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AMCI 3502 Manual

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Module Overview
The 3502 module is a one-axis stepper controller that occupies one slot in a SLC 500 rack.
This unit receives profile data from the PLC and outputs Step and Direction signals or
Clockwise/Counter Clockwise pulses to a stepper driver. Inputs on the module allow for homing,
over travel, and emergency stop. A 5V differential incremental encoder can be attached to the
unit to provide feedback information.
The 3502 module uses 8 input and 8 output registers to communicate with the PLC. Status
bits, the Current Position, and Encoder Count Value, are reported to the Input Registers. The 8
output registers have two purposes. First, they are used to configure the module with
parameters such as Output Type, Homing Type, Inputs Used, Input Active Level, and Starting
Speed. Second, they are used to send the move commands, along with the distance, speed,
and acceleration and deceleration rates used to define the move profile.
Some of the data used by the 3502 can exceed 32767, the value that can be contained in one
16 bit register. Because of this, these parameters are divided into two words, the Most
Significant Word (MSW) and the Least Significant Word (LSW). The MSW has the 1000s places
and the LSW has the 1s, 10s and 100s places. Negative values are handled using a sign
magnitude format where the Most Significant Bit in the MSW is set to indicate a negative value.
For example:
Value
-12,345
12,000
-12,000
Because the 3502 module does not use a non-volatile memory, it must be configured at every
power up.
Sample programs for the 3502 are available from the following page of our website.
https://www.amci.com/industrial-automation-support/sample-progams/
Waste Electrical and Electronic Equipment (WEEE)
At the end of life, this equipment should be collected separately from
any unsorted municipal waste.
20 Gear Drive, Plymouth Industrial Park, Terryville, CT 06786
Tel: (860) 585-1254
Fax: (860) 584-1973
MSW
(decimal)
-32,756
12
-32,756
345
0
-345
-32768
Web:
SLC 500 Motion Controller
MSW
LSW
(hex)
(decimal)
16#800C
345
16#000C
0
16#800C
0
16#0000
345
16#8000
345
www.amci.com
3502 Module
LSW
(hex)
16#0159
16#0000
16#0000
16#0159
16#0159
page: 1
Manual Revision 1.0

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Summary of Contents for AMCI 3502

