Gemini GV6K and Gemini GT6K Programmer's Guide

p/n 88-019934-01 A 

Automation 

Gemini GV6K and 

Gemini GT6K 

Programmer's Guide 

Effective: October 1, 2001

User Information 

WARNING 

! ! 

Gem6K Series products are used to control electrical and mechanical 

components of motion control systems. You should test your motion 

system for safety under all potential conditions. Failure to do so can result 

in damage to equipment and/or serious injury to personnel. 

Gem6K Series products and the information in this user guide are the proprietary property of Parker Hannifin Corporation or its licensers, and 

may not be copied, disclosed, or used for any purpose not expressly authorized by the owner thereof. 

Since Parker Hannifin constantly strives to improve all of its products, we reserve the right to change this user guide and software and 

hardware mentioned therein at any time without notice. 

In no event will the provider of the equipment be liable for any incidental, consequential, or special damages of any kind or nature 

whatsoever, including but not limited to lost profits arising from or in any way connected with the use of the equipment or this user guide. 

© 2001, Parker Hannifin Corporation 

All Rights Reserved 

Motion Planner and Servo Tuner are trademarks of Parker Hannifin Corporation. 

Microsoft and MS-DOS are registered trademarks, and Windows, Visual Basic, and Visual C++ are trademarks of Microsoft Corporation. 

Technical Assistance Contact your local automation technology center (ATC) or distributor, or ... 

North America and Asia: 

Compumotor Division of Parker Hannifin 

5500 Business Park Drive 

Rohnert Park, CA 94928 

Telephone: (800) 358-9070 or (707) 584-7558 

Fax: (707) 584-3793 

FaxBack: (800) 936-6939 or (707) 586-8586 

e-mail: tech_help@cmotor.com 

Internet: http://www.compumotor.com 

Europe (non-German speaking): 

Parker Digiplan 

21 Balena Close 

Poole, Dorset 

England BH17 7DX 

Telephone: +44 (0)1202 69 9000 

Fax: +44 (0)1202 69 5750 

Germany, A ustria, Switzerland: 

HAUSER Elektronik GmbH 

Postfach: 77607-1720 

Robert-Bosch-Str. 22 

D-77656 Offenburg 

Telephone: +49 (0)781 509-0 

Fax: +49 (0)781 509-176 

Tech nical 

Support 

Automation 

E-mail: Tech_Help@cmotor.com

CONTENTS 

OVERVIEW.................................................................. I 

About This Manual......................................................i 

Organization of This Manual...................................i 

Programming Examples..........................................ii 

Reference Documentation.......................................ii 

Assumptions of Technical Experience....................ii 

Before You Begin......................................................iii 

Install and Use Motion Planner .............................iii 

Technical Support......................................................iii 

PROGRAMMING FUNDAMENTALS ..................... 1 

Motion Planner Programming Environment............... 2 

Wizard-Based Programming................................... 2 

Native Code Programming ..................................... 3 

Command Syntax........................................................ 4 

Introduction ............................................................ 4 

Description of Syntax Letters and Symbols............ 5 

General Guidelines for Syntax................................ 6 

Command Value Substitutions ............................... 7 

Assignment and Comparison Operators ................. 7 

Programmable Inputs and Outputs Bit Patterns...... 9 

Creating Programs .................................................... 10 

Program Example ................................................. 10 

Storing Programs ...................................................... 11 

Memory Allocation............................................... 11 

Checking Memory Status...................................... 12 

Executing Programs (options) .................................. 13 

Creating and Executing a Set-up Program................ 13 

Program Security ...................................................... 14 

Controlling Execution of Programs and the Command 

Buffer........................................................................ 14 

COMEXC (Continuous Command Execution)..... 14 

COMEXL (Save Command Buffer on Limit) ...... 15 

COMEXR (Effect of Pause/Continue Input) ........ 15 

COMEXS (Save Command Buffer on Stop) ........ 16 

Restricted Commands During Motion...................... 17 

Variables................................................................... 18 

Converting Between Binary and Numeric Variables 

.............................................................................. 18 

Using Numeric (VAR and VARI) Variables.......... 19 

Using Binary Variables......................................... 22 

Unconditional Looping and Branching................. 23 

Conditional Looping and Branching..................... 25 

Program Interrupts (ON Conditions) ........................ 29 

Error Handling.......................................................... 30 

Enabling Error Checking ...................................... 31 

Defining the Error Program .................................. 31 

Canceling the Branch to the Error Program.......... 32 

Error Program Set-up Example............................. 34 

Non-Volatile Memory .............................................. 35 

System Performance..................................................35 

COMMUNICATION..................................................37 

Communication Options ...........................................38 

Motion Planner Communication Features.................38 

Ethernet Networking .................................................39 

Overview...............................................................39 

Networking Guidelines .........................................42 

Configuring the Gem6K for Ethernet 

Communication.....................................................43 

Networking with Other 6K or Gem6K Products 

(Peer-to-Peer) ........................................................46 

Networking with OPTO22 SNAP I/O...................48 

Networking with a DVT Vision System ...............50 

Networking with an Allen-Bradley SLC 5/05 PLC 

...............................................................................51 

Error Conditions....................................................54 

Serial Communication...............................................56 

Controlling Multiple Serial Ports ..........................56 

RS-232C Daisy-Chaining......................................57 

Daisy-Chaining and RP240s .................................60 

RS-485 Multi-Drop ...............................................60 

BASIC OPERATION SETUP....................................63 

Before You Begin .....................................................64 

Setup Parameters Discussed in this Chapter .........64 

Using a Setup Program..........................................65 

Resetting the Controller ........................................65 

Memory Allocation ...................................................65 

Drive Setup ...............................................................66 

Drive Stall Detection (stepper only)......................66 

Drive Resolution (stepper only) ............................66 

Disable Drive On Kill (servo only) .......................66 

Scaling.......................................................................67 

Units of Measure without Scaling.........................67 

What is Scaling....................................................67 

When Should I Define Scaling Factors ...............67 

Acceleration & Deceleration Scaling (SCLA).......68 

Velocity Scaling (SCLV)......Error! Bookmark not 

defined. 

Distance Scaling (SCLD and SCLMAS)......... Error! 

Bookmark not defined. 

Positioning Modes.....................................................71 

Preset Positioning Mode........................................72 

Continuous Positioning Mode...............................73 

End-of-Travel Limits ................................................77 

Homing (Using the Home Inputs) .............................79 

Encoder-Based Stepper Operation (stepper only) .....84 

Encoder Resolution ...............................................84 

Stall Detection & Kill-on-Stall..............................84 

Encoder Set Up Example ......................................84

Encoder Count/Capture Referencing.................... 85 

Tuning Procedures (servos only) .............................. 85 

Entering Load Settings ......................................... 85 

Position Mode Tuning .............................................. 85 

Position Mode Tuning Procedure ......................... 86 

Filter Adjustments .................................................... 87 

Target Zone Mode (move completion criteria for 

servos only)............................................................... 89 

Programmable Inputs and Outputs (onboard and 

external inputs & outputs) ........................................ 90 

Programmable I/O Bit Patterns............................. 91 

Input Functions..................................................... 94 

Output Functions ................................................ 105 

Variable Arrays (teaching variable data)................ 110 

Basics of Teach-Data Applications..................... 110 

Summary of Related Gem6K Series Commands 112 

Teach-Data Application Example....................... 112 

PRODUCT CONTROL OPTIONS ........................ 115 

Safety Features ....................................................... 116 

Options Overview................................................... 116 

Stand-Alone Interface Options ........................... 116 

Programmable Logic Controller ......................... 117 

Host Computer Interface .................................... 117 

Custom Graphical User Interfaces (GUIs).......... 117 

Programmable I/O Devices..................................... 118 

Programmable I/O Functions.............................. 118 

Thumbwheels ..................................................... 119 

PLCs ................................................................... 119 

PLC Scan Mode.................................................. 120 

RP240 Remote Operator Panel............................... 123 

Configuration...................................................... 123 

Operator Interface Features ................................ 124 

Using the Default Menus.................................... 125 

Joystick Control, Analog Inputs ............................. 130 

Joystick Control.................................................. 130 

Analog Input Interface......... Error! Bookmark not 

defined. 

Host Computer Interface ........................................ 133 

Graphical User Interface (GUI) Development Tools 

................................................................................ 134 

CUSTOM PROFILING ........................................... 135 

S-Curve Profiling.................................................... 136 

S-Curve Programming Requirements................. 136 

Determining the S-Curve Characteristics ........... 136 

Programming Example ....................................... 137 

Calculating Jerk .....Error! Bookmark not defined. 

Compiled Motion Profiling..................................... 139 

Compiled Following Profiles.............................. 142 

Dwells and Direction Changes ........................... 144 

Compiled Motion Versus On-The-Fly Motion... 145 

Related Commands............................................. 146 

Compiled Motion — Sample Application 1 ....... 147 




On-the-Fly Motion (pre-emptive GOs).................... 155 

OTF Error Conditions......................................... 156 

On-The-Fly Motion — Sample Application....... 157 

Registration.............................................................159 

How to Set up a Registration Move ....................159 

Registration Move Accuracy (see also Registration 

Move Status below).............................................159 

Preventing Unwanted Registration Moves 

(methods).............................................................160 

Registration Move Status & Error Handling.......160 

Registration — Sample Application 1 ................161 

Registration — Sample Application 2 .......... Error! 

Bookmark not defined. 

Registration — Sample Application 3 ................163 

Synchronizing Motion (GOWHEN and TRGFN 

operations)...............................................................163 

Conditional “GO”s (GOWHEN)............................163 

Trigger Functions (TRGFN) ................................166 

FOLLOWING ...........................................................167 

Ratio Following – Introduction...............................168 

What can be a master ........................................168 

Following Status (TFSF, TFS & FS Commands) 

............................................................................169 

Implementing Ratio Following ...............................170 

Ratio Following Setup Parameters......................170 

Follower vs. Master Move Profiles.....................175 

Performing Phase Shifts......................................178 

Geared Advance Following.................................180 

Summary of Ratio Following Commands...........181 

Master Cycle Concept.............................................182 

Master Cycle Commands....................................182 

Summary of Master Cycle and Wait Commands 185 

Technical Considerations for Following.................186 

Performance Considerations ...............................186 

Master Position Prediction ..................................187 

Master Position Filtering.....................................187 

Following Error...................................................188 

Maximum Velocity and Acceleration (Stepper 

Axes Only)..........................................................189 

Factors Affecting Following Accuracy...............189 

Preset vs. Continuous Following Moves.............191 

Master and Follower Distance Calculations........192 

Using Other Features with Following .................194 

Troubleshooting for Following (see also Chapter 8) 

................................................................................196 

Error Messages....................................................197 

Following Commands.............................................198 

MULTI-TASKING ...................................................201 

Introduction to Multi-Tasking.................................202 

Using Multi-Tasking to Run Programs ...............202 

Interaction Between Tasks ..................................206 

Tasks ...................................................................208 

How a “Kill” Works While Multi-Tasking .........209 

Using Gem6K Resources While Multi-Tasking .....210 

Associating Axes with Tasks ..............................210 

Sharing Common Resources Between Multiple 

Tasks ...................................................................211 

Locking Resources to a Specific Task ................211 

How Multi-tasking and the % Prefix Affect 

Commands and Responses..................................211 

Input and Output Functions and Multi-tasking ...213

Multi-Tasking Performance Issues ......................... 214 

When is a Task Active ...................................... 214 

Task Swapping.................................................... 214 

Task Execution Speed......................................... 215 

TROUBLESHOOTING ........................................... 217 

Troubleshooting Basics........................................... 218 

Solutions to Common Problems ............................. 218 

Program Debug Tools............................................. 221 

Status Commands ............................................... 222 

Error Messages ................................................... 229 

Trace Mode......................................................... 232 

Single-Step Mode ............................................... 234 

Break Points........................................................ 235 

Simulating I/O Activation................................... 235 

Simulating Analog Input Channel Voltages ....... 237 

Motion Planner’s Panel Gallery.......................... 237 

Technical Support................................................... 238 

Operating System Upgrades ................................... 238 

Product Return Procedure....................................... 238 

INDEX ....................................................................... 239

OVERVIEW 

About This Manual 

This manual is designed to help you implement the Gem6K Series Product’s features in your 

application. Detailed feature descriptions are provided, including application scenarios and 

programming examples. For details on each Gem6K command, refer to the Gem6K Series 

Command Reference. 

Organization of This Manual 

Chapter 

Chapter 1. 

Programming Fundamentals 

Chapter 2. 

Communication 

Chapter 3. 

Basic Operation Setup 

Chapter 4. 

Product Control Options 

Chapter 5. 

Custom Profiling 

Chapter 6. 

Following 

Chapter 7. 

Multi-Tasking 

Chapter 8. 

Troubleshooting 

Information 

Discussion of essential programming guidelines and standard 

programming features such as branching, variables, interrupts, error 

handling, etc. 

Communication considerations, such as using Motion Planner, alert 

event handling, communication server and fast status control, RS-232 

daisy-chains and RS-485 multi-drops, etc. 

General operation setup conditions, such as number of axes, scaling 

factors, feedback device setup, programmable input and output 

functions, end-of-travel limits, homing, etc. 

Considerations for implementing various product control methods, 

such as programmable I/O, a joystick, an RP240, custom GUI, etc. 

Descriptions of custom profiling features such as S-Curves, timed 

data streaming, compiled profiles, on-the-fly motion profiling, 

registration, and synchronized motion. 

Feature descriptions and application examples for using Following 

features. 

Feature descriptions and application examples for using multi-tasking 

in your application. 

Methods for isolating and resolving hardware and software problems.

Programming Examples 

Reference Documentation 

Programming examples are provided in this document to demonstrate how the Gem6K 

product's features may be implemented. These examples are somewhat generalized, due to 

the diverse nature of the family of Gem6K Series products and their application; 

consequently, some attributes, such as the I/O bit pattern referenced, may differ from those 

available with your particular Gem6K product. 

This document is intended to accompany the printed and online documents listed below, as 

part of the Gem6K product user documentation set. 

