Document Outline

• Front Cover
• Important User Information
• Table of Contents
• List of Figures
• Preface - Using this Manual
  • Introduction
  • Who Should Use this Manual
  • Where to Find Help
  • Contents of this Manual
  • Related Documentation
  • Conventions Used in this Manual
  • Using Online Help
  • Allen-Bradley Support
    • Local Product Support
    • Technical Product Assistance
• 1 - Getting Started
  • Introduction to IQ Master
    • About the Allen-Bradley IQ Master Manual
    • ULTRA Plus or IQ-Series System Overview
      • IQ Master
      • IQ-550 Position Control Module
      • Positioning Drive Modules (PDM)
        • PDMs with Integral Power Supply Modules
        • PDMs with Separate Power Supply Modules
      • Power Supply Module (PSM)
      • Motors
      • Operator Terminal
      • Personality Module (PM)
      • Manuals
      • Option Cards
        • Memory and I/O Expansion Card
        • I/O Expansion Card
      • Personal Computer (PC)
    • Symbols and Conventions
    • Minimum Personal Computer Requirements
      • IQ Master
    • New Features
      • New in Version 3.2.4 vs. Version 3.2.3
      • New in Version 3.2 vs. Version 3.0
      • New in Version 3.0 vs. Version 2.1x
      • New in Version 2.1 vs. Version 2.0
      • New in Version 2.x vs. Version 1.x
  • Quick Start Check List
    • Introduction
    • Quick Start Check List
  • Getting Started with IQ Master
    • Hardware and Software Requirements
    • Using Windows Without a Mouse  A Quick Review
      • Windows Hot Keys
      • IQ Master Hot Keys
    • Using the IQ Master Setup Program
    • The Readme File
    • Starting and Quitting IQ Master
      • To Start IQ Master
      • The IQ Master Screen
      • Quitting IQ Master
    • Online Help
      • To Start Help:
    • Upgrading from Version 1
  • Applying Power for the First Time
    • Start-Up Procedure for ULTRA Plus and IQ-2000 Systems
    • Start-Up Procedure for ULTRA Plus and IQ-5000 Systems
      • Power Supply Module
      • Start-Up Procedure for ULTRA Plus or IQ-5000
    • Motor Start-Up Procedure
    • Start-Up Procedure for IQ-550 Systems
    • Operator Terminal
    • Backup Personality Module
• 2 - IQ Master Environment
  • File Menu
    • To Access File Menu Items
    • PC Disk Commands
      • New
      • Open
      • Save
      • Save As
    • IQ Commands
      • Open IQ Program
      • Save Program to IQ (F7)
      • Delete IQ Program
    • File Extensions
    • Miscellaneous Commands
      • Print
      • Transfer
        • To transfer a file
      • Initialize PM
      • Recently Used File List
      • Send Mail
      • Exit
  • Edit Menu
    • To Access Edit Menu Items
    • Undo
    • Cutting and Pasting Text–Selecting Text
      • Selecting Text
      • Clipboard
      • Cut (SHIFT+Delete)
      • Copy (CTRL+Insert)
      • Paste (SHIFT+Insert)
    • Finding Text
      • Find
      • Find Next (F3)
      • Find Previous (F4)
      • Replace
    • The Compiler
      • Compiling a Program
    • Compile Options
      • Compiler Output
      • List Files
      • Expand Macros
      • Program Type
      • Debug Information
  • Parameter Menu
    • To Access Parameter Menu Items
    • Gains/Limits
    • System
      • Absolute Mode
      • Forward Software Travel Limit
      • Reverse Software Travel Limit
      • Ereturn Position
      • Scale
      • Scale2
