop contact will open i.e. all three will be open. The slower the machine approaches one of these stations, the closer it can get before the relays will open.

For information on the I/O connector pin configuration for these outputs, see Table 11.2 on page 11.4.

The previous diagram in Figure 11.3 and Table 11.5 help to illustrate the operation and setup of the stations for the PDM collision avoidance.

Table 11.5 PDM Collision Avoidance Zone ConfigurationZone Station # PDM Operation

Safe Operation Between 3 & 4 All contacts are closed. Normal operation

Controlled Slowdown

Outside 3 & 4 Sync. contact opens. This closure can be wired directly to PLC to ramp the crane down to a lower velocity

Controlled Halt Outside 2 & 5 Sync. and fwd/reverse contacts are open. PLC sends halt or stop command to the crane. Wire to Brake contact.

Emergency Stop Outside 1 & 6 All three contacts are open. E-Stop condition to motor drive. Wire to Safety contact.



Basic Acceleration / Velocity Profile Setup

Once the zones are set-up, the vehicle’s operating parameters must be entered. The time it takes the vehicle to react to a stopping command shall be determined. This value is defined as the vehicles Reaction Lag Time.

Configuration of the Collision Avoidance outputs must also take into consideration other aspects of the vehicle's performance (Velocity and Acceleration). If the vehicle is approaching the Minimum Distance, but decelerates to a stop without entering the Controlled Slowdown Zone, then all the contacts will remain closed. See Figure 11.4 for a graphical representation of this concept.

As long as the distance and velocity measured by the ICS 5000 are with in the appropriate operating zone, the corresponding contacts will remain closed. Basically, the lower the approaching velocity, the closer the vehicle can get to the Minimum Distance without opening any contacts.

Figure 11.4 Zone Setup

If the plane between the Safe Operating Zone and Controlled Slowdown Zone is broken (velocity at specific distance exceeded), then the Controlled Slowdown phase will be initiated. If that is not effective and the next plane is broken then the Controlled Halt phase is initiated. Finally, if all else fails and the vehicle enters the Emergency Stop Zone the Emergency Stopping condition is activated. This illustrates why it is important to setup the Acceleration values and the Lag Factor accurately. If more stopping time is required than was anticipated, then the vehicle will overshoot the Minimum Distance station.

Multi-Vehicle Acceleration / Velocity Profile Setup

When configuring the acceleration values and stopping distances for two vehicles, some special considerations need to be taken into consideration:

BTip – Its important to configure the acceleration values such that the Emergency Stop Zone contact is associated with the highest value.



11.10

1. The worst case stopping distance occurs when all of the closing speed is due to one vehicle. For example: Stopping Distance = V2/(2*A) or 30002/(2*500) = 9000 mm if the relative velocity is 3000 mm/sec and the acceleration is 500 mm/sec2.

2. While the relative velocity for two approaching vehicles is doubled, so is the effective acceleration rate. Unfortunately, the ICS 5000 has no way of determining the source of the velocity (if both vehicles or only one is moving), and is therefore unable to safely take advantage of the higher acceleration. With this in mind, the calculation for two approaching vehicles would be: Stopping Distance = (V2/(2*A) or 60002/(2*500) = 36000 mm if the relative velocity is 6000 mm/sec. (each vehicle at 3000 mm/sec.) and the acceleration is 500 mm/sec2.

3. In order for the Collision Avoidance algorithm to safely protect against all collisions, alarms will be issued prematurely as two vehicles approach each other. In the examples given in the previous points, one vehicle can safely stop in 9000 mm, but the Collision Avoidance algorithm determines that the two vehicles approaching each other require 36000 mm instead of just twice the individual vehicle stopping distance (18000 mm). Because of the higher velocity, all operating zones will be entered sooner.

The equations used to predict the position at which the PDM algorithm needs to open the respective relays are as follows:

BRAKE = [S 1 < (SP1 ≈ TP + K*V + V2 /2A1) < S 6]

FWD/REV = [S 2 < (SP2 ≈ TP + K*V + V2 /2A2) < S 5]

SYNC = [S 3 < (SP3 ≈ TP + K*V + V2 /2A3) < S 4]

Table 11.6 Stopping PositionVariable Description

S # Distance in mm related to that specific station. Stations 1-6 need to be set up as shown in the previous diagram.

SPn Calculated stopping point in mm. This value is compared to the Sn.

TP True position read from distance meter.

K Velocity lag factor in sec. entered by user from Modify Menu in setup software.

V Sampled velocity in mm/sec. read from distance meter

An Acceleration rate entered by user.

Brake Open brake circuit. (Closed = ready to run.)

FWD/REV Open fwd/rev circuit. (Closed = ready to run.)

SYNC Open sync. circuit. (Closed = ready to run.)



A Hysteresis value can be programmed into the algorithm to deal with vehicles re-entering into a zone as depicted in Figure 11.5 that follows.

Figure 11.5 Collision Avoidance Output Operation

As the vehicle moves towards “S 4” the state of the circuit stays closed until the exact distance is reached. As the vehicle moves back away from “S 4” it must move past “S 4” a distance equal to the Hysteresis value before the reset occurs.

The Hysteresis value should be kept as small as possible. Some experimentation may be required before an optimal value is obtained.

The collision avoidance Acceleration values, Hysteresis and Lag Factor are all entered via the ICS 5000 Support Software. For information, see Collision Avoidance on page 11.16.

Beam Break Handling for Collision Avoidance Zones

The relays used in the Collision Avoidance system can be configured in one of three ways to respond on Beam Breaks and Auto-Calibrations, see Table 11.7. Level 1 is the most sensitive, the relays will open as soon as the measurement beam is interrupted while Level 3 ignores interruption of the measurement beam. For information on how to configure each relay’s response to Beam Breaks and Auto-Calibrations, see Collision Avoidance Relays Output, page 11.16.

Table 11.7 Collision Avoidance Zone Beam Break HandlingZone Number Error Handling - Relay Outputs

Level 1 The relays open as soon as the measurement is interrupted. It means that the relay will open even on a short beam break (before the I value is exceeded) or during an auto-calibration.

Level 2 The relays only open if the beam break to ignore value has been exceeded.

Level 3 This choice has no sensitivity at all for beam breaks, the relays will only react if the PDM can measure the distance and the vehicle are at the desired position for opening or closing a relay.

Note – This Level is dangerous because if the PDM is blind it is a risk for collision, but it can be necessary to use in installations with frequent Beam Breaks.



11.12

Filter Setup Precautions

During setup some considerations need to be made when sizing filters for the various feedback parameters. The filter that has the largest effect on the collision avoidance equation is the Position Filter. If this filter is increased beyond a nominal value of 1, the Response Lag constant then must be increased accordingly. Each sample addition to the filter value adds approximately 1/60 second delay to the Response Lag.

The Velocity Filter also effects the Response Lag constant, however, not as greatly as the Position Filter. This filter needs to be kept as small as possible with a recommended upper value of 10. A good rule of thumb is to evaluate the stopping consistency of the vehicle with your filter settings and adjust the Response Lag to correct for any errors. For information on selecting a filter value, see Filter Selection on page 11.5. For information on configuring filter in the Support Software, see Digital Filters on page 11.21.

11.3.5 Analog Output

The PDM algorithm can be configured to use the analog output signal to indicate current Position, Velocity and/or Acceleration. The analog signal can be between 0 to ± 10 VDC. The analog output changes in response to Position, Velocity and Acceleration according to a formula involving the position_gain, velocity_gain and acceleration_gain parameters. For example: a pure position output can be obtained by setting the position_gain to a non-zero value and the other two gains to zero.

The formula for the analog output voltage is:

Voltage = pos_gain * (position - user_offset)

+ vel_gain*velocity

+ accel_gain*acceleration

The resolution of the output signal is 2.5mV. Beam Breaks and Auto-Calibrations can be indicated with the Sync output relay. The relay opens if the data is not fresh.

Note – If the Sync output relay is going to be used for indicating Beam Breaks and Auto-Calibrations, the corresponding Collision Avoidance parameters and Stations must be configured.

For information on configuring the Analog output in the Support Software, see Chapter 11.4.3, Analog Output on page 11.19.


The PDM algorithm supports the modes listed in Table 11.8. The Mode codes are bit mapped. This means that each unique mode has it’s own bit. If two or more different modes are desired, send the summation of the individual modes. For more



information on configuring the modes using the ICS 5000 Support Software, see Wakeup Mode on page 11.22. For information on configuring filters, see Digital Filters on page 11.21.

For information on ASCII protocol status, see Commands and Diagnostics, page A.I.

For PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocol information, see Chapter 5, Advanced Communications Configuration on page 5.1. For information on different Filters, see Filter Selection, page 11.5.

Table 11.8 PDM Algorithm Modes

M Number Mode


The PDM can send a warning for beam breaks when half the I value is exceeded.

• With ASCII protocol, the warning (E 8, #) where #=2 mean almost beam break. # =0 mean no warning.

• With PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocols the warning code is multiplied by 256 and added to the status. For example: The total status on a travelling vehicle (status 8) with a beam break warning will be: 2 * 256 + 8 = 520 The total status on a positioned on destination vehicle (status 16) with a beam break warning will be: 2 * 256 + 16 = 528





4 Enable Small type of standard filter for position, velocity and acceleration readings.

8 Enable Medium type of standard filter for position, velocity and acceleration readings.

12 Enable Large type of standard Standard filter for position, velocity and acceleration readings.


If beam is broken, position data (X & Y) responses will be withheld until the beam is re-established or the I-number is exceeded.





11.14

11.4PDM Parameters Tab[Alt] + [P]

When the PDM algorithm’s has been selected, then the PDM Parameters tab is shown. The PDM Parameters tab (shown below) contains all the parameters used to configure the operation of the PDM algorithm to match your applicaiton.