Reference Document 

Description 

INTERNET ACCESS: 

These documents are 

also available to view 

and print from our web 

site (www.compumotor.com). 

Gem6K Series Hardware Installation Guide Hardware-related information specific to the Gem6K 

Series product: 

• Product hardware specifications 

• Installation instructions 

• Troubleshooting procedures 

• Servo tuning instructions 

Gem6K Series Command Reference 

EVM32 Installation Guide 

COM6SRVR Communications 

Motion Planner Online Help 

Detailed descriptions of all Gem6K Series Programming 

Language commands. Quick-reference tables are also 

provided. 

Specifications and installation instructions for the EVM32 

expansion I/O. 

The COM6SRVR is a 32-bit OLE automation server for adding 

Gem6K communication capability to your custom applications 

created with programming languages such as Visual Basic or 

Visual C++. This companion document includes descriptions 

of all methods and properties, and programming examples. 

Online instructional aids such as: 

• Tutorials 

• Introduction and tutorial for programming with Wizards 

• Context-sensitive help for Wizard-based programming 

• Documentation of programmer’s guide 

• Step-by-step programming coaches 

• Conceptual overviews 

• Advanced programming details 

• Sample programs 

• Documentation of the Gem6K Series command 

language, 

including all command descriptions and the contents of 

the manual you are currently reading 

• Documentation of the Communications Server OLE 

automation server (facilitates communications between 

Gem6K and your custom Windows software) 

Assumptions of Technical Experience 

To effectively use the information in this manual, you should have a fundamental 

understanding of the following: 

• Electronics concepts, such as voltage, switches, current, etc. 

• Motion control concepts such as motion profiles, torque, velocity, distance, force, etc. 

• Programming skills in a high-level language such as C, C++, or BASIC is helpful 

• Ethernet communication protocol (if using the Ethernet port) 

• If you are new to the Gem6K Series Programming Language, we encourage you to 

use the Motion Planner Wizards Editor (version 4.2 or later for Gem6K support). 

ii 

Gem6K Series Programmer’s Guide

Before You Begin 

Install and Use Motion Planner 

Technical Support 

Before you begin to implement the Gem6K controller’s features in your application you 

should complete all the installation and test procedures provided in your Gem6K Series 

Hardware Installation Guide. 

Motion Planner is a Windows-based graphical interface that assists you with programming 

and tuning your Gem6K Series controller, as well as setting up your Compumotor drives. The 

Motion Planner CD-ROM is provided in your ship kit. The Motion Planner interface allows 

you to: 

• Create, edit, download, and upload programs. 

• Tune your servo system. 

• Test & debug programs and controller operation. 

Additional details are provided on page 2 and in the Motion Planner Help System. 

For solutions to your questions about implementing Gem6K product software features, first 

look in this manual. Other aspects of the product (command descriptions, hardware specs, I/O 

connections, graphical user interfaces, etc.) are discussed in the respective manuals or Online 

Help systems listed above in Reference Documentation (see page ii). 

If you cannot find the answer in this documentation, contact your local Automation 

Technology Center (ATC) or distributor for assistance. 

If you need to talk to our in-house application engineers, please contact us at the numbers 

listed on the inside cover of this manual. (The phone numbers are also provided when you 

issue the HELP command to the Gem6K controller.) NOTE: The BBS contains the latest 

software upgrades and late-breaking product documentation. 

FAX number for technical support; 

bulletin board service,#see BBS; 

software, update from BBS; 

BBS; 

Email support: tech_help@cmotor.com 

Overview 

iii

Programming Fundamentals 

1C HAPTER ONE 

Programming 

Fundamentals 

IN THIS CHAPTER 

This chapter is a guide to general Gem6K programming tasks. It is divided into these main topics: 

• Motion Planner programming environment ......................... 2 • Restricted commands during motion ............................ 17 

• Command syntax.................................................................. 4 • Using Variables ............................................................ 18 

• Creating programs................................................................ 10 • Program flow control.................................................... 23 

• Storing programs.................................................................. 10 • Program interrupts ........................................................ 29 

• Executing programs ............................................................. 13 • Error handling............................................................... 30 

• Creating and executing a set-up program ............................. 13 • Non-volatile memory.................................................... 35 

• Program Security.................................................................. 14 • System performance considerations.............................. 35 

• Controlling execution – programs & command buffer......... 14

Motion Planner Programming Environment 

Wizard-Based Programming 

Every Gem6K Series controller is shipped with Motion Planner, a free Windows-based 

programming tool designed to simplify your programming efforts. The Motion Planner CD- 

ROM is provided in your ship kit. Updates may be downloaded, free of charge, from the 

compumotor.com web site. 

Motion Planner supports two programming paradigms: Wizard-based programming, and Native 

Code programming (working directly with the Gem6K programming language). 

Motion Planner includes the Wizard Editor, which is intended to be your primary program 

development environment for the Gem6K. (version 4.2 or later) 

The Wizard Editor makes programming easy, eliminates the need to learn the programming 

language and frees you from concerning yourself with syntax errors. 

• A Start Wizard guides you through creating your program structure and configuring your 

Gem6K (drives, feedback, I/O, servo tuning, etc.). 

• Additional wizards guide you through all other programming tasks, such as creating 

motion profiles, I/O handling, error handling, program logic and branching, adding subprograms, 

etc. 

NOTE: All programming features that can be implemented with native code (in a textbased 

Program Editor) can also be accomplished in the Wizard Editor. 

• The Tag Name Dictionary allows you to label variables, axes, and I/O so that you can 

program in terms that are relevant to your machine. 

• If you have existing programs in an Editor, you can easily include them into the Wizard 

editor (using the Native Code wizard), so you don’t have to rewrite your code. 

• The Wizard Editor also includes interactive debug tools (break points, trace mode) and a 

status window to help you test and debug your application. 

• Context-sensitive help is always available – just click the Help button or press the F1 key. 

How to get started: 

1. Install Motion Planner. 

2. Launch Motion Planner and select your Gem6K product. Motion Planner opens a new 

Wizard Editor file. 

3. When prompted to see an introduction and tutorial, click Yes. This will help you 

understand the basic features of the Wizard Editor and the programming process. 

2 Gem6K Series Programmer’s Guide

Native Code Programming 

As an alternative to using the Wizard Editor, you may program directly with the Gem6K 

Command Language (“Native Code”). Motion Planner has several tools to help you: 

ACCESSING THE TOOLS: These tools are exposed when you first launch Motion 

Planner. 

• Program Editor: This is your primary interface for programming with the Gem6K 

Command Language. 

• Terminal Emulator: This is your primary communications interface to send commands 

directly to the Gem6K. 

• Servo Tuner: This graphical tuning utility helps you visually tune your servo axes. Then 

you can copy the resulting gains into your program in the Program Editor. NOTE: Before 

attempting motion, be sure to tune your axes. Tuning guidelines are provide on page 

• Motion Panel: This feature allows definition of quick command buttons and other useful 

debugging and functional tools to assist in programming your Gem6K. 

• Online Help: While you are programming in Motion Planner’s Editor, Terminal or Servo 

Tuner, you have immediate access to all command descriptions (the contents of the 

Gem6K Series Command Reference, as well as the contents to this Programmer’s Guide). 

To access the command descriptions, click on the Help menu and select Contents; from 

there you can browse the “Gem6K Command Language” or you can search for the 

command or a topic in the Index tab. 

The rest of the contents in this manual are directed toward the native code programmer. If you 

are new to the Gem6K Series Programming Language, be sure to read Chapter 1 (Programming 

Fundamentals) thoroughly. Then proceed to the relevant chapters for the features you need for 

your programs. 

NOTE: If you later decide to use the Wizards Editor, you can copy code from the Program 

Editor and paste it into Native Code objects in the Wizard program tree. 

TIP: For complex programming tasks, like setup programming, error programming, Following 

profile development, etc., you can use the relevant wizard in the Wizards Editor, then copy the 

generated code from the Code Viewer and paste it into a Program Editor file. 

Chapter 1. Programming Fundamentals 3

Command Syntax 

Introduction 

Sample program, as viewed in an editor: 

; ********************************************************* 

; This is a program that executes a trapezoidal motion 

; profile on axes 1 and 2 

; ********************************************************* 

DEL motion ; (a precaution) Delete program called 

"motion" 

DEF motion ; Begin definition of program called "motion" 

DRIVE1 ; Enable drive 

MC0 

; Set position mode to preset 

A20 

; Set accel to 20 units/sec/sec 

V8 

; Set velocity to 8 units/sec 

D100000 ; Set distance to 100,000 counts 

; Execute motion on axes 1 and 2 

END 

; End definition of program called "motion" 

DEL motion 

DRIVE 1 

Text field 

Command name 

Binary data field 

Command name 

The Gem6K programming language accommodates a wide range of needs by providing basic 

motion control building blocks, as well as sophisticated motion and program flow constructs. 

The language comprises simple ASCII mnemonic commands, with each command separated 

by a command delimiter (carriage return, colon, or line feed). The command delimiter signals 

the Gem6K product that a command is ready for processing. 

Upon receiving a command followed by a command delimiter, the Gem6K controller places 

the command in its internal command buffer, or queue. Here the command is executed in the 

order in which it is received. To make the command execute immediately, place an 

exclamation point (!) in front of it (e.g., The TAS command will be executed after all 

commands ahead of it in the command buffer are executed; but !TAS will execute before any 

other commands in the command buffer). 

Spaces and tabs within a command are processed as neutral characters. Comments can be 

specified with the semicolon (;) character — all characters following the semicolon and 

before the command delimiter are considered program comments. 

Some commands contain one or more data fields in which you enter numeric or binary values 

or text: 

• Numeric data fields. For example, A20,10 is an acceleration (A) command that sets the 

acceleration to 20 units/sec 2 . 

• Binary fields. For example, DRIVE1 is a drive enable (DRIVE) command that enables 

the drive. 

• Text fields. For example, STARTPpowrup is a startup program assignment (STARTP) 

command that assigns the program called “powrup” as the startup program to be 

executed automatically when the Gem6K product is power up or reset. 

• To check what the data field settings are for a particular command, simply type in the 

command without the data fields. The Gem6K will display the command settings. For 

example, after executing the A20, noted above, you could type in the A command by 

itself and the Gem6K controller would respond with A20. 

Some commands contain no data fields: 

• Status Commands. For example, TASF responds by displaying a list of status conditions 

for each axis. 

• Reset 

These are command line comments, comprising a semi-colon and text. 

The comments are separated from the command by a tab. 

A carriage return is placed at the end of each command line. 

; ********************************************************* 



; ********************************************************* 

DEL motion ; (a precaution) Delete program called "motion" 


DRIVE1 

; Enable drives 

MC0 


A20 


V8 

; Set velocity to 8 units/sec 

D100000 

; Set distance to 100,000 counts 

GO 

; Execute motion 

END 



Description of Syntax Letters and Symbols 

The command descriptions provided within the Gem6K Series Command Reference use alphabetic letters and ASCII 

symbols within the Syntax description to represent different parameter requirements (see INEN example below). 

INEN 

Input Enable 

Type Inputs; Program Debug Tools 

Syntax INEN... 

Units d = Ø, 1, E, or X 

Range Ø = off, 1 = on, E = enable, X = don't change 

Default E 

Response INEN: *INENEEEE_EEEE_EEEE_EEEE_E 

See Also [ IN ], INFNC, INLVL, INPLC, INSTW, TIN, TIO 

Product Rev 

Gem6K 5.0 

Letter/Symbol 

Description 

a .......... Represents an axis specifier. 

B .......... Represents the number of the product's I/O brick. External I/O bricks are represented by numbers 1 through n (to connect 

external I/O bricks, refer to your product's Installation Guide). On-board I/O are address at brick location zero (Ø). If the 

brick identifier is omitted from the command, the controller assumes the command is supposed to affect the onboard I/O. 

b *......... Represents the values 1, 0, X or x; does not require field separator between values. 

c .......... Represents a character (A to Z, or a to z) 

d .......... Represents the values 1, 0, X or x, E or e ; does not require field separator between values. E or e enables a specific 

command field. X or x leaves the specific command field unchanged or ignored. In the ANIEN command, the “d” symbol 

may also represent a real numeric value. 

i .......... Represents a numeric value that cannot contain a decimal point (integer values only). The numeric range varies by 

command. Field separator required. 

r .......... Represents a numeric value that may contain a decimal point, but is not required to have a decimal point. The numeric 

range varies by command. Field separator required. 

t .......... Represents a string of alpha numeric characters from 1 to 6 characters in length. The string must start with a alpha 

character. 

! .......... Represents an immediate command. Changes a buffered command to an immediate command. Immediate commands 

are processed immediately, even before previously entered buffered commands. 

% .......... (Multitasking Only) Represents a task identifier. To address the command to a specific task, prefix the command with “i%”, 

where “i” is the task number. For example, the 4%CUT command uses task #4 to execute the program called “CUT”. 

, .......... (comma) Represents a field separator. Commands with the symbol r or i in their Syntax description require field 

separators. Commands with the symbol b or d in their Syntax description do not require field separators (but they may be 

included). See General Guidelines table below. 

@ .......... Represents a global specifier, where only one field need be entered. Applicable to all commands with multiple command 

fields. 

< > ...... Indicates that the item contained within the < > is optional, not required by that command. 

NOTE: Do not confuse with , , and , which refer to the ASCII characters corresponding to a carriage 

return, space, and line feed, respectively. 

[ ] ...... Indicates that the command between the [ ] must be used in conjunction with another command, and cannot be used 

by itself. 

* The ASCII character b can also be used within a command to precede a binary number. When the b is used in this context, it is not to be 

replaced with a 0, 1, X, or x. Examples are assignments such as VARB1=b10001, and comparisons such as IF(3IN=b1001X1). 

Order of Precedence for Command Prefix Characters (from left to right): 

 

1 st : Immediate 

2 nd : Task number 

3 rd : Apply to all axes or I/O bricks 

3 rd : Axis number 

3 rd : I/O brick number 


General Guidelines for Syntax 

Guideline Topic Guideline Examples 

Neutral Characters 

• Space () 

• Tab () 

Command Delimiters: 

• Carriage rtn () 

• Line feed () 

• Colon (:) 

Case Sensitivity 

Comment Delimiter (;) 

Using neutral characters anywhere within a 

command will not affect the command. 