  • Page 1 Some of the data used by the 3502 can exceed 32767, the value that can be contained in one 16 bit register. Because of this, these parameters are divided into two words, the Most Significant Word (MSW) and the Least Significant Word (LSW).
  • Page 2 [18] months. Within this warranty period, AMCI shall, at its option, repair or replace, free of charge, any equipment covered by this warranty which is returned, shipping charges prepaid, within one...
  • Page 3 3502 Module SLC 500 Motion Controller Table of Contents Installing the 3502 Module Chapter 1 I/O Configuration Module Specifications Front Panel & LED Functions Output Signals Connector Pinout and Wiring Discrete Input Wiring Single Ended Encoder Wiring Diagnostic Feedback Wiring...
  • Page 4 SLC 500 Motion Controller Chapter 1: Installing the 3502 module WARNING Disconnect power before installing or remove the 3502 module. 1. Verify that your system’s power supply has adequate reserve current capacity. The 3502 module requires 200mA at +5Vdc. 2. Align the module with the grooves in the top and bottom of the SLC rack system and slide the module backwards until the tabs on the plastic housing lock the module in place.
  • Page 5 3. Type a value of 3535 in the “Other” type IO card window that opens. 4. Input Data (data from the 3502 module to the PLC) will appear in Input Image Table registers I:X.0 to I:X.7, where X is the slot number. Output Data (data from the PLC to the 3502 module) will be written to registers O:X.0 to O:X.7, where X is the slot...
  • Page 6 Encoder Inputs 5V differential encoder only A, B, and Z Maximum Input Current: 10mA per channel @5Vdc The A and B signals must both be connected to the 3502 module to have the encoder data increment or decrement. Discrete Inputs...
  • Page 7 Data. Output Signals The 3502 module can be programmed to output either Step and Direction signals or CW / CCW steps. There is no advantage to either type; you must simply configure the 3502 module to match the input type of your driver. The two types of signals are illustrated below.
  • Page 8 -Z Encoder Input Module Common Wiring Notes The 3502 module uses a 9638 differential line driver in series with a 10 resistor for the  stepper (+/- step and +/- direction) outputs. Stepper signals are generally low voltage, low power signals. If you are using A-B ...
  • Page 9 SLC 500 Motion Controller Single Ended Encoder Wiring The 3502 module is designed to work with +5Vdc differential encoders. Use the following table and diagrams to attach single ended encoders to the 3502 module. A current limiting resistor RLim must be installed for encoders that do not operate at 5Vdc.
  • Page 10 SLC 500 Motion Controller Chapter 2: Calculating Move Profiles Before starting a move operation, the 3502 module completely calculates each portion of the move profile. That is, it calculates how many steps of the move profile will be required for acceleration and how many steps will be required for deceleration.
  • Page 11 SLC 500 Motion Controller Calculation Notes 1. The acceleration and deceleration values sent to the 3502 module as part of the move profile have units of steps/ms/sec. If you are using the above formulas to calculate Ta (the time to accelerate), multiply the acceleration value sent to the 3502 module by 1000 before using it in the formulas.
  • Page 12 4. If an External Input will be used and its active state. The external input can be used to stop a Jog Move operation. If the External Input is active when a jog move operation is initiated, the 3502 module will generate one step in the specified direction and then stop.
  • Page 13 3502 Module SLC 500 Motion Controller Configuration Mode Output Data (Eight 16 bit words sent from the PLC to the 3502 module) While in configuration mode, the output registers have the following format. 16 bit output Configuration Units Range Word...
  • Page 14 3502 Module SLC 500 Motion Controller Configuration Bits MSW Bit 0: set when a CW Limit Switch will be used Bit 1: set when a CCW Limit Switch will be used Bit 2: set when the Emergency Stop Input will be used Bit 3: set when an External Input is used.
  • Page 15 3502 Module SLC 500 Motion Controller Invalid Configurations The 3502 module will not accept all possible configurations. The following is a list of the invalid configurations: 1. A configuration without the ability to home the module. 2. A configuration without at least one End Limit Switch, either CW or CCW.
  • Page 16 ABSOLUTE MOVE. A HOME or PRESET operation will have to be performed before the position becomes valid. The distance moved, that is the number of steps issued by the 3502, is equal to the difference between the Target Position and the Current Position. For example, if the Current Position is 5000, and the Target Position is 7500, than the unit will output 2500 steps.
  • Page 17 A Command Error will be generated if all of the other command bits are not reset when  the Hold Command is issued. The 3502 module will ignore any change to the Target Position that is issued with the  Resume Command.
  • Page 18 3502 module will ignore any transitions of the Home Input or the Marker Pulse until it detects the proper transition on the Proximity Input. When the homing operation is complete, the 3502 will set the At Home input bit, and then reset both the current position and the encoder position to zero.
  • Page 19 3502 Module SLC 500 Motion Controller Home Proximity Input with Home Limit Switch or Marker Pulse 2. Runs at the programmed 4. Detects Proximity Input and speed, ignoring any decelerates to the starting speed. transitions of the home 1. Accelerates to input or marker pulse.
  • Page 20 3502 Module SLC 500 Motion Controller End Limit Switch Active when the Home Command is issued 3. Home input is detected 2. Motor turns at the programmed speed in the direction going on and off opposite of the requested homing operation 4.
  • Page 21 This command will set Current Encoder Value to the value present in the Target Position registers. The 3502 module must be configured to use an encoder, and the programmed speed, acceleration, and deceleration parameters must be zero when this command is sent to the module.
  • Page 22 5. It is possible to home the 3502 module off of an end limit switch. 6. Sample Programs are available from the following page of our website https://www.amci.com/industrial-automation-support/sample-progams/...
  • Page 23 The blend move programming is done at one time, with the segments of the blend move profile stored in the internal memory of the 3502. This data will remain in the module’s memory until power is removed from the module, the configuration data is programmed, or a new blend move profile is sent to the unit.
  • Page 24 Current Encoder/Diagnostic Feedback input register. Diagnostic Feedback wiring can only be used if the 3502 module has been configured to output Step and Direction signals. The maximum input frequency that the module can accurately measure in Diagnostic Feedback mode is 250kHz.
  • Page 25 SLC 500 Motion Controller Chapter 5: Command Mode Output Data (Eight 16 bit words sent from the PLC to the 3502 module) All stepper motor operations are performed in command mode. This mode is entered, after a successful configuration file has been transferred to the stepper controller by resetting the Mode Flag bit 15 of Output Word 0.
  • Page 26 Command Mode Programming Information 1. Only a single bit can be set at any one time in the Most Significant Command Word. For this reason, AMCI recommends that MOV or COP be used to send commands to the 3502 module.
  • Page 27 1. Bits 11 and 12 of the MSW Command Word control the transfer of the blend move segments from the PLC to the 3502. The first step is to set bit 11, the Program a Blend Move Profile command bit.
  • Page 28 3502 Module SLC 500 Motion Controller BLEND MOVE DATA – PROGRAMMING BLOCKS 2…17 Word Function 6144 (bits 11 and 12 set) Must be zero Absolute Target Position MSW Absolute Target Position LSW Target Speed MSW Target Speed LSW Acceleration Deceleration BLEND MOVE DATA –...
  • Page 29 Sample Programs are available from the following page of our website; https://www.amci.com/industrial-automation-support/sample-progams/ The 3502 module uses eight 16 bit words to reports its data to the PLC. These input words are defined as I:X.0 to I:X.7, where “X” indicates the slot number. The following table shows the function of these eight words.
  • Page 30 3502 Module SLC 500 Motion Controller Status Word LSW Layout Bit 0 = set when the CW LIMIT SWITCH is active Bit 1 = set when the CCW LIMIT SWITCH input is active Bit 2 = set when the EMERGENCY STOP input is active...
  • Page 31 3502 Module SLC 500 Motion Controller The Stopped Bit will be set under the following conditions 1. When a CW or CCW Jog Move operation has been completed. 2. When the Emergency Stop input has been used to stop a move operation.
  • Page 32 When this input is active, the stepper motor will decelerate to the starting speed, and stop, while keeping track of the current position. If the External Input is active when a jog move operation is initiated, the 3502 module will generate one step in the specified direction and then stop.
  • Page 33 SLC 500 Motion Controller Optical Encoder The 3502 module uses X4 decoding on the encoder signals. Only a 5V differential encoder can be directly attached to the module. Encoders at other voltage levels can be connected to the module if current limiting resistors are used. A move profile does not have to be in progress in order for the unit to count encoder pulses.