The PDM Parameters tab contains links to the following screens:

• Beam Breaks

• Collision Avoidance

• Analog Output

• Digital Filters

• Wakeup Mode


11.4.1 Beam Breaks

[Alt] + [P] + [1]

The Beam Breaks screen (image that follows) allows you to modify the methods which the PDM algorithm uses to deal with Beam Breaks (data losses). The first parameter is the Maximum Expected Velocity which is used to control the maximum number of Beam Breaks to ignore. The next parameter, Number of Beam Breaks to



Ignore, determines the PDM’s sensitivity to Beam Break faults. Finally, the Collision Avoidance Relay Outputs group allows Collision Avoidance users to configure the relays reactions to Beam Breaks.


Maximum Expected Velocity

Use the Maximum Expected Velocity field to enter the maximum expected velocity the vehicle will be able to achieve. The PDM algorithm’s tolerance of Bad data samples depends on the maximum velocity of the vehicle. This parameter is crucial to insure that the PDM will not be blind enough to lose track of the actual position (sampling errors).

Note – As mentioned in the screen, if the PDM is a set up for a Collision Avoidance System with two cranes, the Maximum Expected Velocity parameter must reflect the speed of both cranes.


The I number for maximum consecutive bad samples to Ignore is calculated from the Maximum Expected Velocity. It is based on the time it takes the vehicle to travel 2.4 meters at full speed. When this number is exceeded, the PDM algorithm will issue a Beam Break fault status message and require a new absolute measurement.



11.16

Collision Avoidance Relays Output

Use this group to configure the reactions of each of the Collision Avoidance System relays to Beam Breaks. The relays can be individually configured to react in one of three different ways.

Select the Level matching the application to be controlled.

For additional information on the different levels, see Beam Break Handling for Collision Avoidance Zones, page 11.11.

11.4.2 Collision Avoidance

[Alt] + [P] + [2]

Use the Collision Avoidance screen (shown below) to configure the operation of the Collision Avoidance system. From this screen adjustments are made to the Travel Zones, Stopping Acceleration Time, Reaction Lag and, if required, Hysteresis.

BTip – A combination of the three levels can be a good point to begin testing. - Level 1 for Controlled slow down zone- Level 2 for Controlled Halt zone- Level 3 for Emergency Stop zone



Configuring a Collision Avoidance system requires the setup of 6 stations (1 to 6) for the zone information. If this is the first time entering this menu, and the required six stations have not yet been configured, the following message is displayed.

Click YES to automatically configure the first six stations (the operating zones) for the Collision Avoidance System. Click No if this screen was entered by mistake or if you prefer to configure the stations using the Stations tab.

Answering yes will set the Minimum Distance to 0 mm and the Maximum Distance to infinity for the zones (stations).

Minimum Distance and Stopping Acceleration

Configuring the Collision Avoidance zones can be done by entering the values for Minimum and Maximum Distances or by measuring the position of the distances.

To measure the distance, move the vehicle to the desired distance, then measure the distance double-clicking the appropriate Distance mm field. The current position will be measured and put into the selected field as a Minimum or Maximum Distance value.

Note – If this is a crane-to-crane installation, the Maximum Distance can be left at infinity.

Next enter the estimated Stopping Acceleration for all three zones.

In a normal setup the Brake relay is used for the Emergency stop zone, Fwd/Rev for the Controlled halt zone and Sync is used for the Slow down zone.

The current status for each relay is indicated by the three circles to the right of the parameters. A vehicle outside a zone is indicated with red circle, inside a zone is indicated with green circle.In the above example the one red circle indicates that the Brake relay is open, meaning the position of the vehicle is outside the Safe Operating Zone. The remaining two green circles indicate that the vehicle is inside the Controlled Slowdown Zone. The actual Position of the vehicle is shown in the bottom left side of the screen. For information on the relays status, see Table 11.5 on page 11.8.

CWarning – The Stopping Acceleration value for the Emergency Stop (Brake relay) must be low enough to provide enough distance to stop with.



11.18

For information on the I/O connector pin configuration for these outputs, see Table 11.2 on page 11.4.

Note – Do not forget to configure the relays reaction to Beam Breaks and Auto-Calibrations, see Collision Avoidance Relays Output on page 11.16.

Reaction Lag and Hysteresis

The vehicles Reaction Time Lag is entered in the Reaction Lag field. A Hysteresis distance can be configured if required before indicating that the vehicle is back in the zone.

For information on Hysteresis, see Collision Avoidance Output Operation, page 11.11.

Crane-to-Crane

If setting up a Crane-to-Crane Collision Avoidance system, click the button to set the Maximum Distance back to infinity.

The following warning appears before the change takes place.

Select Yes to change the settings to a Crane-to-Crane setup, click No to get back to the old values.

Velocity Independent

If you choose not to use the Velocity when calculating stopping distances, click the button to set the Stopping Acceleration to infinity and the Reaction

Lag to zero.

The following warning appears before the changes take place.

Select Yes to change the settings to a Velocity Independent setup, click No to restore the old values.

BTip – A typical Reaction Lag value is 0.5 sec.



Disable the Collision Avoidance Configuration

The Collision Avoidance Setup can be disabled. A click on the button disables the configuration.

The following warning appears before the Collision Avoidance Settings are Disabled.

Select Yes to disable the settings, click No to restore the old values.

11.4.3 Analog Output

[Alt] + [P] + [3]

Use the Analog Output screen to configure the scaling of the analog output to accurately indicate Position, Velocity and Acceleration. The analog output changes in response to a formula involving position_gain, velocity_gain and acceleration_gain. The resolution of the output signal is 2.5mV. Beam Breaks and Auto-Calibrations can be indicated with the Sync output relay. The relay opens if the data is not fresh.

The slider in the bottom of the screen indicates the current analog output value.

BTip – Do not forget to adjust the filter settings to match the application. Noise in the measurements will affect the analog output signal.

BTip – Ignore this screen if not using the analog output.



11.20

POS_GAIN Calculator

The POS_GAIN can be calculated with the help of the POS_GAIN Calculator. Enter the minimum required voltage in the Minimum volts field. Enter the minimum position in the Minimum mm fields. Enter the Maximum position to be measured in the Maximum mm field and enter the maximum required voltage in the Maximum volts field.

Note – Entering values in the Minimum field puts an Offset value in the unit.

Calculate the new POS_GAIN value by click the button. The calculated POS_GAIN value is shown in the POS_GAIN field.

ACCEL and VEL_GAIN Calculator

The ACCEL_GAIN and VEL_GAIN can be calculated with the help of the ACCEL and VEL_GAIN Calculator. Select VEL_GAIN or ACCEL_GAIN and enter the maximum velocity/acceleration in the Maximum field.

Select the parameter to calculate (VEL_GAIN or ACCEL_GAIN) and in the Maximum field, enter the maximum velocity or acceleration. Calculate the selected gain by click the button. The calculated value is shown in the VEL_GAIN field or ACCEL_GAIN filed in the Output Gains group.

Output Gains

The Output Gains group shows the gain values for Position in the field POS_GAIN, Velocity in the field VEL_GAIN and Acceleration in the field ACCEL_GAIN.

The different gain values can also be entered directly in the fields.

Note – The slider shows the actual value of the analog output from the ICS 5000 and will not be updated until the new parameters are written to the unit.



11.4.4 Digital Filters

[Alt] + [P] + [4]

The Digital Filters screen allows you to configure the filters for Position, Velocity and Acceleration readings. The filter is a simple running average on the distance meter measurement. Four different sets of filter are supported. Three pre-defined filters are supported, Small, Medium, Large and one User filter with individual configuration for the filtering of Position, Velocity and Acceleration readings.

The measuring result with different filter and sampling frequency settings are shown in the Measured Values and Peak-to-peak Noise groups. This result can be used for configuring proper settings of filters to match your specific installation needs.

Note – The result from a change in filter settings, is shown in the groups as soon as the new settings are written to the PDM unit.

The Measured values group shows the PDM’s Position, Velocity and Acceleration readings.

The Peak-to-peak Noise group shows the noise in the Position, Velocity and Acceleration readings.

Note – If a Collision Avoidance system is used, some considerations need to be taken when sizing the filters for the various feedback parameters. For information, see Filter Setup Precautions, page 11.12.

Its important to be aware of the consequences different filter settings can have on the measuring result. For information on different filters characteristics, see Filter Selection on page 11.5.



11.22

User Filter

The User Filter allows you to define the filter characteristics for Position, Velocity and Acceleration readings. This is configured in the three fields shown below.

Configuring the User Filter is simple, just enter the N value for position readings in the Position Filter field. Enter the N value for velocity readings in the Velocity Filter field and the N value for acceleration readings in the Acceleration Filter field.

For detail information on User Filter settings, see User Filter on page 11.6.

11.4.5 Wakeup Mode

[Alt] + [P] - [5]

The Wake-up Mode screen (shown below) allows you to modify the basic operational modes of the PDM algorithm including: enable Warning Codes, report Auto-Calibration and Wait for Good Data. For information on the different PDM algorithm modes, see Table 11.8 on page 11.13 or the following sections.

Mode 1 Warnings

Enables a Warning code that is sent with the status information. This lets the host controller know when a Beam Break warning occurred (this is a rarely used feature). Adds 1 to the MODE sum. For protocol information, see Table 11.8 on page 11.13.

BTip – By default after a configuration Mode 0 is used. (Warnings off, calibrating info off and Waiting for good data off.) Mode 0 or one of the filter modes are the most commonly used modes for the PDM.



Mode 2 Calibration

Enables reporting of the Auto-Calibration within the status so the host controller can know when an Auto-Calibration is occurring (this is a rarely used feature). Adds 2 to the MODE sum. For protocol information, see Table 11.8 on page 11.13.

Mode 16 Wait

Delays the response of the On Position and Station Location readings if the measurement beam is broken. Adds 16 to the MODE sum. For protocol information, see Table 11.8 on page 11.13.

11.4.6 Finalizing the Configuration

After making sure the vehicle can be monitored. Save the parameters and, if the Collision Avoidance system is configured, test the zone reaction and the resulting stopping distance to insure proper operation.

BTip – For Collision Avoidance, test one zone reaction at a time to isolate the configuration for each one, then test all three together to insure they react correctly.