(In the examples on the right, a space is 

represented by , a tab is ), and a 

carriage return is ) 

All commands must be separated by a 

command delimiter. A carriage return is the 

most commonly used delimiter. To use a line 

in a live terminal emulator session, press 

ctrl/J. The colon (:) delimiter allows you to 

place multiple commands on one line of code, 

but only if you add it in the program editor (not 

during a live terminal emulator session). 

There is no case sensitivity. Use upper or 

lower case letters within commands. 

All text between a comment delimiter and a 

command delimiter is considered program 

comments. 

Set velocity to 10 rps: 

V10 

Add a comment to the command: 

V 10 ;set velocity 

Set acceleration to 10 rev/sec/sec: 

A 10 

A 10 

A 10: V 25: D 25000: GO 

Initiate motion 

GO 

go 

Add a comment to the command: 

V10 ;set velocity 

Field Separator (,) 

Commands with the symbol r or i in their 

Syntax description require field separators. 

INSGLP EXAMPLE 

Global Command 

Identifier (@) 

When you wish to set the command value 

equal on all axes, add the @ symbol at the 

beginning of the command (enter only the 

value for one command field). 

Check the status of all digital outputs (onboard, and 

on external I/O bricks): 

@OUT 

Bit Select Operator (.) 

Left-to-right Math 

Binary and hexadecimal 

values 

Multi-tasking Task 

Identifier (%) 

The bit select operator allows you to affect 

one or more binary bits without having to enter 

all the preceding bits in the command. 

Syntax for setup commands: 

[command name].[bit #]-[binary value] 

Syntax for conditional expressions: 

[command name].[bit #]=[binary value] 

All mathematical operations assume 

left-to-right precedence. 

When making assignments with or 

comparisons against binary or hexadecimal 

values, you must precede the binary value 

with the letter “b” or “B”, and the hex value 

with “h” or “H”. In the binary syntax, an “x” 

simply means the status of that bit is ignored. 

Use the % command prefix to identify the 

command with a specific task. 

Enable error-checking bit #9: 

ERROR.9-1 

Enable error-check bits #9-12: 

ERROR.9-1,1,1,1 

IF statement based on value of axis status bit #12: 

IF(AS.12=b1) 

VAR1=5+3*2 

Result: Variable 1 is assigned the value of 

16 (8*2), not 11 (5+6). 

Binary: IF(IN=b1x01) 

Hexadecimal: IF(IN=h7F) 

Launch the “move1” program in Task 1: 

1%move1 

Check the error status for Task 3: 

3%TER 

Check the system status for Task 3: 

3%TSS 

NOTE: The command line is limited to 100 characters (excluding spaces). 


Command Value Substitutions 

Many commands can substitute one or more of its command field values with one of these 

substitution items (demonstrated in the programming example below): 

VAR..........Places current value of the numeric variable in the corresponding command field. 

VARB .......Uses the value of the binary variable to establish all the command fields. 

VARI .......Places current value of the integer variable in the corresponding command field. 

READ .......Information is requested at the time the command is executed. 

DREAD .....Reads the RP240's numeric keypad into the corresponding command field. 

DREADF...Reads the RP240's function keypad into the corresponding command field. 

TW ............Places the current value set on the thumbwheels in the corresponding command field. 

DAT..........Places the current value of the data program (DATP) in the corresponding command field. 

Programming Example: (NOTE: The substitution item must be enclosed in parentheses.) 

VAR1=15 ; Set variable 1 to 15 

A5,(VAR1),4,4 ; Set acceleration to 5,15,4,4 for axes 1-4, respectively 

VARB1=b1101XX1 ; Set binary variable 1 to 1101XX1 (bits 5 & 6 not affected) 

GO(VARB1) 

; Initiate motion on axes 1, 2 & 4 (value of binary 

; variable 1 makes it equivalent to the GO1101 command) 

OUT(VARB1) ; Turn on outputs 1, 2, 4, and 7 

VARS1="Enter Velocity" ; Set string variable 1 to the message "Enter Velocity" 

V2,(READ1) ; Set the velocity to 2 on axis 1. Read in the velocity for 

; axis 2, output variable string 1 as the prompting message 

; 1. Operator sees "ENTER VELOCITY" displayed on the screen. 

; 2. Operator enters velocity prefixed by !' (e.g., !'20). 

HOMV2,1,(TW1) ; Set homing velocity to 2 and 1 on axes 1 and 2, respectively. 

; Read in the home velocity for axis 3 from thumbwheel set 1 

HOMV2,1,(DAT1) ; Set homing velocity to 2 and 1 on axes 1 and 2, respectively. 

; Read home velocity for axis 3 from data program 1. 

VARI1=2*3 ; Set integer variable 1 to 6 (2 multiplied by 3) 

D(VARI2),,(VARI3) ; Set the distance of axis 1 equal to the value of 

; integer variable 2, and the distance of axis 3 equal to 

; the value of integer variable 3. 

RULE OF THUMB 

Not all of the commands allow command field substitutions. In general, commands with a 

binary command field ( in the command syntax) will accept the VARB substitution. 

Commands with a real or integer command field ( or in the command syntax) will 

accept VAR, VARI, READ, DREAD, DREADF, TW or DAT. 

Assignment and Comparison Operators 

Comparison and assignment operators are used in command arguments for various functions 

such as variable assignments, conditional branches, wait statements, conditional GOs, etc. 

Some examples are listed below: 

• Assign to numeric variable #6 the value of the encoder position on axis #3 (uses the PE 

operator): VAR6=3PE 

• Wait until onboard inputs #3 & #6 become active (uses the IN operator): 

WAIT(IN=bxx1xx1) 

• Continue until the value of numeric variable #2 is less than 36: UNTIL(VAR2

* denotes operators that 

have a correlated status 

display command. 

(e.g., To see a full-text 

description of each axis 

status bit accessed with 

the AS operator, send 

the TASF command to 

the Gem6K controller.) 

See page 222. 

A ...................Acceleration 

AD.................Deceleration 

ANI ..............Voltage at the analog inputs on an expansion I/O brick (see page 91 for bit patterns) * 

ANO ..............Voltage at the analog outputs on an expansion I/O brick (see page 91 for bit patterns) * 

AS.................Axis status * 

ASX ..............Extended axis status (additional axis status items) * 

D ...................Distance 

DAC ..............Digital-to-analog converter (output voltage) value * 

DAT ..............Data program number 

DKEY............Value of RP240 Key 

DPTR............Data pointer location * 

DREAD .........Data from the numeric keypad on the RP240 

DREADF .......Data from the function keypad on the RP240 

ER.................Error status * 

FB.................Position of current selected feedback sources * 

FS.................Following status * 

IN.................Input status (input bit patterns provided on page 91) * 

INO ..............“Other” input status (ENABLE input reported with bit #6) * 

LIM ..............Limit status (end-of-travel limits and home limits) * 

MOV ..............Axis moving status 

NMCY............Current master cycle number * 

OUT ..............Output status (output bit patterns provided on page 91) * 

PANI............Position of analog input, at 205 counts/volts unless otherwise scaled (servo axes) * 

PC.................Commanded position * 

PCC ..............Captured commanded position * 

PCE ..............Captured encoder position * 

PCME............Captured master encoder position * 

PCMS............Captured master cycle position * 

PER ..............Position error (servo axes only) * 

PME ..............Current master encoder position * 

PMAS............Current master cycle position * 

PE.................Position of encoder * 

PSHF............Net position shift since constant Following ratio * 

PSLV............Current commanded position of the slave axis * 

READ............Read a numeric value to a numeric variable (VAR) 

SC.................Controller status * 

SCAN............Runtime of the last scanned PLC program * 

SEG ..............Number of segments available in Compiled Profile memory * 

SS.................System status * 

SWAP............Current active status of tasks * 

TASK............Number of the controlling task * 

TIM ..............Timer value * 

TRIG............Trigger interrupt status * 

TW.................Thumbwheel data read 

US.................User status * 

V ...................Velocity (programmed) 

VAR ..............Numeric variable substitution 

VARI............Integer variable substitution 

VARB............Binary variable substitution 

VEL ..............Velocity (commanded by the controller) * 

VELA............Velocity (actual, as measured by a position feedback device) * 

VMAS............Current velocity of the master axis * 


Bit Select Operator 

Binary and Hex 

Values 

Related Operator 

Symbols 

The bit select operator (.) makes it easier to base a command argument on the condition of one 

specific status bit. For example, if you wish to base an IF statement on the condition that a 

user fault input is activated (error status bit #7 is a binary status bit that is “1” if a user fault 

occurred and “Ø” if it has not occurred), you could use this command: IF(ER=bxxxxxx1). 

Using a bit select operator, you could instead use this command: IF(ER.7=b1). 

Side Note: You can use a bit select operator to set a particular status bit (e.g., to turn on onboard 

programmable output #5, you would type the OUT.5-1 command; to enable error-checking bit 

#4 to check for drive faults, you would type the ERROR.4-1 command). . You can also check 

specific status bits (e.g., to check axis 2’s axis status bit #25 to see if a target zone timeout 

occurred, type the 2TAS.25 command and observe the response). 

When making assignments with or comparisons against binary or hexadecimal values, you must 

precede the binary value with the letter “b” or “B”, and the hex value with “h” or “H”. 

Examples: IF(IN=b1xØ1) and IF(IN=h7F). In the binary syntax, an “x” simply means 

the status of that bit is ignored. Refer also to Using Binary Variables (page 19). 

Command arguments include special operator symbols (e.g., +, /, &, ', >=, etc.) to perform 

bitwise, mathematical, relational, logical, and other special functions. These operators are 

described in detail, along with programming examples, at the beginning of the Command 

Descriptions section of the Gem6K Series Command Reference. 

Programmable Inputs and Outputs Bit Patterns 

I/O pin outs, 

specifications, and 

circuit drawings are 

provided in each 

Gem6K Series 

Hardware Installation 

Guide. 

The Gem6K product has programmable inputs and outputs. The total number of onboard inputs 

and outputs (trigger inputs, limit inputs, digital outputs) depends on the product. The total 

number of expansion inputs and outputs (analog inputs, digital inputs and digital outputs) 

depends on your configuration of expansion I/O bricks connected to the “EXPANSION I/O” 

connector. 

These programmable I/O are represented by binary bit patterns, and it is the bit pattern that you 

reference when programming and checking the status of specific inputs and outputs. The bit 

pattern is referenced in commands like WAIT(IN.4=b1), which means wait until onboard 

programmable input #4 (TRG-2B) becomes active. To ascertain your product’s I/O offering 

and bit patterns, refer to Chapter 3 (page 91). 


Creating Programs 

Reminder: 

The Motion Planner Wizards interface makes programming easy, eliminates the need to 

learn the programming language and frees you from concerning yourself with syntax errors. 

A Start Wizard guides you through creating your program structure and configuring your 

Gem6K (drives, feedback, I/O, servo tuning, etc.). Additional wizards guide you through all 

other programming tasks, such as creating motion profiles, I/O handling, error handling, 

program logic and branching, etc. The Tag Name Dictionary allows you to label variables, 

axes, I/O so that you can program in terms that are relevant to your machine. If you have 

existing programs in an Editor, you can easily include them into the Wizard editor, so you 

don’t have to rewrite your code. For additional details about the Wizards programming 

interface, refer to page 2. 

A program is a series of commands. These commands are executed in the order in which they 

are programmed. Immediate commands (commands that begin with an exclamation point [!]) 

cannot be stored in a program. Only buffered commands may be used in a program. Refer to 

the program example below. 

Debugging Programs: 

Refer to page 221 for 

methods to isolate and 

resolve programming 

problems. 

A subroutine is defined the same as a program, but it is executed with an unconditional branch 

command, such as GOSUB, GOTO, or JUMP, from another program (see page 23 for details 

about unconditional branching). Subroutines can be nested up to 16 levels deep. NOTE: The 

Gem6K family does not support recursive calling of subroutines. 

Compiled profiles & PLC programs are defined like programs, using the DEF and END 

commands, but are compiled with the PCOMP command and executed with the PRUN 

command (PLC programs are usually launched in PLC Scan Mode with the SCANP 

command). Compiled profiles and PLC programs also affect a different part of the product's 

memory, called compiled memory. A compiled profile is an individual axis profile (a series of 

GOBUF commands). A compiled PLC program is a pre-compiled program that mimics PLC 

functionality by scanning through the I/O faster than in normal program execution. For 

information on compiled profiles, refer to page 139; and for information on PLC programs, 

refer to page 120. 

Program Example 

The illustration below identifies the elements that comprise the general structure of a program. 

Use DEF to 

begin 

defining the 

program. 

Contents of the 

program. 

Use END to 

finish defining 

the program. 

Use DEL to 

delete the 

program (a 

precaution). 

; ********************************************************* 



; ********************************************************* 

DEL motion ; (a precaution) Delete program called "motion" 


DRIVE1 ; Enable drives on axes 1 and 2 

MC0 


A20 


V8 

; Set velocity to 8 units/sec, and 

D100000 

; Set distance to 100,000 counts on axis 1, and 

GO 

; Execute motion 

END 


These are command line comments, comprising a semi-colon and text. 

The comments are separated from the command by a tab. 

A carriage return is placed at the end of each command line. 


Storing Programs 

After a program or compiled program/profile is defined (DEF) or downloaded to the Gem6K 

controller, it is automatically stored in non-volatile memory (battery-backed RAM). 

Information on controlling memory allocation is provided below (see Memory Allocation). 

Memory Allocation 

Your controller's memory has two partitions: one for storing programs and one for storing 

compiled profiles & PLC programs. The allocation of memory to these two areas is 

controlled with the MEMORY command. 

“Programs” vs. ”Compiled Profiles & PLC Programs” 

Programs are defined with the DEF and END commands, as demonstrated in the Program 

Example on page 10. 

