8.3 KiB
8.3 KiB
Gateway and Motor-Box System Programming Guide
System Overview
The system consists of three main components:
- Gateway board
- Motor-box board
- Actuators
The Gateway board communicates with Motor-box boards through two independent serial ports. Each serial port can communicate with up to 32 Motor-box boards, for a maximum capacity of 64 Motor-box boards. However, the maximum number of Motor-box boards may be limited by the technical characteristics of the network master (PLC) used. Each Motor-box board can control up to eight actuators (motors).
Network Architecture
- The gateway communicates with the network master (PLC) via an Ethernet interface (EthernetIP, Profinet, etc.)
- The gateway communicates with Motor-box boards via RS485 serial communication
- Communication with Motor-box boards uses polling methodology, starting from node 0 and proceeding sequentially
Gateway Board Configuration
DIP Switch Settings
| Switch Number | Description | OFF Position | ON Position |
|---|---|---|---|
| 1-5 | Highest Motor-box node number (0-31), binary coding | Binary values: 1,2,4,8,16 | |
| 6 | Motor-box network baud rate | 38400 bps | 57600 bps |
| 7 | Port enable | Disabled | Enabled |
| 8 | Reserve |
Notes on configuration:
- The highest node number determines how many Motor-box nodes will be polled
- When using Ethernet/IP (e.g., Rockwell), the sum of the highest node numbers on both gateway ports must not exceed 18
- Setting switch 6 to ON increases communication speed but decreases noise immunity and maximum network length
- If one of the two ports is not used, set only switch 7 to ON for that port and all others to OFF
Baud Rate Settings
-
OFF (recommended):
- Baud rate: 38400 bps
- Polling interval: 25ms
- Example with highest node set to 10: 11*25ms = 275ms to communicate with all Motor-box boards
-
ON (not recommended):
- Baud rate: 57600 bps
- Polling interval: 17ms
- Example with highest node set to 10: 11*17ms = 187ms to communicate with all Motor-box boards
Motor-Box Configuration
DIP Switch Settings
| Switch Number | Description | OFF Position | ON Position |
|---|---|---|---|
| 1-5 | Motor-box node number (0-31), binary coding | Binary values: 1,2,4,8,16 | |
| 6 | Motor-box network baud rate | 38400 bps | 57600 bps |
Important notes:
- Set Motor-box nodes in sequence without skipping intermediate nodes
- Avoid using node 0 as it is the factory default
- The baud rate setting (switch 6) must match the Gateway's baud rate setting for the corresponding port
Communication Protocol
ADI Structure Sequence Order
| ADI | Type | Description |
|---|---|---|
| ADI#110 GATEWAY "P1" | READ | Gateway firmware and connected boxes on port P1 |
| ADI#111 GATEWAY "P1" | READ | Status of motors and boxes on port P1 |
| ADI#120 GATEWAY "P2" | READ | Gateway firmware and connected boxes on port P2 |
| ADI#121 GATEWAY "P2" | READ | Status of motors and boxes on port P2 |
| ADI#211 GATEWAY "P1" | WRITE | Motor commands for boxes on port P1 |
| ADI#212 GATEWAY "P1" | WRITE | Motor current limits for boxes on port P1 |
| ADI#221 GATEWAY "P2" | WRITE | Motor commands for boxes on port P2 |
| ADI#222 GATEWAY "P2" | WRITE | Motor current limits for boxes on port P2 |
Programming Details
Motor Status Bit Definitions (ADI#111, ADI#121)
| Bit | Description |
|---|---|
| 0 | Forward movement in progress |
| 1 | Reverse movement in progress |
| 2 | Position reached |
| 3 | Error or alarm |
| 4 | In zero position |
| 5 | Moving at low speed |
| 6 | Reserved |
| 7 | Reserved |
Motor-Box Status Byte Definitions
| Byte | Bit | Description |
|---|---|---|
| 0 | 0-4 | Firmware version |
| 5-7 | Firmware revision | |
| 1 | 0 | 24V fuse blown |
| 1 | 24V line low (<18V) | |
| 2-7 | Reserved |
Motor ==Command== Byte Definition (ADI#211, ADI#221)
| Byte | Bit | Description |
|---|---|---|
| 0 | 0-7 | Position requested bits 0-7 (0-4095 = 0-409.5mm) |
| 1 | 0-3 | Position requested bits 8-11 (0-4095 = 0-409.5mm) |
| 4 | Position sign (1=positive, 0=negative) | |