11.24

A P P E N D I X

A
Commands and Diagnostics A
In this appendix:

• Introduction

• ACK/NAK

• Special Characters

• Commands and Responses

• Single or grouped Commands

• Status Codes

• Warning Codes

• Diagnostic Commands

ICS 5000 Support Software User Manual A.I

1 Commands and Diagnostics

A.I I IC

A.1 IntroductionWith the standard configuration, communication between the ICS 5000 and the PLC is carried out using a command set of ASCII characters. Remember that the ICS 5000 only responds to capital letters. All commands listed must be followed by a postamble (default = carriage return), or a postamble/line feed combination. Insure that each command used, and it’s expected response, is allowed for by the I/O driver routine.

In general the minimum number of commands should be used. It is possible to build a successful command set with only the “E” (Status code) and “D” (go to a destination in millimeters) commands, but transmission errors and time-outs would then not be handled.

In addition to the standard ASCII character protocol the system can be configured for Modbus, DF1 DeviceNet, PROFIBUS or INTERBUS. These special protocol versions also allow the ASCII protocol to be used for the ICS 5000 Support Software to communicate with the ICS 5000 from the PC.

Note – DeviceNet, PROFIBUS, INTERBUS, Modbus and DF1 configuration is described in Advanced Communications Configuration on page 5.1 of this manual.

A.2 ACK/NAKDuring ASCII communications, the ICS 5000 responds by returning the requested information (distance for example) or by sending back the acknowledge (ACK) character to confirm that the last command was received successfully. The acknowledge string is sent immediately after a “D” or “S” command is received by the ICS 5000. If the transmission of data is unsuccessful, the ICS 5000 will respond with a not acknowledge (NAK) character requesting re-transmission.

The ICS 5000 can also be programmed to send a NAK message when there is too much time between characters. To turn on the feature, select NAK Slow Messages from the ASCII Options -User Settings screen ( [Alt] + [M] + [8] ).

A.3 Special CharactersUnderstanding the following special characters will be helpful during the development of your communications driver.

Table A.1 ICS 5000 Special ASCII Characters

Command ASCIIValue

Symbol Function

Acknowledge (ACK) 6 ♠ Indicates successful transmission of data. A user defined sequence of up to 3 characters can be used instead.

Backspace (BS) 8 BS Deletes last character sent (except postamble).

Carriage Return <CR>

13 CR Indicates end of transmission.


Commands and Diagnostics 1

A.4 Commands and ResponsesTable A.2 that follows contains all of the ASCII command characters and their expected response when sent to the ICS 5000. Use these commands from a terminal program or in the communications driver you develop for your PLC or Host controller. Note that some of these commands have different meanings or do not apply depending upon which control algorithm you are using - TCS, BCS or PDM.

Not Acknowledge 21 § Request re-transmission of data. A user defined sequence of up to 3 characters can be used instead.

Escape (ESC) 27 ^ Aborts Q, W and Z commands and pending X and Y (“wait for good data”) commands if it is necessary to perform some operations immediately such as H (Halt).

Semi-Colon (;) 59 ; Separates multiple commands transmitted with only one carriage return. No (;) must follow the Escape <ESC> character.

NUL (not ASCII 0 = 48)

0 Can be inserted in commands whenever needed (i.e. If a certain number of characters are necessary in a PLC).

Table A.2 ASCII Commands and Responses

Command TCS Response

BCS Response

PDM Response

Description

A A # N/A A # Operating Acceleration

For the TCS this command returns the working acceleration limit set in the ICS 5000 where # is the limit in mm/sec2. This is not necessarily the maximum allowable value.

For the PDM, this command returns the actual acceleration in mm/sec2.

A # ♠ N/A N/A Operating Acceleration

Sets the working acceleration limit where # is the new limit in mm/sec2. If a number greater than the maximum is entered, the maximum will be used.

A value entered in this manner is only temporary and will be replace by the Wake-up Value when power is turned off or the unit is reset.

BT Resets Unit

Resets Unit

Resets Unit

Boot

Use the BT command to reset the ICS 5000. This is not desirable under normal conditions, as this will cause a 5 to 15 second delay before the unit is capable of measuring again.

D D # D # D # Distance Destination

Returns the last destination to which the ICS 5000 was commanded to move. Distance (#) is measured in mm.

Table A.1 ICS 5000 Special ASCII Characters

Command ASCIIValue

Symbol Function

ICS 5000 Support Software User Manual A.I I I


A.IV

D # ♠ ♠ ♠ Distance Destination

Commands the ICS 5000 to move to an absolute value of # millimeters from the target. For the TCS and BCS this command will cause motion. For the PDM, this command just triggers a status change from E 8 to E 16 at the value entered.

E E # E # E # Status

Returns the current status of the ICS 5000 units. See Status Codes on page A.VII for more information.

F F # F # F # Sampling Frequency

Reads the current sampling frequency # of the ICS 5000 in hertz.

H1 ♠ ♠ ♠ Halt

Causes the ICS 5000 to ramp the analogue output signal to 0 VDC at the working acceleration rate and stop trying to control the machine.

Note – Note: Two types of Halt modes can be used for the TCS algorithm. Normal Halt and Simple Halt. Simple Halt is configured by selecting Mode 128 for the TCS.

H #2 ♠ N/A N/A Halt Acceleration

Causes the ICS 5000 to ramp the analogue output signal to 0 VDC at the acceleration rate entered (#) in mm/sec2

The value entered can exceed the maximum value established during the Characterization and could cause the vehicle to skid.

I I # I # I # Beam Breaks to Ignore

Returns the working number (#) of “Bad data samples to Ignore” before declaring a Beam Brake Error. If RETRY>0 the RETRY # multiplied by 256 is added to the working I-number.

I # ♠ ♠ ♠ Beam Breaks to Ignore

Sets the working “Bad data samples to Ignore” limit where # is the new limit. If a number greater than the maximum is entered, the maximum will be used.


J J # J # J # Diagnostic Array

Reads data from diagnostic register. Used in combination with the U command. See Diagnostic Codes.

K K # K # K # Internal Path Strength

Returns the percentage of signal received by the internal path. Working values will be between 30 and 90 percent.

M M # M # M # Operating Mode

Read the Operating Mode of the ICS 5000 units.

M # ♠ ♠ ♠ Operating Mode

Sets the working mode to #. See the description of the Mode command in the Operational Modes section later in this chapter.

A value entered in this manner is only temporary and will be replaced by the Wake-up Value when power is turned off or the unit is reset.



BCS Response

PDM Response

Description



N N # N # N # Next Station

Reads the closest station number that can be stopped at.

O O # O # O # Measurement Offset

Reads the current measurement Offset # in millimeters.

O # ♠ ♠ ♠ Measurement Offset

Sets the working measurement offset where # is the new offset in millimeters.


Q Q # Q # Q # Command Queue

Reads the Queue distance to suspend a command from processing.

Q # ♠ ♠ ♠ Command Queue

Sets a Queue distance.

R R ## R ## R ## Return Signal Strength

Reads percentage of signal returned from target.

This command will disrupt the measurement process and automatically ramp down to a stop and sets the Operating Mode to 1 (halted). Should not be used while the vehicle is in motion.

RON R # R # R # Return Signal Strength

Polls percentage of signal returned from target from the ICS 5000 at the sampling rate. This command is helpful when aligning the unit. See note above for R.

S S # S # S # Station Destination

Returns last station to which the ICS 5000 was commanded to move.

S # ♠ ♠ ♠ Station Destination

Commands the ICS 5000 to move to the entered station (#). If no stations have been established the resulting response will be an E 0. For the TCS and BCS this command will cause motion. For the PDM, this command just triggers a status change from E 8 to E 16 at the station entered.

T T # T # T # Positioning Tolerance

Reads the working positioning tolerance # in millimeters. This value determines how accurately the ICS 5000 will position the vehicle. Values entered are +/- #.

T0 ♠ ♠ ♠ Positioning Tolerance

Initiates an auto-calibration (takes less than 1 sec.). If issued during a move the vehicle will position with the old calibration value, then re-calibrate and, if necessary adjust the position and finally declare E 16.

T # ♠ ♠ ♠ Positioning Tolerance

Sets the working positioning tolerance where # is the new tolerance in millimeters. Values entered are +/- #.




BCS Response

PDM Response

Description

ICS 5000 Support Software User Manual A.V


A.VI

U # ♠ ♠ ♠ Array Index Variable

Sets the diagnostic register pointer to the desired (#) value. See the section on Diagnostic Commands later in this chapter.

V V # V # V # Operating Velocity

Reads the working velocity limit # in millimeters/sec for the TCS or a number from 1-7 indicating the speed setting for the BCS.

For the PDM, this command returns the actual velocity in mm/sec

V # ♠ ♠ ♠ Operating Velocity

Sets the working velocity limit where # is the new limit in millimeters/second for the TCS or a number from 1-7 indicating the speed setting for the BCS. If a number greater than the maximum limit is entered, the maximum will be used.


W W # W # W # Wait Command

Suspends the execution of any command enter after it until the completion of the command enter before it.

X X # X # X # Current Distance

Reads the absolute distance # in millimeters from the ICS 5000 units to the target.

X n X # X # X # Current Distance

Reads the absolute distance # in millimeters from the ICS 5000 units to the target averaged over n number of samples. n can be any number between 2 and 255

XON X # X # X # Current Distance

Polls the absolute distance # in millimeters from the ICS 5000 to the target at the sampling rate.

Y Y # Y # Y # Station Location

Reads the present station location #. Two formats are available. In both formats, the Y number returns the station the machine is at if it is within tolerance of that station.

Format 0 returns a Y-y (y is the closest station #) regardless of the direction it is off station. This is the default format.

Format 1 adds 10000 to the station location when out-of-tolerance and the sign implies the direction. For example, -10005 means the machine's distance is less than station 5, +10005 means it is greater than station 5.

YON Y # Y # Y # Station Location

Polls the present station location # at the sampling rate. Same format as for Y.