Compiled Profiles & PLC Programs are defined like programs, using the DEF and END 

commands, but are compiled with the PCOMP command and executed with the 

PRUN command (PLC programs are usually executed in PLC Scan Mode with the 

SCANP). A compiled profile (a series of GOBUF commands). A PLC program is a 

pre-compiled program that mimics PLC functionality by scanning through the I/O 

faster than in normal program execution. 

Programs intended to be compiled are stored in program memory. After they are 

compiled with the PCOMP command, they remain in program memory and the 

segments (see diagram below) from the compiled program are stored in compiled 

memory. The TDIR report indicates which programs are compiled as compiled 

profiles (“COMPILED AS A PATH”) and which programs are compiled as PLC 

programs (“COMPILED AS A PLC PROGRAM”) . 

For information on compiled profiles, refer to Compiled Motion Profiling on page 

139; and for information on PLC programs, refer to page 120. 

MEMORY 

command 

syntax 

(example) 

MEMORY150000,150000 

Memory allocation for 

Programs (bytes). 

Storage requirements 

depend on the number of 

ASCII characters in the 

program. 

Memory allocation for Compiled Profiles & Programs (bytes). 

Storage requirements depend on the number of segments 

(1 segment consumes 76 bytes). A segment could be one of 

these commands: 

Compiled Motion: 

GOBUF * 

PLOOP 

GOWHEN 

TRGFN 

POUTA 

POUTB 

PLC (PLCP) Program: 

IF ** 

ELSE 

NIF 

L 

LN 

OUT 

ANO 

EXE 

PEXE 

VARI ** 

VARB ** 

* GOBUF commands may require up to 4 segments. 

** IF statement require at least 2 segments, each AND or OR 

compound requires an additional segment. VARI and 

VARB each require 2 segments. 


The table below identifies memory allocation defaults and limits for all Gem6K Series 

products. When specifying the memory allocation, use only even numbers. The minimum 

storage capacity for one partition area (program or compiled) is 1,000 bytes. 

Feature 

All Other Products 

Total memory (bytes) 300,000 

Default allocation (program,compiled) 150000,150000 

Maximum allocation for programs 299000,1000 

Maximum allocation for compiled profiles 1000,299000 

& PLC programs 

Max. # of programs 400 

Max. # of labels 600 

Max. # of compiled profiles & PLC programs 300 

Max. # of compiled profile segments 2069 

Max. # of numeric variables (VAR) 225 

Max. # of integer variables (VARI) 225 

Max. # of binary variables (VARB) 125 

Max. # of string variables (VARS) 25 

When teaching variable data to a data program (DATP), be aware that the memory required 

for each data statement of four data points (43 bytes) is taken from the memory allocation for 

program storage (see Variable Arrays in Chapter 3, page 110, for details). 

CAUTION 

Using a memory allocation command (e.g., MEMORY200000,100000) will erase all existing 

programs and compiled profile segments & PLC programs. However, issuing the MEMORY 

command without parameters (i.e., type MEMORY to request the status of how the 

memory is allocated) will not affect existing programs or compiled segments/programs. 

Checking Memory Status 

To find out what programs reside in your controller's memory, and how much of the available 

memory is allocated for programs and compiled profile segments, issue the TDIR command 

(see example response below). Entering the TMEM command or the MEMORY command 

(without parameters) will also report the available memory for programs and compiled profile 

segments. 

Sample response to 

TDIR command 

*1 - SETUP USES 345 BYTES 

*2 - PIKPRT USES 333 BYTES 

*149322 OF 150000 BYTES (98%) PROGRAM MEMORY REMAINING 

*1973 OF 1973 SEGMENTS (100%) COMPILED MEMORY REMAINING 

Two system status bits (reported with the TSS and SS commands) are available to check when 

compiled profile segment storage is 75% full or 100% full. System status bit #29 is set when 

segment storage reaches 75% of capacity; bit #30 indicates when segment storage is 100% full. 


Executing Programs (options) 

Following is a list of the primary options for executing programs stored in your controller: 

Method Description See Also 

Execute from a terminal Type in the name of the program and press enter; or write a ------- 

emulator 

program to prompt the operator to select a program from the 

terminal. 

Execute as a subroutine 

from a “main” program 

Execute automatically 

when the controller is 

powered up 

Execute from a PLC 

program 

Execute a specific 

program with BCD 

weighted inputs 

Execute a specific 

program with a 

dedicated input 

“Call” from a high-level 

program 

Execute from an RP240 

(remote operator 

interface) 

Execute from your own 

custom Windows 

program 

Use a branch (GOTO, GOSUB, or JUMP) from the main program to 

execute another stored program. 

Assign a specific program as a startup program with the STARTP 

command. When you RESET or cycle power to the controller, the 

startup program is automatically executed. 

Write a PLC program that executes a program (using EXE or PEXE) 

based on a specific condition (e.g., input state). Use the SCANP 

command to launch the PLC program in the PLC Scan Mode. 

Define programmable inputs to function as BCD select inputs, each 

with a BCD weight. A specific program (identified by its number) is 

executed based on the combination of active BCD inputs. Related 

commands: INSELP and INFNCi-B or LIMFNCi-B. 

Define a programmable input to execute a specific program (by 

number). Related commands: INSELP and INFNCi-iP or 

LIMFNCi-P. 

Using a programming language such as BASIC or C, write a 

program that enables the computer to monitor processes and 

orchestrate motion and I/O by executing stored programs (or 

individual commands) in the controller. 

Execute a stored program from the RUN menu in the RP240’s 

standard menu system. 

Use a programming language (e.g., Visual Basic, Visual C++, etc.) 

and the Gem6K Communications Server (provided on the Motion 

Planner CD) to create your own windows application to control the 

Gem6K product. Also included with Motion Planner is PanelMaker, 

a Visual Basic scripting tool for developing your own customer user 

interfaces. 

Page 23 

Page 13 

Page 120 

Page 97 

Page 103 

Page 133 

Page 127 

--------- 

Creating and Executing a Set-up Program 

Wizards Can Help: 

The Motion Planner 

Start Wizard helps you 

with these setup 

programming tasks: 

• Create a Setup 

program that 

configures drives, 

feedback devices, 

scaling, limits (end of 

travel and home), 

and servo tuning. 

• Create a Main 

program, establish it 

as the power-up 

(STARTP) program, 

and include a 

GOSUB to the Setup 

program. 

The intent of the Setup program is to place the Gem6K controller in a ready state for 

subsequent motion control. The setup program must be called from the “main” program for 

your application; or you can designate (with STARTP) the setup program as the program to be 

automatically executed when the Gem6K product is powered up or when the RESET command 

is executed. The setup program typically contains elements such as feedback device 

configuration, tuning gain selections, programmable I/O definitions, scaling, homing 

configuration, variable initialization, etc. (more detail on these “basic” features is provided in 

Chapter 3, Basic Operation Setup). 

The basic process of creating a setup program is: 

1. Create a program to be used as the setup program. 

2. Save the program and download it to the Gem6K product. 

3. Execute the STARTP command to assign your new program as the “start-up” program 

(e.g., STARTP setup assigns the program called “setup” as the start-up program). The 

next time the controller is powered up or reset, the assigned STARTP program will be 

executed. 

Or call the setup program from the main program for your application. 


Program Security 

Issuing the INFNCi-Q or LIMFNCi-Q command enables the Program Security feature and 

assigns the Program Access function to the specified programmable input. The “i” represents 

the number of the programmable input to which you wish to assign the function (see page 91 

programmable input bit patterns for your product). 

The program security feature denies you access to the DEF, DEL, ERASE, MEMORY, INFNC, 

and LIMFNC commands until you activate the program access input. Being denied access to 

these commands effectively restricts altering the user memory allocation. If you try to use 

these commands when program security is active (program access input is not activated), you 

will receive the error message *ACCESS DENIED. 

For example, once you issue the INFNC5-Q command, onboard input #5 is assigned the 

program access function and access to the DEF, DEL, ERASE, MEMORY, INFNC, and 

LIMFNC commands will be denied until you activate onboard input #5. 

NOTE: To regain access to these commands without the use of the program access input, you 

must issue the INEN command to disable the program security input, make the required user 

memory changes, and then issue the INEN command to re-enable the input. For example, if 

input 3 on I/O brick 2 is assigned as the Program Security input, use 2INEN.3=1 to disable 

the input and leave it activated, make the necessary user memory changes, and then use 

2INEN.3=E to re-enable the input. 

Controlling Execution of Programs and the Command Buffer 

The Gem6K controller command buffer is capable of storing 2000 characters waiting to be 

processed. (This is separate from the memory allocated for program storage – see Memory 

Allocation, page 11.) COMEXC affects command execution. Three additional commands, 

COMEXL, COMEXR and COMEXS, affect the execution of programs and the command buffer. 

COMEXC (Continuous Command Execution) 

The COMEXC1 command enables the Continuous Command Execution Mode (default is 

COMEXC0). This mode allows the program to continue to the next command before motion is 

complete. This is useful for: 

• Monitoring other processes while motion is occurring 

• Performing calculations in advance of motion completion 

• Pre-emptive GOs — executing a new profile with new attributes (distance, accel/decel, 

velocity, positioning mode, and Following ratio ) before motion is complete: The 

motion profile underway is pre-empted with a new profile when a new GO is issued. 

The new GO both constructs and launches the pre-empting profile. Pre-emptive GOs are 

appropriate when the desired motion parameters are not known until motion is already 

underway. For a detailed description, refer to On-The-Fly Motion on page 155. 

• Pre-process the next move while the current move is in progress (see CAUTION note). 

This reduces the processing time for the subsequent move to only a few microseconds. 

CAUTION: Avoid executing moves prematurely 

With continuous command execution enabled (COMEXC1), if you wish motion to stop before 

executing the subsequent move, place a WAIT(AS.1=bØ) statement before the 

subsequent GO command. If you wish to ensure the load settles adequately before the next 

move, use the WAIT(AS.24=b1) command instead (this requires you to define end-ofmove 

settling criteria — see Target Zone Mode on page 84 for details). 


In the programming example below, by enabling the continuous command execution mode 

(COMEXC1), the controller is able to turn on output #3 after the encoder moves 4000 units of 

its 125000-unit move. Normally, with COMEXC disabled (COMEXCØ), command processing 

would be temporarily stopped at the GO1 command until motion is complete. 

Programming Example (portion of program only) 

COMEXC1 

;Enable continuous command execution mode 

D125000 

;Set distance 

V2 

;Set velocity 

A10 

;Set acceleration 

GO1 ;Initiate motion on axis 1 

WAIT(1PE>4000) ;Wait for the encoder position to exceed 4000 

OUTXX1 ;Turn on onboard programmable output #3 

WAIT(AS.1=b0) ;Wait for motion to complete on axis 1 (AS bit #1 = zero) 

OUTXX0 ;Turn off onboard programmable output #3 

COMEXL (Save Command Buffer on Limit) 

For more information 

on end-of-travel limits, 


The COMEXL command enables saving the command buffer and maintaining program 

execution when a hardware or software end-of-travel limit is encountered. COMEXL is axis 

specific (e.g., COMEXL1xx1xxx1 enables saving the buffer for axes 1, 4, and 8). 

• COMEXL0: (This is the default setting.) When a limit is hit, every command in the 

command buffer will be discarded and program execution will be terminated. 

• COMEXL1: When a limit is hit, all remaining commands in the command buffer will 

remain in the command buffer (excluding the command being executed at the time the 

limit is hit). 

COMEXR (Effect of Pause/Continue Input) 

The COMEXR command affects whether a “Pause” input (i.e., an input configured as a 

pause/continue input with the INFNCi-E command or the LIMFNCi-E command) will pause 

only program execution or both program execution and motion. 

COMEXRØ: (This is the default setting.) Upon receiving a pause input, only program execution 

will be paused; any motion in progress will continue to its predetermined destination. 

Releasing the pause input or issuing a !C command will resume program execution. 

COMEXR1: Upon receiving a pause input, both motion and program execution will be paused; 

the motion stop function is used to halt motion. After motion has come to a stop 

(not during deceleration), you can release the pause input or issue a !C command 

to resume motion and program execution. 

Other Ways to Pause 

• Issue the PS command before entering a series of buffered commands (to cause motion, 

activate outputs, etc.), then issue the !C command to execute the commands. 

• While program execution is in progress, issuing the !PS command stops program execution, 

but any move currently in progress will be completed. Resume program execution with the !C 

command. 


COMEXS (Save Command Buffer on Stop) 

The COMEXS command determines the impact on motion, program execution, and the 

command buffer when the Gem6K receives a Stop command (S, !S, S1, or !S1) or an 

external Stop input (an input assigned a stop function with INFNCi-D or LIMFNCi-D). 

COMEXS0: Under factory default conditions (COMEXS0), when the Gem6K receives a stop 

command (S, !S, S1, or !S1) or a stop input (INFNCi-D or LIMFNCi-D), the 

following will happen: 

• Motion decelerates to a stop, using the present AD and ADA deceleration 

values. The motion profile cannot be resumed. 

• If S, !S or Stop input: 

– All commands in the Gem6K’s command buffer are discarded. 

– Program execution is terminated and cannot be resumed. 

• If S1, or !S1 (an axis number is included in the command): 

– All commands in the Gem6K’s command buffer are retained. 

– Program execution continues. 

COMEXS1: Using the COMEXS1 mode, the Gem6K allows more flexibility in responding to 

stop conditions, depending on the stop method (see table below). 

Stop Method 

What Stops 

Motion Program 

Resume Motion Profile. 

(Allow resume with a !C 

command or a resume 

input * ) 

Resume Program. 

(Allow resume with a 

!C command or a 

resume input * ) 

!S or S Yes Yes Yes Yes Yes 

!S1 or S1 Yes No No No Yes 

Stop input Yes Yes No Yes Yes 

Pause input * Yes Yes Yes Yes Yes 

(if COMEXR1) 

Pause input * 

(if COMEXR0) 

No Yes No Yes Yes 

Save Command Buffer. 

(Save the commands that 

were in the command 

buffer when the stop was 

commanded) 

* A Pause input is an input configured with the INFNCi-E command or the LIMFNCi-E command. This is also 

the Resume input that can be used to resume motion and program execution after motion is stopped. 