      • Disable on Fault
      • Rotation
      • Rotation 2
      • Latched Position
    • Velocity & Acceleration
    • Inputs
      • Home Switch Active State
      • Pause Switch Active State
      • Selectable Inputs
      • ADC1 Function
      • Debounce Time
      • Home to Encoder Index
      • Program Select Lines
      • Default Run Program
    • Outputs
      • Error Output when Disabled
      • InPosition Mode
      • DAC1 Value
    • Default Outputs
    • Feedback Configuration
      • Configuration Menu
      • Current Configuration
      • Feedback Position Source
      • Encoder Input 2
      • Gear Input
    • Fkey Set Up
      • Mode
      • To Program the Soft Function Keys on the Operator Terminal
    • Serial
      • Baud Rate
      • Parity
      • Communications Mode (RS232C/RS422)
      • Generic Operator Terminal
      • Operator Terminal Address
    • Variables
    • Edit Parameter File
      • New
      • Open
  • Run Menu
    • To Access Run Menu Items
    • Run Control
      • Run Program
      • Home
      • Pause
      • Single Step
      • Move
    • Stop
    • Enable
    • Disable
    • Reset
    • Hardware Reset
    • Define Home Position
    • Tune
      • Auto Tune Velocity and Position Loops
        • To Tune the System using Auto Tune
      • Manual Tune
        • To Tune the Velocity Loop using Manual Tune
        • Some General Rules for Tuning:
        • To Tune the Position Loop using Manual Tune
    • Extended Debug
      • Operational Commands for Debugger
        • Go
        • Trace
        • Auto
        • Resume
        • Pause
        • Abort
      • Step Commands for Debugger
        • Single Step
        • Procedure Step
      • Breakpoint Commands and Options for Debugger
        • Clear all Breakpoints
        • Toggle Breakpoint
        • View Active Breakpoints
        • Debug Options
  • Monitor Menu
    • To Access Monitor Menu Items
    • Status
    • Inputs/Outputs
    • Monitor Variables
      • To assign variables to the Variable Monitor dialog box:
      • Velocity Scale
      • Velocity Monitor Filter
  • Diagnostics Menu
    • To Access Diagnostics Menu Items
    • Encoder
      • To Test and/or Check the Size of an Encoder:
    • DAC1 Output
      • To Test the DAC1 Output:
    • Programmable Monitor Output
      • To Test the Monitor Output:
    • Digital Outputs
      • To Test the Digital Outputs:
    • Operator Terminal
      • To Test the Operator Terminal:
    • Nonvolatile Memory
    • Fault History
    • Version
  • Communications Menu
    • To Access Communications Menu Items
    • Axis Select
    • Terminal
      • Scrolling Keys
    • PC Set Up
      • Baud Rate
      • Communications Port
      • CR (Carriage Return) Translation
      • Data Bits
      • Stop Bits
      • Flow Control
      • Parity
      • Local Echo
      • BRU Emulation
      • Send File LF Toggle
      • Receive File CR Translation
  • Help Menu
    • To Access Help Menu Items
    • Contents
    • How to Use Help
    • Context Sensitive Help
    • About IQ Master
• 3 - Software and Hardware Integration
  • Inputs and Outputs
    • How to Turn an Input ON and OFF
    • What Does Turning ON and OFF an Output Do?
    • General Purpose Inputs
      • Associated Input Instruction
      • Input Debounce Time
    • Assignable Inputs
      • Enable (I3)
        • When Enable Turns ON.