Z Z SS,50VVV,RR.RR,########

Z SS,50VVV,RR.RR,########

Z SS,50VVV,RR.RR,########

Self-Test

Conducts Self-test on unit and returns the result in the following format:

• Z SS, 500VV, RR.RR, ########

• SS = Self-test Code.

• VVV = Version of ICS 5000 program.

• RR.RR = Revision level of ICS 5000 firmware.

• ######## = Serial number of ICS 5000.



BCS Response

PDM Response

Description



A.5 Single or grouped CommandsCommands can be sent separately with a carriage return <CR> after each one or they can be sent as a group with only one <CR>. When sent as a group, the commands must be separated by a semicolon (;) character. Replies will be in the same format. The maximum grouped message length is 120 characters including spaces and semicolons.

For example, you can send the following string to the ICS 5000:

E; X; D <CR>

This will read the status followed by the current distance in mm followed by the destination in mm. You can use this to determine if the move is complete (status) and once complete by how many mm the current distance varies from the destination. The response from the ICS 5000 will look like the following:

E 16; X 34567; D34568 <CR>

A.6 Status Codes

A.6.1 Self-Test Results

The Self-Test is conducted automatically by the ICS 5000 Support Software when initializing communications or anytime a Z command is sent to the ICS 5000. Data returned from the ICS 5000 unit includes the Self-Test code, Program Version, Revision Level and Serial Number.

Format

The format of the Self-Test is as follows:

Z SS, 500VV, RR.RR, ########

SS = Self-test Code

VVV = Version of ICS 5000 program

RR.RR = Revision level of ICS 5000 firmware

######## = Serial number of ICS 5000

1The noise filter together with the transient P and D gains act like a low pass filter and reduce the jerk (how quickly the acceleration changes). This causes the deceleration profile to be rounded on the corners which means the effective or average deceleration rate is lower than one might expect. There will also appear to be a reaction time delay processing the halt command. In those cases where the noise filter is high and/or the P and D gains are low, this filtering effect can be very noticeable. Increasing the deceleration rate helps to stop the machine faster but only up to a point; after that the filtering effects limits how fast the TCS algorithm will halt the machine. This has been addressed with the Simple Halt feature. Simple Halt is configured by selecting Mode 128 for the TCS

2Same as 1 above.

ICS 5000 Support Software User Manual A.VII


A.VII I

Self-Test Codes

The codes returned by the Self-Test can be interpreted as follows:

A.6.2 E Numbers

The status of the ICS 5000 units can be accessed by transmitting the E command to the unit. The response from the unit will be the following:

E # Where # represents a status code from the following list.

Table A.3 Self-Test Codes

Code # Description

1 Fatal error in the Program Memory (PROM)

2 Fatal error in the Working Memory (RAM)

3 Fatal error in some support chips (LSI)

4 Fatal error in the distance meter

5 Calibration constants are lost (correctable with software)

6 Control loop parameters are lost (correctable with software)

7 Station loop-up table is lost (correctable with software if necessary)

8 Fatal error in the digital to analog converter (DAC)

9 Fatal error in digital part of interface board

10 Time-out error. Intermittent failure in distance meter

11 Short term power glitch. Check your power supply for mains interference problems

Table A.4 Status Codes

E Number Status

0 SYNTAX OR OUT OF RANGE ERROR – message not within the ICS 5000’s command structure, or the distance commanded to move to exceed the established limits.

1 HALTED DUE TO“H” OR “R” COMMAND (CONTROL LOOP NOT ACTIVE) – last command transmitted to the TCS was the H command or the R command. Both of these commands will disable the ICS 5000’s control loop if it is actively holding a vehicle on position.

2 HALTED DUE TO BEAM BRAKE (CONTROL LOOP NOT ACTIVE) – this fault occurs when the number of bad samples to Ignore (I) is exceeded.

4 HALTED DUE TO MOTOR FAILURE (CONTROL LOOP NOT ACTIVE) – actual position measured has deviated from the theoretical position expected by more than the user defined limit.

8 IN TRANSIT TO DESTINATION (CONTROL LOOP ACTIVE) – no faults.

16 POSITIONED AT DESTINATION (CONTROL LOOP ACTIVE) – vehicle has been successfully positioned within the defined tolerance.

32 ICS 5000 UNIT IS WARMING UP (CONTROL LOOP NOT ACTIVE) – if this Error condition persists for more than 5 minutes upon initial power up contact Trimble for more information.



The Status Codes are bit mapped. This means that each unique code has its own bit. Only one bit can be set at a time. Therefore each Status Code is unique. No bits set (E 0) means invalid command or Syntax Error.

A.6.3 W Numbers

Status can also be obtained using the W command. This command will return the status once the move has been completed successfully or a fault has occurred. The W command is used with the following syntax:

D 1000; W

This command sequence when transmitted to the TCS will cause the vehicle to move to 1000 millimeters and suppress the ACK and the W response until the TCS finishes processing that command. When the response to the W command is finally received it will look as follows:

ACK;W ## Where ## represents a status code from the previous list for the E command.

A.7 Warning CodesThe Warning Code is enabled using the Wakeup Mode screen [Alt] + [P] + [5] of the Parameters tab. Select option 1 to enable the Warning Codes. The display will change to WARNINGS ON: followed by a brief description of the codes.

When the status is requested and the warning code is enabled the response from the ICS 5000 will appear as follows:

E <status>, ## Where ## represents a status code from the following list.

64 CALIBRATION CYCLE (CONTROL LOOP ACTIVE) – auto calibration cycle in progress.

Note – This status code must be enabled using the ICS 5000 Support Software before it is displayed.

128 FAILED POWER UP SELF TEST (CONTROL LOOP NOT ACTIVE) – hardware or parameter failure use Z command for more information.

Table A.5 Warning Codes

Warning No Status

,2 HALTED DUE TO BEAM BRAKE (CONTROL LOOP NOT ACTIVE) – this fault occurs when half the number of bad samples to Ignore (I) is exceeded.

Table A.4 Status Codes

E Number Status

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The Warning codes are bit mapped. This means that each unique code has its own bit. If more than one bit is set, multiple warnings have occurred and the Warning Number issued will be the sum of the individual warning numbers. No bits set means no Warnings have occurred.

A.8 Diagnostic CommandsWhen a Beam Break or Motor Failure error is reported by a ICS 5000, some helpful information about the fault is stored in that specific fault’s diagnostic register. The U# preceding the J is the pointer used to distinguish between the Beam Break, Motor Failure and the Settling Time diagnostic registers. Information is stored in the register until another fault occurs and changes the code or the unit is shut off.

A.8.1 Beam Break Diagnostics

The Beam Break diagnostic register can tell at what point in the measurement process a fault occurred. This information is especially helpful resolving whether a Beam Break was the result of an internal problem with the Distance Meter or an external blocking of the Beam or mis-alignment.

To read this register send:

U0; J

The response from the ICS 5000 will be:

♠ ; J #

Where # is the diagnostic code - see Table A.6 that follows for details.

When using the register to isolate a problem it is necessary to first initialize the register by setting the value to zero as follows.

U0;J0

This insures that the code being received was actually generated by the fault observed.

,4 HALTED DUE TO MOTOR FAILURE – when a user definable % of allowable deviation between the actual position and the profile generated for the move is exceeded this warning code is activated.

,64 CALIBRATION CYCLE PENDING – at 50% of the time interval between calibration cycles this warning code is activated.

Note – This status code must be enabled using the ICS 5000 Support Software before it is displayed.

Table A.6 Beam Break Diagnostic Codes

J # Code Translation

J 0 No problem with the unit, Beam Break caused externally.

J 1 Interrupted target signal in fine frequency mode during start up.

Table A.5 Warning Codes

Warning No Status



A.8.2 Motor Failure Diagnostics

The Motor Failure diagnostic register tells if a failure was in a leading (over speed) or lagging (under speed) direction. There is also a diagnostic register that carries the information about the settling time of the last positioning.


U1; J

The response from the unit will be:

♠ ; J#

Where # is the diagnostic code - see Table A.7 that follows for details.

When using the register to isolate a problem it is necessary to first initialize the register by setting the value to zero.

U1;J0

J 2 Noisy target signal in fine frequency mode during start up.

J 3 Interrupted reference signal in fine frequency mode.

J 4 Noisy reference signal in fine frequency mode.

J 5 Interrupted reference signal in coarse frequency mode.

J 6 Noisy reference signal in coarse frequency mode.

J 7 Interrupted target signal in coarse frequency mode.

J 8 Noisy target signal in coarse frequency mode.

J 9 Interrupted target signal in fine frequency mode (2nd time).

J 10 Noisy target signal in fine frequency mode (2nd time).

J 11 Distance out of range (less than zero or greater than 1000 Meters).

J 12 Fine and coarse frequencies disagree.

J 13 Distance computes to zero.

J 14 Five meter Error in phase meter.

J 20 Beam Break caused external.

J 21 Measuring range exceeded.

J16000 Could not read zero-constants in memory. This error code can occur together with the other J codes. (J0 to J14)

J31000 The internal Grey wedge is not in the expected position. This error can occur together with the other J codes. (J0 to J14)

J33000 Time-out during measurement. The measurement routine was delayed for some reason. This error can occur together with the other J codes. (J0 to J14)

Table A.6 Beam Break Diagnostic Codes


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A.8.3 Settling Time Diagnostics

Settling time is updated each time a move completes and is a measure of how long it took to do the fine positioning (time from when the machine should be on station to when it actually gets on station). Another way of describing this register is that it is the “hunting around” time or the “fine positioning” time. Typical values are between 0.1 and 2 seconds for the TCS algorithm. For the BCS algorithm there should normally be no units set.

You may want to program your PLC to check the settling time from time to time and display an alarm if its more than some value. As a machine degrades, one of the first indications is that the settling time increases.


U2; J

The response from the unit will be:

♠ ; J#

Where # is the settling time - see Table A.8 that follows for details.

When using the register to isolate a problem it is necessary to first initialize the register by setting the value to zero as follows.