COMEXS2: Using the COMEXS2 mode, the Gem6K responds as it does in the COMEXS0 mode, 

with the exception that you can still use the program-select inputs to select programs 

(INSELP value is retained). The program-select input functions are: BCD select 

(INFNCi-B or LIMFNCi-B) – see page 97, and one-to-one select (INFNCi-P or 

LIMFNCi-P) – see page 103. 


Restricted Commands During Motion 

When motion is in progress on a given axis (or task), some commands cannot have their 

parameters changed until motion is complete (see table below). 

For the commands identified in the table, if the continuous command execution mode is 

enabled (COMEXC1) and you try to enter new command parameters, you will receive the error 

response MOTION IN PROGRESS. If the continuous command execution mode in disabled 

(COMEXCØ), which is the default setting, you will receive the response MOTION IN 

PROGRESS only if you precede the command with the immediate (!) modifier (e.g., !V2Ø); 

if you enter a command without the immediate modifier (e.g., V2Ø), you will not receive an 

error response and the new parameter will be ignored and the old parameter will remain in 

effect. 

Multi-Tasking 

If you are using multi-tasking, the restriction on commands is applicable only for the task to 

which the command is direct. For example, suppose axes 1 and 2 are associated with Task 1 

(TSKAX1,2) and axes 3 and 4 are associate with Task 2 (TSKAX3,4). If motion is in progress 

on axes 1 and 2, Task 1 is considered “in motion” and Task 1 cannot execute a command 

from the list below. However, while motion is in progress in Task 1 and not Task 2, Task 2 

may execute these commands without encountering an error. 

All of the commands in the table below, except for SCALE, are axis-dependent. That is, if 

one axis is moving you can change the parameters on the other axes, provided they are not in 

motion. 

Command Description Command Description 

CMDDIR.........Commanded Direction Polarity JOY............... Joystick Mode Enable 

DRES .............Drive Resolution 

JOYA............. Joystick Acceleration 

DRIVE...........Drive Shutdown 

JOYAA .......... Average Joystick Acceleration 

ENCPOL.........Encoder Polarity 

JOYAD .......... Joystick Deceleration 

ERES .............Encoder Resolution 

JOYADA ........ Average Joystick Deceleration 

FOLEN...........Following Mode Enable 

JOYVH .......... Joystick Velocity High 

HOM ...............Go Home 

JOYVL .......... Joystick Velocity Low 

HOMA .............Home Acceleration 

LHAD............. Hard Limit Deceleration 

HOMAA...........Average Home Acceleration 

LHADA .......... Average Hard Limit Deceleration 

HOMAD...........Home Deceleration 

LSAD............. Soft Limit Deceleration 

HOMADA.........Average Home Deceleration 

LSADA .......... Average Soft Limit Deceleration 

HOMV .............Home Velocity 

PSET............. Establish Absolute Position 

HOMVF...........Home Final Velocity SCALE .......... Enable/Disable Scale Factors * 

JOG ...............Jog Mode Enable 

JOGA .............Jog Acceleration 

JOGAA...........Average Jog Acceleration 

JOGAD...........Jog Deceleration 

JOGADA.........Average Jog Deceleration 

JOGVH...........Jog Velocity High 

JOGVL...........Jog Velocity Low 

SCLA............. Acceleration Scale Factor 

SCLD............. Distance Scale Factor 

SCLV............. Velocity Scale Factor 

* If any axis is in motion, you will cause an error if you attempt to change this command's parameters. 


Variables 

Gem6K Series controllers have four types of variables, each designated with a different 

command. All four types are automatically stored in non-volatile memory. 

Type Command Quantity Function 

Numeric 

(real) 

VAR 225 Store real numeric data (range is ±999,999,999.99999999). Can be 

used to perform mathematical (=, +, -, *, /, SQRT), trigonometric 

(ATAN, COS, PI, SIN, TAN), and Boolean (&, |, ^, ~) operations. 

Can also be used to store (“teach”) variable data in variable arrays 

(called data programs) and later use the stored data as a source for 

motion program parameters (see Variable Arrays on page 110 for 

details). 

Integer VARI 225 Store integer numeric data (range is ±2,147,483,647). Can be used 

to perform mathematical (=, +, -, *, /) and Boolean (&, |, ^, ~) 

operations. 

Binary VARB 125 Store 32-bit binary or hexadecimal values. Can also store the binary 

status bits from status registers. Frequently used registers are: 

inputs (IN), outputs (OUT), limits (LIM), system (SS), Following (FS), 

axis (AS & ASX), and error (ER). For example, the VARB2=IN.3 

command assigns the binary state of input 12 to binary variable 2. 

Also use to perform bitwise operations (&, |, ^, ~, >>,

Using Numeric (VAR and VARI) Variables 

NOTES 

• The examples below show the use of real numeric variables (VAR). Integer variables may 

be used in the same operations with these exceptions: 

- Values are truncated to nearest integer value 

- Operations using square root (SQRT) and trigonometric (ATAN, COS, PI, SIN, TAN) 

operators are not allowed 

• Some numeric variable operations reduce precision. The following operations reduce the 

precision of the return value: Division and Trigonometric functions yield 5 decimal places; 

Square Root yields 3 decimal places; and Inverse Trigonometric functions yield 2 decimal 

places. 

Mathematical 

Operations 

The following examples demonstrate how to perform math operations with numeric variables. 

Operator precedence occurs from left to right (e.g., VAR1=1+1+1∗3 sets VAR1 to 9, not 5). 

Addition (+) Example Response 

VAR1=5+5+5+5+5+5+5 

VAR1 

*VAR1=35.0 

VAR23=1000.565 

VAR11=VAR1+VAR23 

VAR11 

*VAR11=+1035.565 

VAR1=VAR1+5 

VAR1 

*VAR1=+40.0 

Subtraction (-) Example Response 

VAR3=20-10 

VAR20=15.5 

VAR3=VAR3-VAR20 

VAR3 

*VAR3=-5.5 

Multiplication (*) Example Response 

VAR3=10 

VAR3=VAR3*20 

VAR3 

*VAR3=+200.0 

Division (/) Example Response 

VAR3=10 

VAR20=15.5 

VAR20 *+15.5 

VAR3=VAR3/VAR20 

VAR3 *+0.64516 

VAR30=75 

VAR30 *+75.0 

VAR19=VAR30/VAR3 

VAR19 *+116.25023 

Square Root (SQRT) Example Response 

VAR3=75 

VAR20=25 

VAR3=SQRT(VAR3) 

VAR3 *+8.660 

VAR20=SQRT(VAR20)+SQRT(9) 

VAR20 *+8.0 


Trigonometric 

Operations 

The examples below demonstrate how to perform trigonometric operations with numeric 

variables. 

Sine Example Response 

RADIAN0 

VAR1=SIN(0) 

VAR1 

*VAR1=+0.0 

VAR1=SIN(30) 

VAR1 

*VAR1=+0.5 

VAR1=SIN(45) 

VAR1 

*VAR1=+0.70711 

VAR1=SIN(60) 

VAR1 

*VAR1=+0.86603 

VAR1=SIN(90) 

VAR1 

*VAR1=+1.0 

RADIAN1 

VAR1=SIN(0) 

VAR1 

*VAR1=+0.0 

VAR1=SIN(PI/6) 

VAR1 

*VAR1=+0.5 


VAR1 

*VAR1=+0.70711 


VAR1 

*VAR1=+0.86603 


VAR1 

*VAR1=+1.0 

Cosine Example Response 

RADIAN0 

VAR1=COS(0) 

VAR1 

*VAR1=+1.0 

VAR1=COS(30) 

VAR1 

*VAR1=+0.86603 

VAR1=COS(45) 

VAR1 

*VAR1=+0.70711 

VAR1=COS(60) 

VAR1 

*VAR1=+0.5 

VAR1=COS(90) 

VAR1 

*VAR1=+0.0 

RADIAN1 

VAR1=COS(0) 

VAR1 

*VAR1=+1.0 

VAR1=COS(PI/6) 

VAR1 

*VAR1=+0.86603 


VAR1 

*VAR1=+0.70711 


VAR1 

*VAR1=+0.5 


VAR1 

*VAR1=+0.0 


Tangent Example Response 

RADIAN0 

VAR1=TAN(0) 

VAR1 

*VAR1=+0.0 

VAR1=TAN(30) 

VAR1 

*VAR1=+0.57735 

VAR1=TAN(45) 

VAR1 

*VAR1=+1.0 

VAR1=TAN(60) 

VAR1 

*VAR1=+1.73205 

RADIAN1 

VAR1=TAN(0) 

VAR1 

*VAR1=+0.0 

VAR1=TAN(PI/6) 

VAR1 

*VAR1=+0.57735 


VAR1 

*VAR1=+1.0 


VAR1 

*VAR1=+1.73205 

Inverse Tangent 

(Arc Tangent) 

Example 

RADIAN0 

VAR1=SQRT(2) 

VAR1=ATAN(VAR1/2) 

VAR1 

VAR1=ATAN(.57735) 

VAR1 

Response 

*VAR1=+35.26 

*VAR1=+30.0 

Boolean Operations 

Gem6K Series products have the ability to perform Boolean operations with numeric variables. 

The following examples illustrate this capability. Refer to the Gem6K Series Command 

Reference for more information on each operator (&, |, ^, and ~). 

Boolean And (&) Example Response 

VAR1=5 

VAR2=-1 

VAR3=VAR1 & VAR2 

VAR3 

*VAR3=+0.0 

Boolean Or (|) Example Response 

VAR1=5 

VAR2=-1 

VAR3=VAR1 | VAR2 

VAR3 

*VAR3=+1.0 

Boolean Exclusive 

Or (^) 

Example 

VAR1=5 

VAR2=-1 

VAR3=VAR1 ^ VAR2 

VAR3 

Response 

*VAR3=+1.0 

Boolean Not (~) Example Response 

VAR1=5 

VAR3=~(VAR1) 

VAR3 

*VAR3=+0.0 

VAR1=-1 

VAR3=~(VAR1) 

VAR3 

*VAR3=+1.0 


Using Binary Variables 

The following examples illustrate the Gem6K Series product's ability to perform bitwise 

functions with binary variables. 

Storing binary values. The Gem6K Series Language allows you to store binary numbers in 

the binary variables (VARB) command. The binary variables start at the left with the least 

significant bit, and increase to the right. For example, to set bit 1, 5, and 7 you would issue 

the command VARB1=b1xxx1x1. Notice that the letter b is required. When assigning a 

binary variable, any bit set to “x” remains “x” until set to “1” or “0”. Any bit that is 

unspecified is set to “x”. To change, or check, one bit without affecting the others, use the bitselect 

operator (e.g., use VARB1.3-1 to set only bit #3 of VARB1). 

Example 

VARB1=b1101XX1 

Response 

*VARB1=1101_XX1X_XXXX_XXXX_XXXX_XXXX_XXXX_XXXX 

Storing hexadecimal values. Hexadecimal values can also be stored in binary variables 

(VARB). The hexadecimal value must be specified the same as the binary value—left is least 

significant byte, right is most significant. For example, to set bit 1, 5, and 7 you would issue 

the command VARB1=h15. Notice that the letter h is required. NOTE: When assigning a 

hexadecimal value to a binary variable, all unspecified bits are set to zero. 

Example 

VARB1=h7FAD 

VARB1 

Response 

*VARB1=1110_1111_0101_1011_0000_0000_0000_0000 

Bitwise And (&) Example Response 

VARB1=b1101 

VARB1 

*VARB1=1101_XXXX_XXXX_XXXX_XXXX_XXXX_XXXX_XXXX 

VARB1=VARB1 & bXXX1 1101 

VARB1 

*VARB1=XX01_XX0X_XXXX_XXXX_XXXX_XXXX_XXXX_XXXX 

VARB1=h0032 FDA1 & h1234 43E9 

VARB1 

*VARB1=0000_0000_1100_0000_0010_1000_0101_1000 

Bitwise Or (|) Example Response 

VARB1=h32FD 

VARB1 

*VARB1=1100_0100_1111_1011_0000_0000_0000_0000 

VARB1=VARB1 | bXXX1 1101 

VARB1 

*VARB1=11X1_1101_1111_1X11_XXXX_XXXX_XXXX_XXXX 

VARB1=h0032 FDA1 | h1234 43E9 

VARB1 

*VARB1=1000_0100_1100_0110_1111_1111_0111_1001 

Bitwise Exclusive 

Or (^) 

Example 

Response 

VARB1=h32FD ^ bXXX1 1101 

VARB1 

*VARB1=XXX1_1001_XXXX_XXXX_XXXX_XXXX_XXXX_XXXX 

VARB1=h0032 FDA1 ^ h1234 43E9 

VARB1 

*VARB1=1000_0100_0000_0110_1101_0111_0010_0001 

Bitwise Not (~) Example Response 

VARB1=~(h32FD) 

VARB1 

*VARB1=0011_1011_0000_0100_1111_1111_1111_1111 

VARB1=~(b1010 XX11 0101) 

VARB1 

*VARB1=0101_XX00_1010_XXXX_XXXX_XXXX_XXXX_XXXX 

Shift Left to Right 

(>>) 

Example 

Response 

VARB1=h32FD >> h4 

VARB1 

*VARB1=0000_1100_0100_1111_1011_0000_0000_0000 

VARB1=b1010 XX11 0101 >> b11 

VARB1 

*VARB1=0001_010X_X110_101X_XXXX_XXXX_XXXX_XXXX 

Shift Right to Left 

(

Program flow refers to the order in which commands will be executed, and when or whether 

they will be executed at all. In general, commands are executed in the order in which they are 

received. However, certain commands can redirect the order in which commands will be 

processed. 

You can affect program flow with: 

• Unconditional Loops and Branches 

• Conditional Loops and Branches 

Unconditional Looping and Branching 

Unconditional 

Looping 

The Loop (L) command is an unconditional looping command. You may use this command to 

repeat the execution of a group of commands for a predetermined number of iterations. You 

can nest Loop commands up to 16 levels deep. The code sample (portion of a program) below 

demonstrates a loop of 5 iterations. 