        • When Enable Turns OFF
      • Emergency Return (I10)
        • When Emergency Return Turns ON
        • When Emergency Return Turns OFF
      • Home Command (I6)
        • When the Home Command Turns ON
        • When Home Command Turns OFF
      • Home Switch (I5)
      • Jog Forward (I7) and Jog Reverse (I8)
        • When a Jog Input is Turned ON
        • When a Jog Input is Turned OFF
      • Forward Travel Limit (I1) and Reverse Travel Limit (I2)
        • When a Travel Limit Turns ON (open)
        • When a Travel Limit Turns OFF (closed to 24 Volt common)
      • Pause (I9)
      • Start (I4)
        • When Start Turns ON
        • When a Start Turns OFF
      • Define Home
        • When Define Home Turns ON
        • When Define Home Turns OFF
      • Hardware Reset
        • When Hardware Reset is ON
        • When Hardware Reset is Turned OFF
      • X Kill Motion
      • Program Select Lines
    • Interrupt Inputs
      • Purpose
      • Propagation Delay
      • When an Interrupt Turns ON
      • When an Interrupt Turns OFF
      • Associated Input Interrupt Instruction, Variables and Flags
    • General Purpose Outputs
    • Assignable Outputs
      • AtHome (05)
      • Error (08)
      • Home Sequence Complete (O6)
      • Program Running (O4)
      • InPosition (O7)
    • Enabled Output (P3-2)
    • Ready Output (P3-1)
    • DAC1 Output (P3-6)
      • DAC1 Value
    • ADC1 Input (P35)
    • Encoder 2
  • Starting a Program
    • Assigned Input
    • IQ Master - Run Control
    • Function Key Program
    • Host Language Commands (Serial)
  • Stopping or Suspending a Program
    • Assigned Inputs
    • Host Language Commands (Serial)
    • Program Instructions
    • Fault Conditions
  • Faults
    • When a Fault Occurs
    • Clearing Faults
      • Enable Input
      • Jog Inputs
      • Cycle Power
      • Run Menu
        • RESET
        • HRESET
      • Host Language Commands
        • RESET
        • HRESET
        • JOGF / JOGR
  • Operator Terminal
    • Installation
    • Displaying & Reading Data
    • Function Keys
    • Xkeys
    • Yes / No Keys
    • Status Key
  • I/O Expansion
    • Using the Additional I/O
      • Inputs
      • Outputs
      • Analog Inputs
  • Expansion Memory
    • Using Expansion Memory
      • Storing Programs in Expansion Memory
      • Running Programs Stored in Expansion Memory
• 4 - Programming
  • A Tutorial Introduction
    • Getting Started
      • How to Communicate with the ULTRA Plus or IQ
      • Touring a Dialog Box
    • Hardware Configuration Considerations
      • Scale
      • Timebase
      • Enable
      • Auto Tune
    • Motion
      • Incremental Motion
      • Homing
      • Absolute Motion
    • Programming Basics
    • Inputs and Outputs
      • Dedicated Inputs Setup
      • Read Inputs
      • Set Outputs
      • Monitor I/O Status
      • Scanned Event to Implement a Programmable Limit Switch
    • Local/Run-time Values
    • Variables
    • IF/ELSE Statement, ASSIGN, Block Structure { }
    • Stick Moves
    • SCurve Acceleration
    • Subroutines and Loops
  • User Variables and Arithmetic
    • User Variables
      • Scope
      • Nonvolatile vs. Volatile Variables
      • Resolution and Accuracy
      • Variable Characteristics Summary
    • Arithmetic
      • Precedence and Order of Evaluation
    • Boolean Operators
      • AND
      • NAND
      • OR
      • NOR
      • XOR
      • NOT
      • Examples
    • Conversions
      • Encoder Counter Rollover
    • Summary of User Variables and Arithmetic
  • System Variables & Flags
    • Introduction
      • What is a System Flag?
      • What is a System Variable?