| 5 | ==Position mode (0=relative position, 1=zero then position)== | |
| 6 | Stop motor (1=stop) | |
| 7 | Reset alarm (1=reset) |
Current Limit Byte Definition (ADI#212, ADI#222)
| Bit | Description |
|---|---|
| 0-2 | Reverse movement current limit |
| 3-5 | Forward movement current limit |
| 6-7 | Reserved |
Current Limit Values:
| Bit 2/5 | Bit 1/4 | Bit 0/3 | Current Limit Value |
|---|---|---|---|
| 0 | 0 | 0 | 650mA (default) |
| 0 | 0 | 1 | 200mA |
| 0 | 1 | 0 | 300mA |
| 0 | 1 | 1 | 400mA |
| 1 | 0 | 0 | 500mA |
| 1 | 0 | 1 | 600mA |
| 1 | 1 | 0 | 700mA |
| 1 | 1 | 1 | 800mA |
Programming Considerations
Command Execution
- Commands are executed when either of the two command bytes changes, provided they are not both zero
- When both bytes are zero, the command has no effect on the current movement
- Due to asynchronous communication between the network master and gateway, and between the gateway and Motor-box, once a command is given, maintain the command active while monitoring the motor status until command execution is complete
- Only stop the command when intentionally stopping the motor
Movement Limitations
- Maximum stroke for actuator commands is limited to 409.5mm
- For motors with longer strokes, use multiple relative positioning commands, waiting for positioning to complete before sending a new command
- Sending a different command while a movement is in progress will interrupt the current movement and start the new command
- To ensure accurate positioning, only send a new command when the current command has successfully completed
- In case of error during positioning, the only way to ensure the actuator's position is to reset the actuator and repeat the commands
Configuration File Generation
GSDML File Generation (for Profinet)
- Make sure the Gateway board is not powered
- Set the Gateway's DIP switches based on the number of boxes connected to each gateway
- Power up the Gateway board
- Connect the PC to the Gateway's Ethernet port via Ethernet cable
- Start the "IP CONFIG" program and set the IP address for the Gateway board
- Start the "HMS PROFINET GSD Generator Tool"
- Follow the configuration screens to generate the GSDML file
- Import the GSDML file into the PLC project, inserting the modules in the following order:
- ADI#110
- ADI#111
- ADI#211
- ADI#212
- ADI#120
- ADI#121
- ADI#221
- ADI#222
EDS File Generation (for EthernetIP)
- Make sure the Gateway board is not powered
- Set the Gateway's DIP switches based on the number of boxes connected to each gateway
- Note: Be careful not to exceed the sum of 18 as the total of the values set via DIP switches for the boxes connected to both gateway ports
- Power up the Gateway board
- Connect the PC to the Gateway's Ethernet port via Ethernet cable
- Start the "IP CONFIG" program and set the IP address for the Gateway board
- Start the "HMS EtherNetIP EDS Generator"
- Follow the configuration screens to generate the EDS file
- Modify the generated EDS file as needed
- Import the EDS file into your PLC project, disabling the electronic key check
Troubleshooting
Motor Does Not Move
- Cause: Incorrect connection
- Solution: Check the correct connection of the motor to the M12 connector of the Motor-box
- Cause: Motor failure
- Solution: Replace the motor
- Cause: Motor has reached its maximum stroke
- Solution: Verify the set positions or replace with a motor with greater stroke
Motor Stops with Alarm After a Few Millimeters
- Cause: Incorrect connection
- Solution: Check the motor wiring
- Cause: Encoder failure
- Solution: Replace the motor
Motor-Box Not Recognized by the Network
- Cause: Incorrect 24VDC power supply
- Solution: Verify power supply is never below 19VDC
- Cause: Incorrect RS485 termination resistors
- Solution: Properly install termination resistors based on network topology
- Cause: Incorrect DIP switch settings
- Solution: Verify DIP switch settings are correct
- Cause: Wiring error
- Solution: Check electrical wiring