MA0 ; Sets unit to Incremental mode 

A50 ; Sets acceleration to 50 

V5 ; Sets velocity to 5 

L5 ; Loops 5 times 

D2000 ; Sets distance to 2,000 

GO1 ; Executes the move (Go) 

T2 ; Delays 2 seconds after the move 

LN ; Ends loop 

Unconditional 

Branching 

When an unconditional branch is processed, the flow of program execution (“control”) passes 

to the program or label specified in the branch command. Depending on the branch command 

used, processing may or may not return to the original program (the “calling” program). There 

are three ways to branch unconditionally: 

GOSUB: The GOSUB command branches to the program name or label stated in the GOSUB 

command. After the called program or label is executed, processing returns to the 

calling program at the next command line after the GOSUB branch command. 

GOTO: 

JUMP: 

The GOTO command branches to the program name or label stated in the GOTO 

command. After the called program or label is executed, processing does not return 

to the calling program—instead, the program will end. This holds true unless the 

subroutine in which the GOTO resides was called with a GOSUB by another 

program; in this case, the END in the GOTO program will initiate a return to the 

calling program. For example, if processing flows from a GOSUB in program A to 

program B, and then a GOTO from program B to program C, when the END 

command is processed in program C, processing returns to program A at the 

command line after the GOSUB. 

The JUMP command branches to the program name or label stated in the JUMP 

command. All nested IFs, WHILEs, and REPEATs, loops (L), and subroutines are 

cleared; thus, the program or label that the JUMP initiates will not return control to 

the calling program; instead, the called program will end. 

If an invalid program or label name is entered, the branch command will be ignored and 

processing will continue with the next line in the program. 

Gem6K Series products do not support recursive calling of subroutines. 

Using labels: Labels, defined with the $ command, provide a method of branching to specific 

locations within the same program. Labels can only be defined within a program and executed 

with a GOTO, GOSUB, or JUMP command from within the same program (see Example B below). 


NOTE 

Be careful about performing a GOTO within a loop or branch statement area (i.e., between 

L & LN, between IF & NIF, between REPEAT & UNTIL, or between WHILE & NWHILE). 

Branching to a different location within the same program will cause the next L, IF, REPEAT, 

or WHILE statement encountered to be nested within the previous L, IF, REPEAT, or WHILE 

statement area, unless an LN, NIF, UNTIL, or NWHILE command has already been 

encountered. 

** To avoid this nesting situation, use the JUMP command instead of the GOTO command. 

Example A 

DESCRIPTION: The program cut1 is executed until it gets to the command GOSUB 

prompt. From there it branches unconditionally to the subroutine (actually a program) called 

prompt. The subroutine prompt queries the operator for the number of parts to process. 

After the part number is entered (e.g., operator enters the !'12 command to process 12 parts), 

the rest of the prompt subroutine is executed and control goes back to the cut1 program and 

resumes program execution with the next command after the GOSUB, which is MAØØ. 

DEL cut1 

; Delete a program before defining it 

DEF cut1 

; Begin definition of program cut1 

HOM11 

; Send axes 1 and 2 to the home position 

WAIT(1AS=b0XXX1 AND 2AS=b0XXX1) ; Wait for axes 1 and 2 to come 

; to a halt at home 

GOSUB prompt 

; Go to subroutine program called prompt 

MA00 

; Place axes 1 and 2 in the incremental mode 

A10,30 ; Set acceleration: axis 1 = 10, axis 2 = 30 

AD5,12 ; Set deceleration: axis 1 = 5, axis 2 = 12 

V5,8 ; Set velocity: axis 1 = 5, axis 2 = 8 

D16000,100000 ; Set distance: axis 1 = 16,000; axis 2 = 100,000 

OUT.3-1 ; Turn on onboard output number 3 

T5 

; Wait for 5 seconds 

L(VAR2) 

; Begin loop (number of loops = value of VAR2) 

GO11 ; Initiate moves on axes 1 and 2 

T3 

; Wait for 3 seconds 

LN 

; End loop 

OUT.3-0 ; Turn off onboard output number 3 

END 

; End definition of program cut1 

DEF prompt 

; Begin definition of program prompt 

VARS1="Enter part count >" ; Place message in string variable #1 

VAR2=READ1 ; Prompt operator with string variable #1, 

; and read data into numeric variable #2 

; NOTE: Type !' before the part count number. 

END 

; End definition of program prompt 

Example B DESCRIPTION: This example demonstrates the use of labels ($). 

DEL pick 

; Delete a program before defining it 

DEF pick 

; Begin definition of program pick 

GO1100 ; Initiate motion and axes 1 and 2 

IF(VAR1=5) 

; If variable 1 = 5, then execute commands 

; between IF and ELSE. Otherwise, execute 

; commands between ELSE and NIF 

GOTO pick1 

; Goto label pick1 

ELSE 

; Else part of IF statement 

GOTO pick2 

; Goto label pick2 

NIF 

; End of IF statement 

$ pick1 ; Define label for pick1 

GO0011 ; Initiate motion on axes 3 and 4 

BREAK 

; Break out of current subroutine or program 

$ pick2 ; Define label for pick2 

GO1001 ; Initiate motion on axes 1 and 4 

END 

; End definition of program pick 


Conditional Looping and Branching 

Flow Control 

Expression 

Examples 

Conditional looping (REPEAT/UNTIL and WHILE/NWHILE) entails repeating a set of 

commands until or while a certain condition exists. In conditional branching 

(IF/ELSE/NIF), a specific set of commands is executed based on a certain condition. Both 

rely on the fulfillment of a conditional expression, a condition specified in the UNTIL, 

WHILE, or IF commands. 

A WAIT command pauses command execution until a specific condition exists. 

This section provides examples of expressions that can be used in conditional branching and 

looping commands (UNTIL, WHILE, and IF) and the WAIT command. These expressions can 

be constructed, in conjunction with relational and logical operators, with the following 

operands: 

• Numeric variables and binary variables 

• Inputs and outputs 

• Current motion parameters and status 

• Current commanded and actual position 

• Error, axis, and system status 

• Timer value 

• Data read from the serial port 

• Data read from the RP240 

• Following conditions 

• Multi-tasking conditions 

Numeric and Binary 

Variables 

A numeric variable (VAR or VARI) can be used within an expression if it is compared against 

another numeric variable, a value, or one of the comparison commands (see list on page 7). 

When comparing a variable against another value, variable, or comparison command, the 

relational operators (=, >, >=, =, =, , >=,

Expression 

(VAR1, >=,

RP240 Data Read 

Immediate Mode 

The DREADI1 command allows continual numeric or function key data entry from the RP240 

(when used in conjunction with the DREAD and/or DREADF commands). In this immediate 

mode, program execution is not paused (waiting for data entry) when a DREAD or DREADF 

command is encountered. Refer to the DREAD and DREADF command descriptions for 

programming examples. 

NOTES 

• While in the Data Read Immediate Mode, data is read into numeric variables only (VAR). 

• This feature is not designed to be used in conjunction with the RP240's standard menus; 

the RUN, JOG, and DJOG menus will disable the DREADI mode. 

• Do not assign the same variable to read numeric data and function key data—pick only one. 

Following Conditions These Following conditions are available for conditional expressions: Axis status bit #26 

(AS.26), Error status bit #14 (ER.14), Following status (FS), NMCY, PCME, PCMS, PMAS, 

PME, PSHF, PSLV, and VMAS. 

Expression 

(2AS.26=b1) 

(1ER.14=b1) 

(3FS.7=b0) 

(2NMCY>200) 

(1PMAS>12) 

(1PSHF>1.5) 

(3PSLV>24) 

(1VMAS

UNTIL(IN=b1110 OR VAR5>10) ; When inputs 1-4 are 1110, respectively, or 

; VAR5 is greater than 10, the loop will stop. 

OUT1 

; Turn on output 1 when finished with REPEAT loop 

END 

; End program definition 

RUN prog10 ; Initiate program prog10 

All commands between WHILE and NWHILE are repeated as long as the WHILE condition is 

true. The following example illustrates how a typical WHILE/NWHILE conditional loop 

works. In this example, the WHILE loop will execute if the expression is true. If the 

expression is false, the WHILE loop will not execute. 

VAR5=0 ; Initializes variable 5 to 0 

DEL prog10 ; Delete a program before defining it 

DEF prog10 ; Defines program prog10 

INFNC1-A 

; Assign onboard input 1 as g.p. input for use with IN 

INFNC2-A 


INFNC3-A 


INFNC4-A 


OUTFNC1-A ; Assign onboard output 1 is a general-purpose output 

A50 ; Acceleration is 50 

AD50 ; Deceleration is 50 


D25000 ; Distance is 25,000 

WHILE(IN=b1110 OR VAR5>10) ; While the inputs 1-4 are 1110, respectively 

; or VAR5 is greater than 10, the loop will continue. 

GO1 

; Executes the move (Go) 

VAR5=VAR5+1 ; Variable 5 counts up from 0 

NWHILE 

; End WHILE command 

OUT1 

; Turn on output 1 when finished with WHILE loop 

END 


; ***************************************************** 

; * To run prog10, execute the "RUN prog10" command * 

; ***************************************************** 

Conditional 

Branching 

You can use the IF command for conditional branching. All commands between IF and 

ELSE are executed if the expression contained within the parentheses of the IF command is 

true. If the expression is false, the commands between ELSE and NIF are executed. If the 

ELSE is not needed, it may be omitted. The commands between IF and NIF are executed if 

the expression is true. Examples of these commands are as follows. 

DEL prog10 ; Delete a program before defining it 

DEF prog10 ; Defines program prog10 

INFNC1-A 


INFNC2-A 


INFNC3-A 


INFNC4-A 





IF(VAR1>0) ; IF variable 1 is greater than zero 

D25000 ; Distance is 25,000 

ELSE 

; Else 

D50000 ; Distance is 50,000 

NIF 

; End if command 

IF(IN=b1110) ; If onboard inputs 1-4 are 1110, initiate axis 1 move 

GO1 

; Executes the move (Go) 

NIF 

; End IF command 

END 


; ***************************************************** 

; * To run prog10, execute the "RUN prog10" command * 

; ***************************************************** 


Program Interrupts (ON Conditions) 

Multi-Tasking 

Each task has its own 

ONP program and its 

own set of ON 

conditions. 

While executing a program, the Gem6K controller can interrupt the program based on several 

possible ON conditions: programmable input(s) status, user status, or the value of numeric 

variables #1 or #2. These ON conditions are enabled with the ONCOND command, and are 

defined with the commands listed below. After the ON conditions are enabled (with the 

ONCOND command), an ON condition interrupt can occur at any point in program execution. 

When an ON condition occurs, the controller performs a GOSUB to the program assigned as 

the ON program and then passes control back to the original program and resumes command 

execution at the command line from which the interruption occurred. 

Within the ON program, the programmer is responsible for checking which ON condition 

caused the branch (if multiple ON conditions are enabled with the ONCOND command). 

Once a branch to the ON program occurs, the ON program will not be called again until after 

it has finished executing. After returning from the ON program, the condition that caused the 

branch must evaluate false before another branch to the ON program will be allowed. 

SETUP FOR PROGRAM INTERRUPT (see programming example below) 

1. Define a program to be used as the ON program to which the controller will GOSUB 

when an ON condition evaluates true. 

2. Use the ONP command to assign the program as the ON program. 

3. Use the ONCOND command to enable the ON conditions that you are using. The syntax 

for the ONCOND command is ONCOND, where the first is for the ONIN 

condition, the second for ONUS, the third for ONVARA, and the fourth for ONVARB. 

ON conditions: 

ONIN 

ONUS 

ONVARA 

ONVARB 

Specify an input bit pattern that will cause a GOSUB to the program 

assigned as the ON program (see programming example below). 

Specify an user status bit pattern that will cause a GOSUB to the ON 

program. The user status bits are defined with the INDUST command. 

Specify the range of numeric variable #1 (VAR1) that will cause a GOSUB 

to the ON program. For example, ONVARAØ,2Ø establishes the condition 

that if the value of VAR1 is ≤0 or ≥20, the ON program will be called. 

This is the same function as ONVARA, but for numeric variable #2 (VAR2) 

Programming Example: Configures the controller to increment variable #1 when input #1 goes active. 

If input #1 does go active, control will be passed (GOSUB) to the ON program (onjump), the commands 

within the ON program will be executed, and control will then be passed back to the original program. 

DEF onjump ; Begin definition of program onjump 

VAR1=VAR1+1 ; Increment variable 1 

END 

; End definition of program onjump 

VAR1=0 ; Initialize variable 1 

ONIN1 

; When input 1 becomes active, branch to the ON program 

ONP onjump ; Assign the onjump program as the ON program 

ONCOND1000 ; Enable only the ONIN function. Disable the ONUS, 

; ONVARA, and ONVARB functions, respectively 

Situations in which ON 

conditions WILL NOT 

interrupt immediately 

These are situations in which an ON condition does not immediately interrupt the program in 

progress. However, the fact that the ON condition evaluated true is retained, and when the 

condition listed below is no longer preventing the interrupt, the interrupt will occur. 

• While motion is in progress due to GO, GOL, GOWHEN, HOM, JOY, JOG, or PRUN and the 

continuous command execution mode is disabled (COMEXCØ). 

• While a WAIT statement is in progress 

• While a time delay (T) is in progress 

• While a program is being defined (DEF) 

• While a pause (PS) is in progress 

• While a data read (DREAD, DREADI, DREADF, or READ) is in progress 


Error Handling 

Wizards can help: 

Motion Planner’s Wizard 

Editor provides an Error 

Program wizard that 

creates an Error program, 

provides safeguards for 

preventing unwanted calls 

to the Error program, and 

includes conditional code 

to handle the errors you 

wish to check. 

DEBUG TOOLS 

For information on 

program debug tools, 


The Gem6K Series products have the ability to detect and recover the following error conditions: 

Error bit 1* ........Stall Detected: Functions when stall detection has been enabled (ESTALL or DSTALL) 

and ESK1 is set. 