U2;J0


Table A.7 Motor Failure Diagnostic Codes


J -# A negative value implies the machine was lagging behind schedule by “value” millimeters. This is the situation when the motor is not working at all or has insufficient acceleration/velocity. The ICS 5000 ramps the analog output down to zero then opens the Safety and Brake outputs.

J # A positive value implies the machine was ahead of schedule by “value” millimeters. This is the situation when the motor has gone wild or has insufficient deceleration. The ICS 5000 immediately opens the Safety and Brake outputs, then ramps down the analog output to zero.

J -99999 This special case means that the analog output circuitry has failed. The ICS 5000 reacts by immediately opening the Safety and Brake outputs, then ramping the analog output down.

Table A.8 Settling Time Diagnostic Code


J # For a TCS algorithm the units are samples (1 sample=1/30 sec.) and for a BCS algorithm, the units are the number of jogs (1 jog is approx. 1 sec.).



A.8.4 Laser Pointer (U3;J)

The optical alignment is easier when the laser pointer is turned on. It may be turned on for periods longer than 2 seconds by sending U3; J1 over and over. The laser pointer will automatically shut off when the PLC stops sending the command.

Note – Laser pointer is only available on ICS 5000 L.

Table A.9 Laser Pointer Diagnostic Code

J# Code translation

J1 U3;J1 turns the laser pointer on for about 2 seconds. U3;J0 turns the laser pointer off immediately.

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A P P E N D I X

B
Advanced Protocol Specifics B
In this appendix:

• DF1 Protocol Information

• MODBUS Protocol Information

B.1 DF1 Protocol Information

B.1.1 Supported DF1 Functions

Of the many functions defined in the DF1 protocol, only these functions (FNC byte) are currently supported:

0 - word range read (typically used by PLC-3 “message” command)

1 - word range write (typically used by PLC-3 “message” command)

67 - typed range write (typically used by PLC-5 “message” command)

68 - typed range read (typically used by PLC-5 “message” command)

Any other function requested by the PLC will result in an ILLEGAL FUNCTION response (STS byte = 0x60). Exception responses are listed later in this document.

B.1.2 Message Framing

With DF1, it takes 4 messages to complete a data transfer or transaction as it is commonly called. These are:

1. Command (sent by PLC)

2. Command acknowledge (sent by ICS 5000)

3. Reply (sent by ICS 5000 after a short time)

4. Reply acknowledge (sent by PLC)

Acknowledges are always DLE ACK (0x10 and 0x06). Commands and replies always begin with DLE STX (0x10 and 0x02) and end with DLE ETX BCC (0x10, 0x03 and check sum byte). The BCC or check sum is calculated on everything between but not including the DLE STX and the DLE ETX.

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A Advanced Protocol Specifics

B.I I IC

Note – All of the details of the protocol are handled automatically by the PLC. you just need to use a properly configured “message” command in your ladder program.

The details at the protocol level are listed in this document because sometimes you have to debug communications at a more primitive level.

B.1.3 Function 0, Word Range Write

This command is used to write one or more words of data to the ICS 5000. The command message format from the PLC is:

DLESTXDST Destination byte, ICS 5000 address/station #SRC Source byte, PLC address/station #CMD Command byte=0x0F indicates word range read & writeSTS Status byte=0x00TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byteFNC Function code=0x00, indicates write (see CMD above)OFFSET_LO Low byte of packet offset (often 0x00)OFFSET_HI High byte of packet offset (often 0x00)WORDS_LO Low byte of number of words to readWORDS_HI High byte of number of words to readFLAG Bits in flag indicate what data is to followTABLE_# Data table number, optional depending on flag byteFILE_# File number, optional depending on flag byteELEMENT_# Which element in file to start with, optionalSUB_ELEMENT Which bit in element to start with, optionalDATA_LO Low byte of transmitted data starting with ELEMENT_#.DATA_HI High byte of transmitted data....DATA_LO Low byte of data (ELEMENT_# + WORDS - 1)DATA_HI High byte of data.DLEETXBCC

The reply message packet format from the ICS 5000 is:

DLESTXDST Destination byte, PLC address/station #SRC Source byte, ICS 5000 address/station #CMD Command byte=0x4F indicates word range read & writeSTS Status byte 0x00=ok, 0x10=illegal command, 50H=address-ing problem,

0x60=function disallowed.TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byteDLEETXBCC


Advanced Protocol Specifics A

B.1.4 Function 0, Word Range Read

This command is used to read one or more words of data from the ICS 5000. The command message format from the PLC is:

DLESTXDST Destination byte, ICS 5000 address/station #SRC Source byte, PLC address/station #CMD Command byte=0x0F indicates word range read & writeSTS Status byte=0x00TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byteFNC Function code=0x01, indicates read (see CMD above)OFFSET_LO Low byte of packet offset (often 0x00)OFFSET_HI High byte of packet offset (often 0x00)WORDS_LO Low byte of number of words to readWORDS_HI High byte of number of words to readFLAG Bits in flag indicate what data is to followTABLE_# Data table number, optional depending on flag byteFILE_# File number, optional depending on flag byteELEMENT_# Which element in file to start with, optionalSUB_ELEMENT Which bit in element to start with, optional#_BYTES How many bytes to read, 2*WORDSDLEETXBCC


DLESTXDST Destination byte, PLC address/station #SRC Source byte, ICS 5000 address/station #CMD Command byte=0x4F indicates word range read & writeSTS Status byte 0x00=ok, 0x10=illegal command,

50H=addressing problem, 0x60=function disallowed.TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byteDATA_LO Low byte of requested data starting with ELEMENT_#.DATA_HI High byte of requested data....DATA_LO Low byte of data (ELEMENT_# + WORDS - 1)DATA_HI High byte of data.DLEETXBCC

B.1.5 Function 67, Typed Write

This command is used to write one or more words of data to the ICS 5000. The command message format from the PLC is:

DLESTXDST Destination byte, ICS 5000 address/station #SRC Source byte, PLC address/station #CMD Command byte=0x0F indicates word range read & writeSTS Status byte=0x00TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byte

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FNC Function code=0x67, indicates typed writeOFFSET_LO Low byte of packet offset (often 0x00)OFFSET_HI High byte of packet offset (often 0x00)WORDS_LO Low byte of number of words to readWORDS_HI High byte of number of words to readFLAG Bits in flag indicate what data is to followTABLE_# Data table number, optional depending on flag byteFILE_# File number, optional depending on flag byteELEMENT_# Which element in file to start with, optionalA_FLAG 0x97 indicates arrayA_DESC 0x09 of similar elementsA_SIZE 0x02 type is integer with 2 bytes per integerDATA_LO Low byte of transmitted data starting with ELEMENT_#.DATA_HI High byte of transmitted data....DATA_LO Low byte of data (ELEMENT_# + WORDS - 1)DATA_HI High byte of data.DLEETXBCC



50H=addressing problem, 0x60=function disallowed.TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byteDLEETXBCC

Note – The PLC-5 “message” command normally uses a typed read/write command when reading or writing integer files.

B.1.6 Function 68, Typed Read

This command is used to read one or more words of data from the ICS 5000. The command message format from the PLC is:

DLESTXDST Destination byte, ICS 5000 address/station #SRC Source byte, PLC address/station #CMD Command byte=0x0F indicates word range read & writeSTS Status byte=0x00TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byteFNC Function code=0x68, indicates typed readOFFSET_LO Low byte of packet offset (often 0x00)OFFSET_HI High byte of packet offset (often 0x00)WORDS_LO Low byte of number of words to readWORDS_HI High byte of number of words to readFLAG Bits in flag indicate what data is to followTABLE_# Data table number, optional depending on flag byteFILE_# File number, optional depending on flag byte



ELEMENT_# Which element in file to start with, optionalSUB_ELEMENT Which bit in element to start with, optionalBYTES_LO How many bytes to read, 2*WORDSBYTES_HI High byte of number of words to readDLEETXBCC



50H=addressing problem, 0x60=function disallowed.TNS_LO Transaction # low byte (to make each transaction unique)TNS_HI Transaction # high byteA_FLAG 0x97 indicates arrayA_DESC 0x09 of similar elementsA_SIZE 0x02 type is integer with 2 bytes per integerDATA_LO Low byte of requested data starting with ELEMENT_#.DATA_HI High byte of requested data....DATA_LO Low byte of data (ELEMENT_# + WORDS - 1)DATA_HI High byte of data.DLEETXBCC

B.1.7 Exception Responses

There are 3 exception responses supported by the ICS 5000:

• 0x10 ILLEGAL COMMAND - the CMD byte was not 0x0F

• 0x50 ADDRESSING PROBLEM - the ELEMENT_# byte was out of the range 0-22 of ELEMENT_# + WORDS was out of the range 0-22.

• 0x60 ILLEGAL FUNCTION - the FNC byte was not 0, 1, 67 or 68.

These codes are returned in the STS byte of the reply message. Any of these conditions cause the syntax LED to turn on until the next message is received.

B.2 MODBUS Protocol Information

B.2.1 Supported MODBUS Functions

Of the 17 functions defined in the MODBUS protocol, only functions 3 (read multiple registers), 6 (write single register) and 16 (write multiple registers) are supported. Any other function requested by the PLC will result in an ILLEGAL FUNCTION exception response. Exception responses are listed later in this document.

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RTU Mode Message Framing

In RTU mode, messages are made of 8 bit binary entities called bytes. Functions 3 and 6 always use 8 bytes per message which can be broken down as follows:

The Address is 1 to 255...The ICS 5000 will ignore any message that does not have an address that matches its address defined in the setup software.

The Function must be 3, 6 or 16 or the ICS 5000 will reply with an ILLEGAL FUNCTION exception response.

Data1 and Data2 are parameters whose definition depends on the function being used.

The CRC is error checking information so the ICS 5000 can detect when a data transmission error has occurred. If such an error has occurred, the ICS 5000 ignores the message.

The beginning and ending of messages is done by inserting time gaps greater than or equal to 3.5 characters (once synchronized with the host, the ICS 5000 does not need the time gap). If any byte in a message has a parity, framing or over-run error associated with it, the entire message is discarded. The ICS 5000 can be receiving a message at the same time it is transmitting a reply to the previous message (full duplex).