      • The Personality Module
    • Variable and Flag Summary
  • IQ Programming Structure
    • Introduction
      • Program Structure
        • Title
        • Header
        • End of program
    • Program Structure Instructions
      • DO/WHILE Structure
      • WHILE Structure
      • Subroutines
      • IF Structure
      • IF/ELSE Structure
      • WAIT Statement
      • ON Structure
      • JUMP / Label
      • Program Structure Instruction Summary
    • Scanned Event (Sn) Instructions
      • Sn:IF condition action
      • Sn:TMRm condition action
      • Sn:TMRm start condition, stop condition action
      • Sn ON/OFF/CONT
      • Timer
      • Scanned Event Instructions Summary
    • Xkey (Xn) Functions
      • Xn ON/OFF/CONT
      • XNPGM Statement
      • Xkey Versus Fkey
      • Xkey Instruction Summary
    • Fkey (Fn) Functions
      • Program Control of Fkeys
      • FNPGM Statement
      • Creating and Replacing Fkey Routines
      • Xkey Versus Fkey
      • Fkey Instruction Summary
    • Interrupts
      • Interrupts Step by Step
      • Example:
      • Interrupt Variable, flags and Instructions Summary
    • Miscellaneous Structure Instruction
      • Miscellaneous Structure Instructions Summary
  • Motion
    • Introduction
    • Incremental (MOVD) and Absolute (MOVP) Motion
      • Incremental (MOVD) Motion
      • Absolute (MOVP) Motion
    • Stick Moves
      • D, V Segments (Sticks)
      • DIF Segments (Sticks)
      • SCurve Acceleration
    • Gearing
    • Step and Direction
    • Combination Motion
    • Feedrate
    • Dwell Statement
    • Delay Statement
    • Motion Instruction Summary
  • Closed Loop Control
    • Introduction
    • Closed Loop Position Control
    • Closed Loop Velocity Control
  • Inputs / Outputs
    • Introduction
    • I/O Instruction Summary
  • Operator Terminal
    • Introduction
    • Operator Terminal Instruction Summary
  • Miscellaneous
    • Introduction
      • CONFIG Statement
      • Define Home (DH), Define Position (DP) and Define Position 1 or 2
      • Enable / Disable
    • Miscellaneous Instruction Summary
• 5 - Language Reference
  • Reserved Words
  • Language Reference
    • Format
      • KEYWORD
    • Reference
      • @
      • ABORT
      • ABSMODE
      • ACCEL
      • ACTIVESN
      • ACTIVEXN
      • ADCn
      • ALL
      • ASSIGN
      • ATHOME
      • Bn
      • BCD Om, n BIN Om, n
      • BCD variable = Im, n BIN variable = Im, n
      • CALL
      • CLEAR
      • CLRPEAKS
      • COMMENTS
      • COMPILETOMEMORY
      • CONFIG
      • CTOU1
      • CTOU2
      • D, V
      • DACn
      • DEBUG
      • DELAY
      • DH
      • DHCMD
      • DIF
      • DISABLE
      • DISLIM
      • DO/WHILE
      • DP
      • DPn
      • DWELL
      • EFLAG
      • ENABLE
      • END
      • ENUM
      • ERET
      • ERETPOS
      • EXPANDMACROS
      • Fn
      • FDR
      • FE
      • FEL
      • FET
      • FGAIN
      • FIn
      • FIDXn
      • FILTER
      • FNACTIVE
      • FNPGM
      • FOUNDHOME
      • FVEL1
      • Gn
      • GEAR
      • GEAREN
      • GPOS
      • HLIMITS
      • HOFFS
      • HOMECMD
      • HRESET
      • HSEQCPL
      • HSWEN
      • HSWSTAT
      • HVEL
      • Im
      • InPm
      • IAVE
      • IAVG
      • ICMD
      • IDXn ON/OFF
      • IF
      • IGAIN
      • ILIMIT
      • INDEXEN
      • INPOSN
      • INT
      • INTn ON/OFF/ CONT
      • IXnPm
      • IZONE
      • JACCEL
      • JDECEL
      • JOGACTIVE
      • JOGF
      • JOGR
      • JUMP
      • JVEL
      • KFF
      • KI
      • KP
      • KPZ
