Page 2 - Motion Controller
525 Programmable Motion Controller Information furnished by EMERSON Motion Control is believed to be accurate and reliable. However, no responsibility is assumed by EMERSON Motion Control for its use. EMERSON Motion Control reserves the right to change the design or operation of the equipment descri...
Page 5 - Introduction; Product Overview
Introduction Product Overview The Emerson Motion Control 525 PMC (Programmable Motion Controller) is a complete closed-loop position controller for use with external analog or digital servo drives in positioning applications. The 525 PMC accepts all current PCM Application Modules and peripherals in...
Page 6 - External Drive Interface
2 525 Programmable Motion Controller The 525 PMC uses PCX Version 6.02 or newer for setup, calibration and programming. A single PCX program can control multiple axes including a mixture of Positioning Drives and 525 PMC's. All 525 PMC gain settings are pre-programmed and can be changed from PCX sof...
Page 7 - Operating Modes
3 Introduction Operating Modes The 525 PMC offers three standard modes of operation: Indexing, Pulse and Analog. Indexing Mode The indexing mode allows up to thirty-two different indexes or positions to be pre-programmed and stored in non-volatile memory. These indexes and other commands such as sto...
Page 9 - Installation; Installation Overview
Installation Installation Overview The following installation requirements, methods and procedures are provided to ensure reliable and trouble free installation and operation of your Emerson Motion Control 525 PMC. The methods and procedures are outlined on the following pages and include site requi...
Page 10 - AC Input Line; Grounding
2 525 Programmable Motion Controller Figure 1 External Disconnect Example AC Input Line The AC line voltage of the input power must be within the specified range and free of voltage transients that exceed this range. If this is not the case, additional AC line conditioning may be required. The AC in...
Page 11 - Electrical Noise
3 Installation Figure 2 System Grounding illustration Electrical Noise If any sensitive electronic equipment (i.e. digital computer, test equipment, etc.) is operating on the same line as the 525 PMC additional EMI/RFI filtering may be required to reduce the effects of conducted noise. Effects of el...
Page 12 - Magnetic Coil Noise; Shielding
4 525 Programmable Motion Controller Magnetic Coil Noise All relay coils, solenoid coils, electrical brakes and similar devices must be suppressed. The placement of the noise suppressor should be as close to the coil as possible. In the case of DC coils, a diode is installed across the coil in a dir...
Page 13 - Selecting An Enclosure
5 Installation of Electro-Magnetic Interference (EMI). A foil shield is the most effective way to minimize Radio Frequency Interference (RFI). A cable that provides both types of shielding is preferred, however, a braided shield alone will usually provide adequate protection. To reduce chances of gr...
Page 14 - Encoder Feedback
6 525 Programmable Motion Controller Encoder Feedback The 525 PMC utilizes an xe "ENCODERS:Incremental Encoder" incremental encoder as the feedback device from the motor. The type of encoder used must have two complimentary channels electrically spaced 90 from each other. These encoder chann...
Page 17 - Encoder Feedback Cables
9 Installation Encoder Feedback Cables The encoder must be connected to the motor so a clockwise rotation of the motor shaft, as viewed from the shaft end of the motor, will cause a count up condition. The cable drawings below (for the two types of encoders EMC supplies) assume that CW motor rotatio...
Page 18 - External Drive Connections To The 525 PMC
10 525 Programmable Motion Controller External Drive Connections To The 525 PMC The 525 PMC has two keyed, detachable terminal blocks on the bottom of the unit for connecting the external drive and encoder. The terminal blocks are divided into two sections of 13 (1-13 & 14-26). Connections shoul...
Page 22 - Minimum System Configuration
14 525 Programmable Motion Controller Minimum System Configuration The following diagram illustrates the minimum 525 PMC system configuration. Figure 17 Minimum System Configuration A positive command voltage to the external drive must cause CW motion of the motor as viewed from the shaft end of the...
Page 24 - Mode Selection
16 525 Programmable Motion Controller Mode Selection 18 defines the switch settings for the four alternative modes of operation. Figure 18 Dip Switches/Mode Selection (Factory Defaults Shown)
Page 25 - Pulse Mode
17 Installation Pulse Mode In the Pulse mode the 525 PMC responds to a serial pulse train representing externally generated incremental position change commands. This mode is commonly used to control DC stepper motors or numeric controlled (CNC) machinery. The Pulse/Pulse or Pulse/ Direction operati...
Page 30 - Serial Interface; Serial A
22 525 Programmable Motion Controller NOTE: Both the hardware and software position travel limits are active if they are set up. Serial Interface All 525 PMC's are equipped with two RS423 serial interface connectors which are RS232C/RS422 signal compatible. The serial interface has a DIP switch sele...
Page 33 - Serial Cables
25 Installation Dip Switch Function Descriptions Baud rate switches Switches 1, 2 and 3 of the eight position DIP switch are used to match the baud rate of the drive to the baud rate of the programming device. If the two baud rates are not the same, serial communication will not be possible. Axis id...
Page 35 - Input Output Interface
27 Installation Input Output Interface The 525 is equipped with 8 inputs and 4 outputs which operate on +10 to +30 vdc. Each input and output has 2 screw terminals associated with it to provide for either sinking or sourcing operation. The first 8 pairs of designated terminals are inputs and the las...
Page 36 - Input and Output Functions
28 525 Programmable Motion Controller Input and Output Functions The basic drive can be configured from a list of 21 input functions and 10 output functions. When a IOM/PCM module is added the number of available I/O functions is increased. NOTE: For detailed description of I/O functions see PCX PRO...
Page 37 - Installation of Application Modules; PCM Modules I/O Connections
29 Installation Installation of Application Modules The IOM-1 and PCM application modules allow for memory expansion, I/O expansion and more complex motion programming capability. The IOM-1 and PCM application modules (Programmable Control Module) attach to the front of the drive amplifier with two ...
Page 39 - Overview; Fault Polarity
Fault Polarity and Calibration Overview The PCX 4.5 software package provided with each 520 PMC allows setting the polarity of the inputs on the drive interface terminal strips. It also allows for system calibration. Fault Polarity The Fault Input polarity feature allows the user to adapt the 520 PM...
Page 40 - System Calibration
2 525 Programmable Motion Controller Figure 1 Fault Input Setup (Fault 9) The cursor is then located on the polarity of either Input. Use the UP/DOWN arrows to position the cursor on the desired input to be changed. Use the LEFT/RIGHT arrows to toggle the polarity to "+" and "-". Onc...
Page 41 - Setting the System Calibration
3 Fault Polarity and Calibration Setting the System Calibration After following the examples in the "Setting the Fault Input Polarity" section, proceed to the 520 PMC Setup Options menu. By moving the cursor to the System Calibration position and entering a carriage return, the user enters t...
Page 47 - Specifications
Specifications Environmental CharacteristicsOperating TemperatureRelative Humidity 0 to 45 (32 to 113 F)0% to 95%, non-condensing Input PowerAC Voltage and Current 96-132 VAC or 192-264 VAC, 47-63 Hz (switch selectable) single phase (Note: Factory default is 192 - 264 VAC). 1 amp @ 115 VAC, 0. 5 amp...
Page 48 - Mounting Information
2 525 Programmable Motion Controller Mounting Information Figure 1 Mounting Information