Function 3, Read Multiple Registers

When the function byte is 3, Data1 is interpreted as the first register of a group to be read, and Data2 is interpreted as the number of registers in the group. Therefore, the length of the reply will depend on Data2. In the PLC, the registers are numbered 40001, 40002, etc. but at the protocol level, the same registers are 0, 1, etc. This means that the range of registers the ICS 5000 will support is 40001 to 40026 at the PLC level and 0 to 25 when referring to Data1. Hence, if Data1 is not in the range 0 to 25, an ILLEGAL REGISTER exception response will be sent. If Data1 + Data2 is outside the range, an ILLEGAL DATA VALUE exception response will be sent.

The normal reply from the ICS 5000 is formatted as follows:

After all the registers as requested by Data2 have been added to the message, a 2 byte CRC is calculated and appended.

Table B.3 RTU Message FramingAddress Function MSB of

Data1LSB of Data1

MSB of Data 2

LSB of Data 2

MSB of CRC

LSB ofCRC

Table B.4 ICS 5000 Message FramingAddress Function 2*data 2 MSB of

register Data1

LSB of register Data1

MSB of register Data1

LSB of RegisterDaten1+1

etc.



Function 6, Write Single Register

When the function byte is 6, data1 is interpreted as the register number to be written to. Data2 is interpreted as the value to write to it. If data1 is not in the range 0..25 (40001..40026 to the PLC), an ILLEGAL REGISTER exception response is sent. If data2 is outside the range permitted by the register, an ILLEGAL DATA VALUE exception response is sent. Only registers 1 (40002) and 4 (40005) have range limits. Consult the detailed register description below for more detail.

The normal response from function 6 is to send back the same message the ICS 5000 received.

Function 16, Write Multiple Registers

When the function byte is 16 (0x10), data1 is interpreted as the first register of several registers to write to. Data2 is interpreted as the number of registers to be written. The last register to be written is data1+data2-1; if this value exceeds 25 an ILLEGAL REGISTER exception response will be sent to the PLC. Function 16 includes some extra data before the CRC which is a byte count and 2 bytes of data per register.

Exception Responses

There are 7 exception responses outlined in the MODBUS® protocol, only 3 were applicable to the ICS 5000 situation.

1. ILLEGAL FUNCTION, used when the message contains a function byte other than 3, 6 or 16.

2. ILLEGAL REGISTER, used when data1+data2-1 is greater than 25 for functions 3 & 16 and when data1 is greater than 25 for function 6.

3. ILLEGAL DATA VALUE, used when the data written to 40002 or 40005 exceeds the end-of-travel limits. (Old TCS/BCS system 4000 only)

Any of these conditions cause the syntax LED to turn on until the next message is received.

Exception response formatting is as follows:

Examples

Numbers in the following messages are grouped in hexadecimal bytes. The PLC address is assumed to be 1.

Read register 40001

HOST MSG: 01 03 00 00 00 01 84 0ATCS/BCS REPLY: 01 03 02 00 20 B9 9CMEANING: 40001 IS DECIMAL 32 (TCS/BCS IN WARM-UP MODE)

Table B.5Address Function

+128Code1.3

MSB of CRC

LSB of CRC

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Read registers 40001 through 40005HOST MSG: 01 03 00 00 00 05 85 C9TCS/BCS REPLY: 01 03 0A 00 10 00 07 00 07 04 CE 04 CC 48 2CMEANING: 40001 IS DECIMAL 16 (TCS/BCS IS ON-STATION)

40002 IS DECIMAL 7 (STATION DESTINATION IS 7)40003 IS DECIMAL 7 (ACTUAL POSITION IS STATION 7)40004 IS DECIMAL 1230 (DESTINATION IS 1230*65536+1228)40005 IS DECIMAL 1228 (DESTINATION IS 1230*65536+1228)

Read register 40001 with CRC errorHOST MSG: 01 03 00 00 00 01 84 0BTCS/BCS REPLY:MEANING: NO REPLY, CRC ERROR IN HOST MSG.

Read register 40001 in PLC number 2HOST MSG: 02 03 00 00 00 01 84 39TCS/BCS REPLY:MEANING: NO REPLY, PLC ADDRESS DOES NOT MATCH TCS/BCS.

Read register 30001 via Function 4HOST MSG: 01 04 00 00 00 01 31 CATCS/BCS REPLY: 01 84 01 82 CDMEANING: ILLEGAL FUNCTION EXCEPTION RESPONSE BECAUSE FUNCTION 4

IS NOT SUPPORTED (ONLY 3 AND 6 ARE SUPPORTED)

Read register 40027HOST MSG: 01 03 00 1B 00 01 C4 0ETCS/BCS REPLY: 01 83 02 C0 F1MEANING: ILLEGAL REGISTER EXCEPTION RESPONSE BECAUSE REGISTER

40027 DOES NOT EXIST.

Read registers 40001 through 40027HOST MSG: 01 03 00 00 00 1B 84 05TCS/BCS REPLY: 01 83 03 01 31MEANING: ILLEGAL DATA VALUE EXCEPTION RESPONSE BECAUSE REGISTER

40027 DOES NOT EXIST

Write register 40002 to decimal 8HOST MSG: 01 06 00 01 00 08 D9 CCTCS/BCS REPLY: 01 06 00 01 00 08 D9 CCMEANING: THE TCS/BCS BEGINS MOVING THE MACHINE TO STATION 8.

READING REGISTER 40002 WILL RETURN 8 ANDREADINGREGISTER 40004 & 5 WILL RETURN THE EQUIVALENTDESTINATION IN MM. REGISTER 40001 WILL CHANGE TO 8(IN TRANSIT) EVENTUALLY, REGISTER 0003 WILL EQUAL 8AS WELL UNLESS THERE IS A PROBLEM.

Write register 40005 to decimal 1000

HOST MSG: 01 06 00 04 03 E8 79 74TCS/BCS REPLY: 01 06 00 04 03 E8 79 74MEANING: THE TCS/BCS BEGINS MOVING THE MACHINE TO A

DESTINATION OF 1000 MM. READING REGISTER 40005 WILL



RETURN 1000. REGISTER 40002 REMAINS UNCHANGED.REGISTER 40001 WILL CHANGE TO 8 (IN TRANSIT).EVENTUALLY, REGISTER 40007 WILL BE WITHIN TOLERANCEOF 1000 UNLESS THERE HAS BEEN A PROBLEM.

Write register 40004 to decimal 1000 with CRC error

HOST MSG: 01 06 00 03 03 E8 79 73TCS/BCS REPLY:MEANING: NO REPLY, CRC ERROR IN HOST MSG

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A P P E N D I X

C
Network Configuration Files C
In this appendix:

• DeviceNet EDS File Example

• PROFIBUS GSE File Example

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C.I I IC

C.1 DeviceNet EDS File ExampleThe ICS 5000’s EDS file name is ICS500.eds.

$ Electronic Data Sheet for Trimble ICS5000 with DeviceNet protocol$[File] DescText = "ICS5000 EDS File"; CreateDate = 08-24-2000; CreateTime = 16:10:00; ModDate = 05-24-2001; ModTime = 14:14:00; Revision = 1.2;

[Device] VendCode = 639; $ Vendor Id VendName = "Trimble AB"; $ Vendor Name ProdType = 12; $ Device Type ProdTypeStr = "Communications Adapter"; $ Device Type String ProdCode = 1; $ Product Code MajRev = 2; $ Major Rev MinRev = 5; $ Minor Rev ProdName = "ICS5K"; $ Product Name$ Catalog = ""; $ Catalog Number Icon = "Ics5k.ico"; $ ICON File

[IO_Info] Default = 0X0001; $ Poll (bit 0) PollInfo = 0X0001, $ Can't be combined with anything 1, $ Default Producing Connection 1; $ Default Consuming Connection

$ Communication with the device is done via polled I/O. There is no actual$ attribute that can be read, and the length is pre-configured.$ So we specify a dummy vendor specific object class instance$ which is inaccessible via the explicit route.$ Trying to access it will result in a "Service Not Supported" error. Output1 = 30, $ 30 bytes 0, $ All bits are significant 0x0001, $ Poll Connection "Output", $ Name String 6, $ Path Size "20 64 24 01 30 64", $ Class 64, Instance 01, Attribute 64 ""; $ Help String $ OUTPUT SIZE for the scanner (same as Tx Size) $ tells the scanner how many bytes of data to send to the ICS. $ You configure it in the setup software WRITE REGISTER screen $ (found in MODIFY WAKEUP MODE-I/O REGISTERS) by specifying the size $ and quantity of elements in the register list. The ICS only works $ in a polled mode (group 2 master-slave conn.) i.e. no explicit $ messaging.

Input1 = 30, $ 30 bytes 0, $ All bits are significant 0x0001, $ Poll Connection "Input", $ Name String 6, $ Path Size "20 64 24 01 30 64", $ Class 64, Instance 01, Attribute 64 ""; $ Help String $ INPUT SIZE for the scanner (same as Rx Size) $ tells the scanner how many bytes of data to expect from the ICS. $ You configure it in the setup software READ REGISTER screen $ (found in MODIFY WAKEUP MODE-I/O REGISTERS) by specifying the size $ and quantity of elements in the register list. The ICS only works $ in a polled mode (group 2 master-slave conn.) i.e. no explicit $ messaging.


Network Configuration Files A

$[ParamClass]$[Params]$[EnumPar]$[Groups]

C.2 PROFIBUS GSE File ExampleThe ICS 5000’s GSE file name is ICS_068A.gse. A bitmap file named ICS5000n.BMP is also available for the PROFIBUS master configuration tool.