      • LABELS
      • LISTFILE
      • LOOP
      • LOOPINDEX
      • LPOS
      • MONOUT
      • MOVD
      • MOVECOMPLETE
      • MOVP
      • MOVV
      • MVOEN
      • Om = ON/OFF/ flag
      • ON variable JUMP
      • OTMON
      • OVERSPEED
      • PAUSE
      • PCAM
      • PCAMACTIVE
      • PCMD
      • PEXT
      • PEXTACTIVE
      • PFE
      • PGAIN
      • PGEN
      • PGMNUM
      • PGMRUNNING
      • PGMTYPE
      • PICMD
      • PJOG
      • POS1
      • POS2
      • POS3
      • POSN
      • PRINT
      • PRINTWARN
      • PURGEMOTION
      • PURGEMOTIONACTIVE
      • PVEL1
      • PZONE
      • READ
      • REPEAT
      • RETURN
      • RFDR
      • ROT
      • ROTT
      • ROT2
      • Sn ON/OFF/CONT
      • Sn: IF
      • Sn: TMRm
      • Sn: TMRm
      • SCALE
      • SCALE2
      • SEN
      • SETTASKTIMES
      • SINT2
      • SLEW
      • SLEWEN ON/OFF
      • SRESET
      • STARTP
      • STOP
      • SUB
      • SYSERROR
      • SYSWARN
      • TBASE
      • TIMERn
      • TITLE
      • TRACKINGEXTPOSSELECT
      • TRACKINGMODE
      • TRACKINGSYNCED
      • UTOC1
      • UTOC2
      • Vn
      • VCMD
      • VEL
      • VEL1
      • VEL2
      • WAIT
      • WFLAG
      • WHILE
      • WINDOW
      • WNUM
      • Xn:
      • Xn ON/OFF/CONT
      • XEND
      • XLOOPINDEX
      • XNACTIVE
      • XNPGM
• 6 - IQ Host Command Language
  • Introduction
    • Overview
    • Reserved Host Commands
    • Implementation
    • Addressing
  • Syntax
    • Command Syntax
    • Response Syntax
      • Acknowledge
      • Value
      • Error
  • Execution Commands
    • Motion Execution Commands
      • HOME (System Program #25) ERET (System Program #26)
      • MOVD or MD distance [[, ][V =] velocity] MOVP or MP position [[, ][V =] velocity]
      • MOVV or MV velocity
      • RUN [program] SRUN program
      • STEP
      • X
    • Non-Motion Execution Commands
      • (Null)
      • CLRPEAKS
      • DH DP position DPn position
      • ENABLE or EN DISABLE or DIS
      • HRESET
      • RESET or RES
    • Runtime Status and Version Commands
      • S
      • SI
      • DBG
      • VER [option]
  • Variables and Flags Assignment and Request Commands
    • Introduction
      • Personality Module Variables and Flags
      • Example Commands
      • Table Format
    • Acceleration and Velocity
    • Current
    • Gains
    • Homing
    • Inputs – Analog and Digital
    • Interrupts
    • Motion
    • Outputs – Analog and Digital
    • Position
    • Serial
      • COM1 word COM2 word
    • System
      • CF1 word CF2 word CF3 word CF4 word
    • Tune Mode
    • User Variables and Flags
  • File Commands
    • Program Maintenance and Directory Commands
      • DEL program SDEL program
      • DELS program SDELS program
      • DIRI program SDIRI program
      • FREE [page]
      • DIR [page] SDIR
    • Transfer Commands
      • SAVE or LOAD MEM [page] SAVE or LOAD ALL [page] SAVE or LOAD PAR
      • SAVE or LOAD program SSAVE or SLOAD program SAVEE or LOADE program SSAVEE or SLOADE program
  • Operator Terminal Commands
    • Commands
      • FNPGM fn#
      • OTADDR address
      • OTCLS
      • OTCP
      • OTFILL byte
      • OTFLUSH
      • OTGET
      • OTLN1, OTLN2, OTLN3, OTLN4
      • OTMn
      • OTMON
      • OTPUT char
      • OTS word
      • OTTBL key [,code]
      • OTW Row, Col, “Text”
      • OTX flag
      • XNPGM Xkey#
    • Operator Terminal Key Codes
• Appendixes
  • DDE Server
    • DDE Initialization Failure
  • System Programs
    • What are System Programs?
    • When are system programs run?