Error bit 2 ..........Hard Limit Hit: Functions when hard limits are enabled (LH). 

Error bit 3 ..........Soft Limit Hit: Functions when soft limits are enabled (LS). 

Error bit 4 ..........Drive Fault: Detected only if the drive is enabled (DRIVE1). 

Error bit 5 ..........Command Kill or Commanded Stop: K, !K,K, S, or !S command sent. 

Error bit 6 ..........Kill Input: When an input is defined as a Kill input (INFNCi-C) and that input 

becomes active. 

Error bit 7 ..........User Fault Input: When an input is defined as a User fault input (INFNCi-F) and that 

input becomes active. 

Error bit 8 ..........Stop Input: When an input is defined as a Stop input (INFNCi-D) and that input 

becomes active. 

Error bit 9 ..........Enable Input is activated (not grounded). 

Error bit 10 ........Pre-emptive (on-the-fly) GO or a registration move not possible 

Error bit 11** ....Target zone settling timeout period (set with the STRGTT command) is exceeded. 

Error bit 12** ....Maximum position error (set with the SMPER command) is exceeded. 

Error bit 13 ........RESERVED. 

Error bit 14 ........GOWHEN condition already true when GO, FSHFC, or FSHFD was executed 


Error bit 16 ........Bad command detected (bit is cleared with TCMDER command). 


Error bit 18 ........Cable to expansion I/O brick is disconnected or power to the I/O brick is lost; error is 

cleared by reconnecting to I/O brick and issuing the ERROR.18-0 command and then 

the ERROR.18-1 command. (Multi-tasking: this condition also kills all tasks.) 

Error bits 19-22 .RESERVED. 

Error bit 23 ........Error bit 20 RESERVED. 

Error bit 23 ........Ethernet Client connection error. 

Error bit 24 ........Error bit 24 Ethernet Client polling error. 

Error bit 25-32...RESERVED. 

* Steppers only 

** Servos only 


Enabling Error Checking 

To detect and respond to the error conditions noted above, the corresponding error-checking 

bit(s) must be enabled with the ERROR command (refer to the ERROR Bit # column in the 

table below). If an error condition occurs and the associated error-checking bit has been 

enabled with the ERROR command, the Gem6K controller will branch to the error program. 

For example, if you wish the Gem6K controller to branch to the error program when a 

hardware end-of-travel limit is encountered (error bit #2) or when a drive fault occurs (error 

bit #4), you would issue the ERRORØ1Ø1 command to enable error-checking bits #2 and #4. 

MULTI-TASKING 

If you are operating multiple tasks, be aware that you must enable error conditions (ERROR) and 

specify an error program (ERRORP) for each task (e.g., 2%ERROR.2-1 and 2%ERRORP FIX for 

Task 2). Each task has its own error status register (reported with ER, TER, and TERF). 

Regarding axis-related error conditions (e.g., drive fault, end-of-travel limit, etc.), only errors on 

the task’s associated (TSKAX) axes will cause a branch to the task’s ERRORP program. 

☞ Helpful Hint: 

Within the structure of your error program, you can use the IF and ER 

commands to check which error caused the call to the ERRORP program 

and respond accordingly. 

Defining the Error Program 

The purpose of the error program is to provide a programmed response to certain error 

conditions (see list above) that may occur during the operation of your system. Programmed 

responses typically include actions such as shutting down the drive(s), activating or deactivating 

outputs, etc. Refer to the error program set-up example below. 

Using the ERRORP command, you can assign any previously defined program as the error 

program. For example, to assign a previously defined program named CRASH as the error 

program, enter the ERRORP CRASH command. To un-assign a program from being the error 

program, issue the ERRORP CLR command (e.g., as in this example, it does not delete the 

CRASH program, but merely unlinks it from its assignment as the error program). 


Canceling the Branch to the Error Program 

NOTE: In addition to 

canceling the branch to 

the error program, you 

must also remedy the 

cause of the error; 

otherwise, the error 

program will be called 

again when you resume 

operation. Refer to the 

How to Remedy the 

Error column in the table 

below for details. 

If an error condition occurs and the associated error-checking bit has been enabled with the 

ERROR command, the Gem6K controller will branch to the error program. The error program 

will be continuously called/repeated until you cancel the branch to the error program. (This is 

true for all cases except error condition #9, ENABLE input activated, in which case the error 

program is called only once.) 

There are three options for canceling the branch to the error program: 

• Disable the error-checking bit with the ERROR.n-Ø command, where "n" is the 

number of the error-checking bit you wish to disable. For example, to disable error 

checking for the kill input activation (bit #6), issue the ERROR.6-Ø command. To reenable 

the error-checking bit, issue the ERROR.n-1 command. 

• Delete the program assigned as the ERRORP program (DEL ). 

• Satisfy the How to Remedy the Error requirement identified in the table below. 

ERROR 

Bit # 

Cause of the Error 

Branch Type to Error 

Program 

How to Remedy the Error 

1 Steppers only: Stall detected (Stall Detection and 

Kill On Stall must be enabled first—see ESTALL 

and ESK, respectively). 

Gosub 

Issue a GO command. 

2 Hard Limit Hit. 

(hard limits must be enabled first—see LH) 

3 Soft Limit Hit. 

(soft limits must be enabled first—see LS) 

If COMEXLØ, then Goto; 

If COMEXL1, then Gosub 

If COMEXLØ, then Goto; 

If COMEXL1, then Gosub 

Change direction & issue GO command on the axis 

that hit the limit; or issue LHØ. 

Change direction & issue GO command on the axis 

that hit the limit; or issue LSØ. 

4 Drive Fault (Detected only if you enable drive, 

DRIVE1, and drive fault input, DRFEN.) 

5 Commanded Stop or Kill (whenever a K, !K, 

K, K, or !S command is sent). 

See note below entitled 

“Commanded Kill or Stop”. 

Goto 

If !K, then Goto; 

If !S & COMEXSØ, then 

Goto; 

If !S & COMEXS1, then 

Gosub, but need !C 

Clear the fault condition at the drive, & issue a 

DRIVE1 command for the faulted axis. 

No fault condition is present—there is no error to 

clear. 

If you want the program to stop, you must issue 

the !HALT command. 

6 Kill Input Activated (see INFNCi-C or LIMFNCi-C) Goto Deactivate the kill input. 

7 User Fault Input Activated 

(see INFNCi-F or LIMFNCi-F). 

8 Stop input activated 

(see INFNCi-D or LIMFNCi-C). 

Goto 

Goto 

Deactivate the user fault input, or disable it by 

assigning it a different function (INFNC or 

LIMFNC). 

Deactivate the stop input, or disable it by assigning 

it a different function. 

9 ENABLE input not grounded. (see “ESTOP” below) Goto Re-ground ENABLE input, and issue @DRIVE1. 

10 Profile for pre-emptive GO or registration move not 

possible at the time of attempted execution. 

11 Servos only: Target Zone Timeout (STRGTT value 

has been exceeded). 

Gosub 

Gosub 

Issue another GO command. 

Issue these commands in this order: 

STRGTEØ, DØ, GO, STRGTE1 


12 Servos only: Exceeded Max. Allowable Position 

Error (set with the SMPER command). 

Gosub 

Issue a DRIVE1 command to the axis that 

exceeded the allowable position error. Verify that 

feedback device is working properly. 

14 GOWHEN condition was already true when the 

subsequent GO, GOL, FGADV, FSHFC, or FSHFD 

command was executed. 

Goto Issue another GOWHEN command; or issue a !K 

command and check the program logic (use the 

TRACE and STEP features if necessary). 

16 Bad command was detected. Gosub Issue the TCMDER command to I.D. the command. 

17 Encoder failure detected (EFAIL1 must be 

enabled before this error can be detected). 

18 Cable to an expansion I/O brick is disconnected, 

or power to the I/O brick is lost. 

23 Ethernet Client connection error. See the Ethernet 

Client section for additional details. 

24 Ethernet Client polling error. See the Ethernet 

Client section for additional details. 

Gosub 

Goto 

Gosub 

Gosub 

Reconnect the encoder while the axis is in the 

EFAIL1 mode. 

Reconnect I/O brick cable. Issue the ERROR.18-0 

command and then the ERROR.18-1 command. 

Reserved Bits: Bits 13, 15, 19-22 and 25-32. 

Branching Types: If the error condition calls for a GOSUB, then after the ERRORP program is executed, program control returns to the point 

at which the error occurred. To prevent a return to the point at which the error occurred, use the HALT command to end program execution or 

use the GOTO command to go to a different program. If the error condition calls for a GOTO, there is no way to return to the point at which the 

error occurred. 

Commanded Kill or Stop: When ERROR bit 5 is enabled (ERROR.5-1), a Stop (S or !S) or a Kill (K, !K or K) command will cause the 

controller to branch to the error program. Note, however, that this error condition does not set an error bit (ER), because there is no way to 

clear the error condition upon leaving the error program. Therefore, you should use the IF(ER=b00000000000000000000000000000000) 

statement in your error program to determine if the cause of the error was a commanded kill or stop (i.e., if no error bits are set). 

If ESTOP (ENABLE input) also cuts power to drives: This note is for systems in which power to the drives (not the Gem6K) is cut if the 

ENABLE input is opened. If you enable ERROR bit #9: When the ENABLE input is opened (and power is cut to the drives), the ERRORP 

program is called. Because the drives have lost power, the Gem6K will detect drive faults, which in turn kills the ERRORP program. If the 

ENABLE input is still ungrounded, the ERRORP program will again be called and then killed because of the drive fault condition (causing an 

endless loop). The resolution is to place the @DRFEN0 command in the ERRORP program so that it can disable checking the drive fault input 

and thereby circumvent the endless loop of calling the ERRORP program. Be sure to later re-enable drive fault checking with @DRFEN1 after the 

ENABLE input is re-grounded. 


Error Program Set-up Example 

The following is an example of how to set up an error program. This particular example is for 

handling the occurrence of a user fault. 

Step 1 

Create a program file (in Motion Planner’s Editor module) to set up the error program: 

; ******************************************************************** 

; * Assign the user fault input function to onboard trigger input 1. * 

; * The purpose of the user fault input is to detect the occurrence * 

; * of a fault external to the Gem6K controller and the motor/drive. * 

; * This input will generate an error condition. * 

; ******************************************************************** 

INFNC1-F 

; Define onboard trigger input #1 as a user fault input 

; ******************************************************************** 

; * Define a program to respond to the user fault (call the program * 

; * fault), and then assign that program as the error program. The * 

; * purpose of the fault program is to display a message to inform * 

; * the operator that the user fault input has been activated. * 

; ******************************************************************** 

DEL fault ; Delete a program before defining it (a precaution) 

DEF fault ; Begin definition of program fault 

IF(ER.7=b1) ; Check if error bit 7 equals 1 

; (which means the user fault input has been activated) 

WRITE"FAULT INPUT\10\13" ; Send the message FAULT INPUT 

T3 

; Wait 3 seconds 

NIF 

; End IF command 

END 

; End definition of program fault 

ERRORP fault ; Assign the program called fault as the error program 

; ******************************************************************** 

; * Enable the user fault error-checking bit by putting a “1” in * 

; * the seventh bit of the ERROR command. After enabling this * 

; * error-checking bit, the controller will branch to the error * 

; * program whenever the user fault input is activated. * 

; ******************************************************************** 

ERROR0000001 ; Branch to error program upon user fault input (As an 

; alternative to the ERROR0000001 command, you could also 

; enable bit #7 by issuing the ERROR.7-1 command.) 

Step 2 

Step 3 

Save the program file in the Editor module. Then, using the Terminal module, download the 

program file to the Gem6K controller. 

Test the error handling: 

1. While in the terminal emulator, enter these four commands: 

L 

; Loop command 

WRITE"IN LOOP\10\13" ; Display the message "IN LOOP" 

T2 

LN 

; Wait 2 seconds 

; End the loop ("IN LOOP" will be displayed 

; once every 2 seconds) 

2. While the loop (IN LOOP) is executing in the terminal emulator, enter the !INEN1 

command. The !INEN1 command disables input #1 and forces it on for testing 

purposes. This simulates the physical activation of input #1. (Since the error program is 

called continuously until the branch to the error program is canceled, the message FAULT 

INPUT will be repeatedly displayed once every 3 seconds.) 

3. While the FAULT INPUT loop is executing in the terminal emulator, enter the !INENE 

command. The !INENE command re-enables input #1. The message IN LOOP will not 

be displayed again, because the user fault input error is a GOTO branch (not a GOSUB 

branch) to the error program. 


Non-Volatile Memory 

The items listed below are automatically stored in the Gem6K product’s non-volatile memory 

(battery-backed RAM). Cycling power or issuing a RESET command will not affect these 

settings. 

• Power-up program (STARTP) 

• Programs (defined with DEF & END) 

• Compiled profiles and PLC programs (PCOMP). Compiled profiles and PLC programs are 

always saved in the Compiled portion of battery-backed RAM. However, compiled 

individual axis profiles (GOBUF profiles) are removed from Compiled memory if you run 

them with the PRUN command and later cycle power or reset the controller (you will 

have to re-compile them with the PCOMP command). 

• Memory allocation (MEMORY) 

• Axis type definition (AXSDEF) 

• Variables: VAR, VARI, VARB, and VARS 

• Scaling: SCALE, SCLA, SCLD, SCLV, SCLMAS 

• Commanded direction polarity (CMDDIR) 

• Encoder polarity (ENCPOL) 

• Device address for RS-232 or RS-485 serial communication (ADDR) 

• Baud rate for RS-232 or RS-485 serial communication (BAUD) 

• Ethernet IP address (NTADDR 

• Ethernet network mask (NTMASK) 

• RP240 check and serial port functionality (DRPCHK) 

• RP240 password (DPASS) 

• Servo gain sets (SGSET) 

A checksum is calculated for the non-volatile memory area each time you power up or reset 

your Gem6K controller. A bad checksum indicates that the user memory has been corrupted 

(possibly due to electrical noise) or has been cleared (due to a spent battery). The controller 

will clear all user memory when a bad checksum is calculated on power up or reset, and bit 22 

will be set in the TSS command response. 