;===========================================================; GSD File for ICS5000; Freeze_Mode_supp, Sync_Mode_supp, Auto_Baud_supp, 12Mbit/s; ; Copyright (C) Trimble AB 2002 All Rights Reserved. Confidential;; Date : 14.11.02; File : ICS_068A.GSE;===========================================================#Profibus_DP;; Unit-Definition-List:GSD_Revision=2Vendor_Name="TRIMBLE AB"Model_Name="ICS 5000"Revision="V1.0"Ident_Number=0x068AProtocol_Ident=0Station_Type=0Hardware_Release="V1.0"Software_Release="V1.1"9.6_supp=119.2_supp=145.45_supp=193.75_supp=1187.5_supp=1500_supp=11.5M_supp=13M_supp=16M_supp=112M_supp=1MaxTsdr_9.6=60MaxTsdr_19.2=60MaxTsdr_45.45=60MaxTsdr_93.75=60MaxTsdr_187.5=60MaxTsdr_500=100MaxTsdr_1.5M=150MaxTsdr_3M=250MaxTsdr_6M=450MaxTsdr_12M=800Implementation_Type="SPC3"Bitmap_Device="ICS5000N"Bitmap_SF="ICS5000N";; Slave-Specification:Freeze_Mode_supp=1Sync_Mode_supp=1Repeater_Ctrl_Sig=0Redundancy=024V_Pins=0Auto_Baud_Supp=1Set_Slave_Add_Supp=0

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Min_Slave_Intervall=1Max_Diag_Data_Len=10Modul_Offset=0Slave_Family=0fail_safe = 0Modular_Station=1Max_Module=34Max_Input_Len=224Max_Output_Len=224Max_Data_Len=448

; User-Parameter-DefinitionPrmText=1Text(0)="Not Active"Text(1)="Active"EndPrmTextPrmText=2Text(0)="INTEL (low-high)"Text(1)="MOTOROLA (high-low)"EndPrmText;ExtUserPrmData=1 "Ext. diagnostics"Bit(0) 0 0-1Prm_Text_Ref=1EndExtUserPrmDataExtUserPrmData=2 "Word format"Bit(1) 1 0-1Prm_Text_Ref=2EndExtUserPrmData

; UserPrmData: Length and Preset:Max_User_Prm_Data_Len=2Ext_User_Prm_Data_const(0)=0Ext_User_Prm_Data_Ref(1)=1Ext_User_Prm_Data_Ref(1)=2

;; Module-Definitions:;

Module = "R E Status 1 Byte" 0x10EndModuleModule = "R E Status 1 Word" 0x50EndModuleModule = "R E Status 2 Word" 0x51EndModule

Module = "R S Station Destination 1 Byte" 0x10EndModuleModule = "R S Station Destination 1 Word" 0x50EndModuleModule = "R S Station Destination 2 Word" 0x51EndModuleModule = "W S Station Destination 1 Byte" 0x20EndModuleModule = "W S Station Destination 1 Word" 0x60EndModuleModule = "W S Station Destination 2 Word" 0x61EndModule

Module = "R Y Station Location 1 Byte" 0x10EndModuleModule = "R Y Station Location 1 Word" 0x50EndModuleModule = "R Y Station Location 2 Word" 0x51



EndModule

Module = "R D Distance Destination 1 Word" 0x50EndModuleModule = "R D Distance Destination 2 Word" 0x51EndModuleModule = "W D Distance Destination 1 Word" 0x60EndModuleModule = "W D Distance Destination 2 Word" 0x61EndModule

Module = "R X Current Distance 1 Word" 0x50EndModuleModule = "R X Current Distance 2 Word" 0x51EndModule

Module = "R R Return Signal Str 1 Byte" 0x10EndModuleModule = "R R Return Signal Str 1 Word" 0x50EndModuleModule = "R R Return Signal Str 2 Word" 0x51EndModuleModule = "W R Return Signal Str 1 Byte" 0x20EndModuleModule = "W R Return Signal Str 1 Word" 0x60EndModuleModule = "W R Return Signal Str 2 Word" 0x61EndModule

Module = "W H Halt Acc 1 Byte" 0x20EndModuleModule = "W H Halt Acc 1 Word" 0x60EndModuleModule = "W H Halt Acc 2 Word" 0x61EndModule

Module = "R A Op Acceleration 1 Word" 0x50EndModuleModule = "R A Op Acceleration 2 Word" 0x51EndModuleModule = "W A Op Acceleration 1 Word" 0x60EndModuleModule = "W A Op Acceleration 2 Word" 0x61EndModule

Module = "R A Neg Op Acc 1 Word" 0x50EndModuleModule = "R A Neg Op Acc 2 Word" 0x51EndModuleModule = "W A Neg Op Acc 1 Word" 0x60EndModuleModule = "W A Neg Op Acc 2 Word" 0x61EndModule

Module = "R A Pos Op Acc 1 Word" 0x50EndModuleModule = "R A Pos Op Acc 2 Word" 0x51EndModuleModule = "W A Pos Op Acc 1 Word" 0x60EndModuleModule = "W A Pos Op Acc 2 Word" 0x61EndModule

Module = "R I Beam Breaks to Ignore 1 Byte" 0x10EndModuleModule = "R I Beam Breaks to Ignore 1 Word" 0x50

ICS 5000 Support Software User Manual C.V


C.VI

EndModuleModule = "R I Beam Breaks to Ignore 2 Word" 0x51EndModuleModule = "W I Beam Breaks to Ignore 1 Byte" 0x20EndModuleModule = "W I Beam Breaks to Ignore 1 Word" 0x60EndModuleModule = "W I Beam Breaks to Ignore 2 Word" 0x61EndModule

Module = "R M Op Mode 1 Byte" 0x10EndModuleModule = "R M Op Mode 1 Word" 0x50EndModuleModule = "R M Op Mode 2 Word" 0x51EndModuleModule = "W M Op Mode 1 Byte" 0x20EndModuleModule = "W M Op Mode 1 Word" 0x60EndModuleModule = "W M Op Mode 2 Word" 0x61EndModule

Module = "R O Measurement Offset 1 Word" 0x50EndModuleModule = "R O Measurement Offset 2 Word" 0x51EndModuleModule = "W O Measurement Offset 1 Word" 0x60EndModuleModule = "W O Measurement Offset 2 Word" 0x61EndModule

Module = "R T Positioning Tolerance 1 Byte" 0x10EndModuleModule = "R T Positioning Tolerance 1 Word" 0x50EndModuleModule = "R T Positioning Tolerance 2 Word" 0x51EndModuleModule = "W T Positioning Tolerance 1 Byte" 0x20EndModuleModule = "W T PositioningTolerance 1 Word" 0x60EndModuleModule = "W T Positioning Tolerance 2 Word" 0x61EndModule

Module = "R V Op Velocity 1 Word" 0x50EndModuleModule = "R V Op Velocity 2 Word" 0x51EndModuleModule = "W V Op Velocity 1 Word" 0x60EndModuleModule = "W V Op Velocity 2 Word" 0x61EndModule

Module = "R V Neg Op Velocity 1 Word" 0x50EndModuleModule = "R V Neg Op Velocity 2 Word" 0x51EndModuleModule = "W V Neg Op Velocity 1 Word" 0x60EndModuleModule = "W V Neg Op Velocity 2 Word" 0x61EndModule

Module = "R V Pos Op Velocity 1 Word" 0x50EndModuleModule = "R V Pos Op Velocity 2 Word" 0x51



EndModuleModule = "W V Pos Op Velocity 1 Word" 0x60EndModuleModule = "W V Pos Op Velocity 2 Word" 0x61EndModule

Module = "R U0 Beam Break Diag Code 1 Byte" 0x10EndModuleModule = "R U0 Beam Break Diag Code 1 Word" 0x50EndModuleModule = "R U0 Beam Break Diag Code 2 Word" 0x51EndModuleModule = "W U0 Beam Break Diag Code 1 Byte" 0x20EndModuleModule = "W U0 Beam Break Diag Code 1 Word" 0x60EndModuleModule = "W U0 Beam Break Diag Code 2 Word" 0x61EndModule

Module = "R U1 Motor Failure Diag 1 Word" 0x50EndModuleModule = "R U1 Motor Failure Diag 2 Word" 0x51EndModuleModule = "W U1 Motor Failure Diag 1 Word" 0x60EndModuleModule = "W U1 Motor Failure Diag 2 Word" 0x61EndModule

Module = "R U2 Settling Time 1 Byte" 0x10EndModuleModule = "R U2 Settling Time 1 Word" 0x50EndModuleModule = "R U2 Settling Time 2 Word" 0x51EndModule

Module = "R U3 PointingLaser Status 1 Byte" 0x10EndModuleModule = "R U3 PointingLaser Status 1 Word" 0x50EndModuleModule = "R U3 PointingLaser Status 2 Word" 0x51EndModuleModule = "W U3 PointingLaser Status 1 Byte" 0x20EndModuleModule = "W U3 PointingLaser Status 1 Word" 0x60EndModuleModule = "W U3 PointingLaser Status 2 Word" 0x61EndModule

Module = "R U4 Digital I/O Status 1 Byte" 0x10EndModuleModule = "R U4 Digital I/O Status 1 Word" 0x50EndModuleModule = "R U4 Digital I/O Status 2 Word" 0x51EndModule

Module = "R U5 DAC Voltage 1 Word" 0x50EndModuleModule = "R U5 DAC Voltage 2 Word" 0x51EndModule

Module = "R Z System Self-test 1 Byte" 0x10EndModuleModule = "R Z System Self-test 1 Word" 0x50EndModule

ICS 5000 Support Software User Manual C.VII


C.VII I

Module = "R Z System Self-test 2 Word" 0x51EndModule

Module = "R General Purpose 1 Byte" 0x10EndModuleModule = "R General Purpose 1 Word" 0x50EndModuleModule = "R General Purpose 2 Word" 0x51EndModule

Module = "W General Purpose 1 Byte" 0x20EndModuleModule = "W General Purpose 1 Word" 0x60EndModuleModule = "W General Purpose 2 Word" 0x61EndModule