      • On Power Up
      • Operator Terminal Function Keys
      • Assigned Inputs
      • Error conditions
      • Serial Host Command
      • From another program
    • Modifying System Programs
    • System Program 0 - Auto
      • Program Listing
    • System Program 1 - Jog Forward
      • Program Listing
    • System Program 2 - Jog Reverse
      • Program Listing
    • System Program 3 - Start
      • Program Listing
    • System Program 4 - Stop
      • Program Listing
    • System Program 5 - Run
      • Program Listing
    • System Program 6 - Execute Home
      • Program Listing
    • System Program 7 - Define Home
      • Program Listing
    • System Program 8 - Set Feedrate
      • Program Listing
    • System Programs 9-12
    • System Program 13 - Monitor VEL1
      • Program Listing
    • System Program 14 - Monitor POSN
      • Program Listing
    • System Program 15 - Monitor PCMD
      • Program Listing
    • System Program 16 - Monitor FE
      • Program Listing
    • System Program 17 - Monitor ICMD
      • Program Listing
    • System Program 18 - Monitor IAVE
      • Program Listing
    • System Program 19 - Monitor RFDR
      • Program Listing
    • System Program 20 - Monitor ADC1
      • Program Listing
    • System Programs 21-24
    • System Program 25 - Home
      • Standard Home Program
      • Program Listing
    • System Program 26 - Emergency Return
      • Program Listing
    • System Program 27 - Error Routine
      • Program Listing
    • System Programs 28-31
  • Optional Operator Terminal Function Key Programs
    • Clear Peaks
    • Disable
    • Enable
    • Hardware Reset
    • Monitor FVEL1
    • Monitor PFE
    • Monitor PICMD
    • Monitor POS1
    • Monitor POS2
    • Monitor PVEL1
    • Monitor VCMD
    • Monitor VEL2
    • Pause
    • Reset
  • Optional Home Programs
    • Home to a Limit Switch
    • Home without Limit Switches
    • Home to Encoder Index only
  • Application Examples
    • SmartBelt Application
      • Description
        • Advantages of a Servo System
      • Design Considerations
        • Sensor Placement & Wiring
        • Mechanics
        • Correction Belt Length
        • Product Slippage
        • Performance/Accuracy
      • Flow Chart
      • ULTRA Plus or IQ Parameter Settings
    • Feed-To-Length Application
      • Description
        • Advantages of a Servo System
      • Design Considerations
        • Mechanics
        • Slippage
        • Accuracy
        • Interfacing
        • Registration
      • Flow Chart
    • Continuous Web with Registration
      • Description
        • Requirements
        • Description of the ULTRA Plus or IQ Solution
      • Design Considerations
        • Correction Algorithm
        • Program Parameters
        • I/O Connections
        • ULTRA Plus or IQ System Considerations
      • Flow Chart
    • Auger Dispensing Application
      • Description
        • Advantages of Servo System
        • Mechanics
        • Interfacing
      • Flow Chart
    • Thermoformer Application
      • Description
        • Advantages of Servo System
      • Design Considerations
        • Mechanics
        • Thermal Management
        • Accuracy
        • Interfacing
      • Flow Chart
    • In-line Bottle Filler
      • Description
        • Advantages of a Servo System
      • Design Considerations
        • Mechanics
        • Interfacing
        • System Parameters
        • Sensor Placement & Wiring/Registration
      • Flow Chart
    • Vertical, Form, Fill and Seal
      • Description
        • Advantages of a Servo System
      • Design Considerations
        • Mechanics
        • Accuracy
        • Operator Interface
        • I/O Requirements
        • Registration
        • The ULTRA Plus or IQ Solution
      • Flow Chart
    • Lane Diverter
      • Description
      • Design Considerations
        • I/O Connections
        • System Parameters
        • Program Parameters
      • Program Description
      • Flow Chart
    • Automated Test Station
      • Description
        • Advantages of Servo System
      • Design Considerations
        • Mechanics
        • Test Options
        • Torque Measurement Considerations
        • Serial Host Interface
        • Input/Output Connections
      • Flow Chart
  • What’s New in Each Version
    • New Features
      • Changes to Version 3.2.4 from Version 3.2.3
      • Changes to Version 3.2 from Version 3.0
      • Changes to Version 3.0 from Version 2.1
      • Changes to Version 2.1 from Version 2.xx
      • Changes to Version 2.0 from Version 1.xx
      • Syntax Changes to Version 2.0 from Version 1.xx
      • Define Home (DH)
      • PRINT and READ
      • GEAREN
      • LOOP
      • Name Changes for Version 2
  • Upgrading From Version 1
    • Backup Existing Files and Personality Module
    • Install new EPROMS
    • Install IQ Master
    • Upgrade Personality Module
      • To upload ALLPROG.QAP to the IQ
  • Error Messages
• Index
• Back Cover