Index
A
Acceleration 9.19acceleration 9.41Acceleration and Velocity 9.19acceleration filtering 11.6acceleration time 10.27acceleration_gain 11.19ACK/NAK A.IIAdding Multiple Speeds 10.30Address Monitor 5.60advanced communications protocols 5.2Advanced Skew Controller 9.6, 9.26Algorithm 3.3, 3.4Analog Output 8.9analog output 11.19Analog Output Calibration 8.13analog output signal 11.12ASC Parameters 9.26Auto Gain Limit 9.10, 9.17Auto-Calibration 9.23Automatic Retries 9.22, 10.19Average Settling Time 8.7

B

BCS algorithm 10.4BCS algorithm error handling 10.2BCS Parameters tab 10.13, 11.14BCS1 10.5BCS2 10.5Beam Break 5.42Beam break 5.42Beam Break Handling 11.11Beam Breaks 9.21, 10.18, 11.14Beam Breaks to Skip 9.22, 10.19bi-polar 10.5Bi-Polar Output 9.6bi-polar output 9.6BRAKE 9.16, 10.14, 10.15Brake 11.17Brown tuning 9.48

C

CAN_High 5.31CAN_Low 5.31

CANNEL 0 5.9, 5.13CANNEL 1A 5.10Capture button 3.8CHANNEL 0 5.8CHANNEL 1 5.8CHANNEL 1A 5.15characterization 9.27Characterization Log 9.43Characterization Menu 9.29Characterization Program 9.21Chart Recorder 8.9Collision Avoidance 11.7collision avoidance 3.4collision avoidance outputs 11.7COM 4.16Command Listing 5.67Company name 2.4Configure zones 11.17Connections menu 2.10Control Block 5.11, 5.15Control Options screen 3.3Control Parameters 9.15, 10.14, 10.22Controlled Halt 11.8Controlled Halt Zone 11.7, 11.17Controlled Slow Down Zone 11.7, 11.9Controlled Slow down Zone 11.9Controlled Slowdown 11.8CPU/PROFIBUS master 5.46Crane-to-Crane Collision Avoidance 11.18Curve Fitting 9.45curve fitting routine 9.44cycle power 2.16

D

Data folder 2.7Data Highway Plus (DH+) 5.8Deadband 9.40Deadband holding 9.23default communications parameters 2.15, 2.16Default settings 2.15Description screen 3.3Destination Folder 2.5destination folder 2.7Device Parametrization 5.58DeviceNet communications 5.20DF1 B.I–??

ICS 5000 Support Software User Manual Index.I

Index

DF1 network 5.7DF1 protocol 5.4digital filter 11.5Digital Filters 11.21Digital I/O Status Word 5.71Direct Connection 3.5direction of motion 9.40disaster 9.51Disturbance Response 9.49Disturbance response 9.47disturbance response 9.46DOS based Support Software 2.14Downloading firmware 8.10

E

EDS file 5.65EDS file(s) 5.24Emergency Decel Time 10.16Emergency deceleration 10.27Emergency Stop 11.8Emergency Stop Zone 11.7, 11.9, 11.17Emergenzy STOP 9.38Enabling the DF1 Protocol 5.5Ending Position 9.35END-OF-THE-CHAIN 5.55Extended Diagnostic 5.42Extended Diagnostic Register 5.42

F

Fail Limit 10.27fail-safe design 9.2File Menu 2.9filter 9.47, 11.21Fine Pos. Fail Limit 10.16Fine Pos. Jog Time 10.15Fine Pos. Wait Time 10.15Fine Pos.Wait Time 10.27Firmware 8.10Firmware Revision 3.3Firmware/Version Check 2.16Flash Loader 2.11, 8.10Full servo 9.11Fwd/Rev 11.17

G

gear box 9.31Gear Box Considerations 9.32General 3.1general configuration 3.2Go ON Line 2.15

H

Halt 9.12, 9.24, 10.27Hardware Configuration 8.12head room 9.19Help menu 2.12Help, context-sensitive 1.2Horizontal vs. Vertical 9.33Hysteres 11.18hysteresis 11.11

I

ICS 5000 Modules Object Properties 5.49importing data 2.14Incorrect data 10.23install 2.3installation 2.2installation folder 2.5installation type 2.6Installing new GSE 5.44Installing the Software 2.8InstallShield Wizard 2.4insulator 5.32integrator 9.24Interpolate 6.4ITAE tuning 9.48

J

JOG pulses 10.15Jog Time 10.26

K

KF-2 Module 5.8

L

Lagging 5.42lagging 9.13Laser Alignment 3.6Leading 5.42leading 9.13load sway 9.46log file 9.39Loss of Data 9.3Low Pass Filter 9.20, 9.49LSW 5.66

M

Manual Controls 9.47Manuals folder 2.7

Index.I I ICS 5000 Support Software User Manual

Index

Menu bar 2.2menu bar 2.9Message instruction 5.11Message instruction usage 5.16MODBUS B.V–B.IXMODBUS Address 5.20MODBUS communications 5.17MODBUS protocol 5.18Mode 10.20, 11.22Modes 9.10, 9.11, 10.11, 11.13Modify Stations 6.3Modify Stations screen 6.3Monitoring 5.57Monitoring State 5.58Motor Drive tuning 9.34Motor Failure 5.42, 9.15Motor Tuning 9.29Motor Tuning Aid 8.5Motor Warning 9.15MSW 5.66Multi-Speed Algorithm 10.24Multi-speed algorithms 10.23

N

Navigation 2.2Negative Deadband 9.18Noise and Filter 9.20Noise Gain 9.20Noise Limi 9.48non-ideal machine 9.32non-recursive filters 11.5Normal limits 3.8Number Conventions 5.66Number of Speeds 10.23

O

ON Line 2.15online help 1.2Opening an Existing Data File 2.13Operating State 5.57Options Menu 2.11Output Format 3.3, 3.4Output Status 9.12, 10.11Output Test 8.8Over/Undershoot 10.29Over-/Undershoot Control 8.4Overshoot 8.4, 10.29

P

Parameterization Telegram 5.43Pause 9.36, 9.38PDM Parameters tab 11.14

performance related deviations 9.3PID gains 9.17pin configuration 5.50Pink Noise 9.30Pink Noise Data 9.44pink noise ramps 9.43PLC 5.8PLC's Serial Port 5.9PLC-5 5.9Pointing Laser 3.7polarity 9.39, 10.28Polarity and Deadband tests 9.40position drift 9.39position filter 11.12position filtering 11.6position smoother 9.20Position vs. Time Graph 8.5position_gain 11.19Positive Deadband 9.18PROFIBUS Master 5.46Profibus.txt 5.48Program Window 2.2protocol switch-over 5.3

R

RA 4.16ramp generator 9.35Ramp Rate 8.7, 9.34Ramp Retardation 9.24Ramp retardation 9.12Random Moves 8.7RB 4.16Reaction Lag time 11.9Reaction Time Lag 11.18Read from ICS 2.16read service 5.57Read Table Configuration 5.64readme.txt file 1.2Relay Outputs 8.9relays reaction 11.16release notes 1.2re-release brake 9.16RS-232 port 5.50RS232 port 4.15RS422 port 4.15RTU B.VIRXD 4.16

S

Safe Operating Zone 11.9Sample Rate 3.5sampling frequency 9.9, 10.10sealing nut 5.33

ICS 5000 Support Software User Manual Index.I I I

Index

Self Adaptive Function 9.10Self Test 9.7, 10.6Self-Test 2.16serial communications parameters 5.6Serial Number 3.3settling times 9.31Setup Description 2.14, 2.15Setup Description window 3.3shortcut 2.7Siemens Step 7 software 5.43Signal Strength 3.7Skew Distance 9.27Skew Limit 9.26SLC 5.8SLC 5/0X 5.12SLC 5/0X message instruction 5.14Slow Down Zone 11.17Software Organization 2.3Speed 1 min. Distance 10.15Speed 1 Voltage 10.15Speed 2 min. Distance 10.15Speed 2 Voltage 10.15Speed Regulation test 9.41speeds 10.14Square Wave 8.6start delay 9.36Starting Station Number 6.2Static Data 9.44Static Data tab 9.37Station Location (Y command) Format 6.2Station Setup 6.2Stations 6.3Step Response 9.45Step response 9.45sticky test 9.41stop swinging 9.16, 9.17Stopping Acceleration 11.18stopping distance 11.10stopping position 11.8strain relief cleat 5.32strain relief collet 5.33string multiple commands 8.4support 1.2support computer 2.2Sync 11.17Sync input relay 9.25, 10.21synchronization of the data 2.16synchronization process 2.16system model 9.2, 9.44

T

TA 4.17TB 4.17TCS algorithm 9.5TCS Parameters tab 9.14

TCS1 9.5TCS2 9.5technical support 1.2Temporary limits 3.8Terminal 8.2Toolbar 2.2, 2.12top speed 10.17Top Speed Determination 10.17transaction B.ITransient Response 9.46, 9.47, 9.49transient response 9.46Trapezoid Wave 8.7Travel Limits 3.8, 6.3Triangle Wave 8.7Trimble License Agreement 2.4Tuning Algorithm 9.47Tuning Strength 9.47, 9.48Two Speed 10.9TXD 4.16Typical Settling Time 8.8

U

Undershoot 8.4, 10.29Uni-Polar 10.6Uni-Polar Output 9.7usage 2.8USB to serial converters 2.2User Filter 11.22User name 2.4User settings 2.15Utilities menu 2.11

V

V- 5.31V+ 5.31Velocity 9.19velocity 9.41, 11.15velocity filter 11.12velocity filtering 11.6velocity_gain 11.19Vertical Application 9.33, 9.42visible pointing laser 3.7

W

Wake-up Mode 9.22Wake-up values 9.14warning 9.51Warning code 9.23Windows operating system 2.2Work ON Line 2.15worm-gears 9.31worst case stopping distance 11.10

Index.IV ICS 5000 Support Software User Manual

Index

write service 5.57Write Table Configuration 5.65Write to ICS 2.16

ICS 5000 Support Software User Manual Index.V

Index

Index.VI ICS 5000 Support Software User Manual

Reader Comment FormICS 5000 Support Software User Manual March 2004571 701 721 Revision 1.0

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