System Performance 

Several commands (listed below), when enabled, will slow command processing. This 

degradation in performance will not be noticeable for most applications. But for some, it may 

be necessary to disable one or all of these commands. 

• SCALE (enable/disable scaling) 

• INDUSE (enable/disable user status updates) 

• INFNC (trigger and extended input functions; excluding functions “A” and “H”) 

• LIMFNC (limit input functions; excluding functions “A”, “R”, “S”, and “T”) 

• OUTFNC (digital output functions; excluding function “A”) 

• ONCOND (enable/disable ON conditions) 


Communication 

2C HAPTER TWO 

Communication 


• Communication options (protocols, connections)........................................................ 38 

• Motion Planner communication features ................................................................. 38 

• Ethernet Networking Overview: ................................................................................. 39 

− Networking Guidelines.......................................................................................... 56 

− Configuring the Gem6K for Ethernet Communications ........................................ 57 

− Networking with other 6K or Gem6K Products (peer-to-peer) ............................. 56 

− Networking with a DVT Vision System................................................................ 57 

− Networking with an Allen-Bradley SLC 5/05 PLC............................................... 56 

− Networking with OPTO22 SNAP I/O ................................................................... 56 

• Ethernet Client operation ............................................................................................. 39 

• Serial Communication: 

− Controlling multiple serial ports............................................................................ 56 

− RS-232C daisy-chaining........................................................................................ 57 

− RS-485 multi-drop................................................................................................. 60

Communication Options 

RS-232/485 

+24V DC 

24V RTN 

RELAY COM 

RELAY N.O. 

WARNING: Hazardous voltage may exist for up to 

30 seconds after power is removed. 

MOTOR 

GV-U3/6/12 

COMPUMOTOR 

SERVO 

U 

V 

W 

VBUS+ 

VBUS– 

L2/N 

L1 

DRIVE I/O MOTOR FEEDBACK 

GV6K 

Gemini 

Servo 

RS-232 EXPANSION I/O ETHERNET MASTER ENCODER 

RS-232/485 (COM1) 

RS-232 (COM2) 

Expansion I/O 

+24VDC Power Input 

Relay 

Motor Power 

I/O Connections 

Ethernet 

AC Power 

Motor Feedback 

Master Encoder 

RS-232/485 

+ 24V D 

24V RT 

RELAY CO 

RELAY N.O 

DRIVE I/O 

MOTOR FEEDBACK 

GV6K 

Gemini 

Servo 

RS-232 EXPANSION I/O ETHERNET MASTER ENCODER 

COM1 Port (RS-232/485) 

COM2 Port (RS-232) 

Ethernet Port 

Set up for use as the primary RS-232 or RS-485 port. Configurable for the RP240 

(requires external +5VDC supply) 

Set up for use as an additional RS-232 port. Configurable for the RP240. Operating 

system upgrades via this port only. 

Refer to the configuration procedures that follow. 

Using multiple ports 

Motion Planner Communication Features 

You can communicate to either the Ethernet port or COM1 at any given time. Enabling 

the Ethernet port (NTFEN1) will disable COM1. COM2 is always enabled for use as 

RS232 or with an RP240. 

Motion Planner provides easy direct communication links to the product: 

• Communicate directly from any Motion Planner utility (Wizard Editor, Program Editor, 

Terminal Emulator, and Panels). 

• Communication setup parameters (Ethernet and serial communication). 

• Download the Gem6K product’s soft operating system. The operating system is loaded 

at the factory, but may use this feature to download upgrades. 

• Download motion programs to the controller, and upload motion programs from the 

controller. 

Communications Server: Also available on the Motion Planner CD is a 32-bit OLE 

automation server for adding Gem6K communication capability to your custom applications 

created with programming languages such as Visual Basic or Visual C++. For details, refer to 

the COM6SRVR Programmer’s Guide or to the Motion Planner Help System. 


Ethernet Networking 

Overview 

The Gem6K is equipped for Ethernet communication. It includes 10Base-T (10Mbps twisted 

pair); TCP/IP protocol. RJ-45 connector. Default IP address is 192.168.10.30. You have these 

options for networking the Gem6K over Ethernet: 

Setup Wizard Available 


Wizard Editor provides a 

setup wizard, called 

“Network”, to help you 

establish 6K Client/Server 

communication (up to six 

servers). 

• Gem6K as a client. You can connect the Gem6K via Ethernet to multiple devices, 

creating a client/server network. The Gem6K is the client, and has the ability to open or 

close a connection with another device (server) and request information from that 

device. The Gem6K supports up to 6 simultaneous server connections. Devices (servers) 

that may be connected to the Gem6K include: 

− Allen Bradley SLC5-05 PLC (see page 51 for setup procedures) 

− OPTO22 SNAP I/O, using Modbus/TCP protocol (see page 48 for setup 

procedures) 

− DVT vision system cameras (see page 50 for setup procedures) 

EXAMPLE — Closed Network: 

Ethernet Switch 

(255.255.255.0) 

out 


(255.255.0.0) 

out 

6K 

Client (Server to PC) 

IP = 192.168.10.30 

Device 1 

Server 

IP = 192.168.10.120 

Device 2 

Server 

IP = 192.168.10.80 

Ethernet 

Card 

Connection to 

company network 

Ethernet 

Card 

PC 

Client 

IP = 192.168.10.31 IP = 172.20.44.180 

EXAMPLE — Direct Connect to One Server: 

Crossover Cable 

provided in 6K ship kit 

(p/n 71-017635-01) 

Serial Cable 

Device 

6K 

PC 

Chapter 2. Communication 39

• Gem6K as a server. The Gem6K waits for a PC to establish a connection with it and then 

provides information on a continual or requested basis. The PC communicates with the 

Gem6K through the use of the COM6SRVR Communications Server, which is what 

Motion Planner uses to communicate with the Gem6K (for details, refer to the 

COM6SRVR Communications Server Programmer’s Reference—see 

www.compumotor.com for this document). The Gem6K does not support simultaneous 

connections with multiple clients (PCs). 

EXAMPLE — Closed Network: 

Switch or Hub 

(255.255.255.0) 

Switch or Hub 

(255.255.0.0) 

6K 

Server 

IP = 192.168.10.30 

Ethernet 

Card 

Connection to 


Ethernet 

Card 

PC 

Client 

IP = 192.168.10.31 IP = 172.20.44.180 

EXAMPLE — Direct Connect to PC: 

Crossover Cable 

provided in 6K ship kit 

(p/n 71-017635-01) 

Switch or Hub 

(255.255.0.0) 

6K 

Server 

IP = 172.20.34.30 

Ethernet 

Card 

Connection to 


Ethernet 

Card 

PC 

Client 

IP = 172.20.34.160 IP = 172.20.44.180 


• Combination of server and client. For example, the Gem6K could be the client for an 

OPTO22 (server) and an Allen-Bradley PLC (server). At the same time, a software 

program running on a PC could be using the Gem6K as a server. 


(255.255.255.0) 

out 


(255.255.0.0) 

out 

6K 


IP = 192.168.10.30 

Device 1 

Server 

IP = 192.168.10.120 

Device 2 

Server 

IP = 192.168.10.80 

Ethernet 

Card 

Connection to 


Ethernet 

Card 

PC 

Client 

IP = 192.168.10.31 IP = 172.20.44.180 

Setup Wizard Available 


Wizard Editor provides a 

setup wizard, called 

“Network”, to help you 

establish 6K peer-to-peer 

communication. 

• Peer-to-peer network with other 6K or Gem6K units. The 6K may be connected to 

other 6K devices (6K Controllers or Gem6K drive/controllers) via Ethernet. Up to eight 

6K devices may be networked in this manner. This type of connection uses UDP 

broadcasting and is not a client/server relationship. (see page 46 for setup procedures) 


(255.255.255.0) 

out 


(255.255.0.0) 

out 

6K unit 1 

IP = 192.168.10.30 

Connection to 


6K unit 2 

IP = 192.168.10.40 

Ethernet 

Card 

Ethernet 

Card 

PC 

IP = 192.168.10.31 

IP = 172.20.44.180 


Networking Guidelines 

• Use a closed network. Because of network broadcasts, it is best to put the Gem6K, 

along with any associated server devices, on a closed network with its own subnet. If 

you have a PC connected to the Ethernet Client/Server network and the PC is also 

connect to your company’s network, use one Ethernet card for the Ethernet 

Client/Server network and another Ethernet card for the company network (refer to the 

example below) . 


(255.255.255.0) 

out 


(255.255.0.0) 

out 

6K 


IP = 192.168.10.30 

Device 1 

Server 

IP = 192.168.10.120 

Device 2 

Server 

IP = 192.168.10.80 

Ethernet 

Card 

Ethernet 

Card 

PC 

Client 

IP = 192.168.10.31 IP = 172.20.44.180 

• If the Gem6K is placed on an open network, put the Gem6K and any associated server 

devices on one side of a Ethernet network switch with its own subnet and install a 

bridge to filter traffic, such that broadcast traffic does not pass in either direction (see 

diagram below). This will prevent the Gem6K from broadcasting to the entire network. 


(255.255.255.0) 

out 


(255.255.0.0) 

out 

Bridge 

6K 

Client 

IP = 192.168.10.30 

Device 1 

Device 2 

Server 

IP = 192.168.10.120 

Server 

IP = 192.168.10.80 

Ethernet 

Card 

IP = 172.20.44.180 

PC 

• A switch (recommended) or hub must be used if you are making more than one 

Ethernet connection with the Gem6K. 

• The Gem6K client must have the same subnet address as all of the server devices it will 

connect to (PLC, OPTO22, DVT, etc.). For example, if the subnet mask (NTMASK) is 

255.255.255.0, and the subnet address is 192.168.10.*, then all devices (including the 

Gem6K) must have an address starting with 192.168.10.*, where the * number is 

unique to the device. 

• Fieldbus (DeviceNet or Profibus) versions of the Gem6K (part numbers Gem6Kn-DN 

or Gem6Kn-PB) cannot also communicate as an Ethernet Client at the same time. If 

you have a Fieldbus unit and need to use Ethernet instead, execute the OPTENØ 


command, then the RESET command (this disables the Fieldbus features), and then the 

NTFEN1 or NTFEN2 command. To re-enable Fieldbus communication, execute the 

NTFENØ command, then the RESET command (this disables Ethernet communication), 

and then the OPTEN1 command. 

• You cannot communicate to the Gem6K with simultaneous transmissions over both the 

“ETHERNET” and “RS-232” (PORT1) connections. 

• Follow the manufacturer’s setup procedure for each Allen-Bradley PLC, DVT camera 

and OPTO22 Ethernet I/O rack. 

• You should be able to ping every Gem6K, DVT camera, PLC and OPTO22 I/O rack 

from the PC. Use the ping command at the DOS prompt: 

ping 192.168.10.30 

(space) 

Device’s IP Address 

If your PC responds with “Request Timed Out”, 

check your Ethernet wiring and IP address setting. 

• The following Ethernet setup commands need only be sent once to the Gem6K, 

because they are saved in non-volatile memory and are remembered on power-up and 

RESET: NTID, NTIO, NTIP, NTMPRB, NTMPRI, NTMPWB, and NTMPWI. 

• If a PC is connected to the Gem6K/Device Ethernet network, then the PC should 

include all devices in a static mapping table. The static mapping procedure, for the 

Gem6K’s address, is found on page 44. 

• If the Gem6K is in a peer-to-peer network, enable Ethernet communication with the 

NTFEN1 command (NTFEN2 mode is not compatible with peer-to-peer communication). 

Configuring the Gem6K for Ethernet Communication 

PC-to-Gem6K 

Communication over 

RS-232 Only 

PC-to-Gem6K 

Communication over 

Ethernet 

If your PC will be communicating to the Gem6K over RS-232 (not Ethernet), follow this 

procedure: 

1. Connect the Gem6K controller to your network (refer to Networking Guidelines on page 

42). 

2. Establish an RS-232 communication link between the Gem6K and your computer (connect to 

the Gem6K’s “RS-232” connector according to the instructions in the Gem6K Installation 

Guide). 

3. Install Motion Planner on your computer, and launch Motion Planner. Click on the Terminal 

tab to view the terminal emulator. 

4. In the Terminal window, click on the button to view the Communications Settings dialog. 

Select the Port tab and select the COM port that is connected to the Gem6K’s “RS-232” 

connector (see Step 2 above). Click OK. 

5. In the Terminal window, enable Ethernet communication with the appropriate NTFEN 

command: 

a. If you are using the Gem6K as a server or client, type the NTFEN2 command and press 

ENTER, then type the RESET command and press ENTER. 

b. If you are using the 6K in a peer-to-peer connection with another 6K or Gem6K, type the 

NTFEN1 command and press ENTER, then type the RESET command and press ENTER. 

If your PC will be communicating to the Gem6K over Ethernet, follow this procedure: 

1. Connect the Gem6K controller to your network (refer to Networking Guidelines on page 

42). 


Changing the Gem6K’s 

IP Address or Subnet 

Mask 

The factory default Gem6K 

IP address is 

192.168.10.30; the default 

mask is 255.255.255.0. 

If the default address and 

mask are not compatible 

with your network, you 

may change them with the 

NTADDR and NTMASK 

commands, respectively 

(see Gem6K Series 

Command Reference for 

details on the NTADDR and 

NTMASK commands). To 

ascertain the Gem6K’s 

Mac address, use the 

TNTMAC command. The 

NTADDR, NTMASK and 

TNTMAC commands may 

be sent to the 6K controller 

over an RS-232 interface 

(see Steps 4-6). NOTE: If 

you change the 6K’s IP 

address or mask, the 

changes will not take affect 

until you cycle power or 

issue a RESET command. 

2. Install your Ethernet card and configure it for TCP/IP protocol. Refer to your Ethernet card’s 

user documentation for instructions. (If you need to change the 6K’s IP address or subnet mask, 

refer to the note on the left.) 

3. (see illustration below) Configure your Ethernet card’s TCP/IP properties so that your 

computer can communicate with the 6K controller. 

a. Access the Control Panels directory. 

b. Open the Network control panel. 

c. In the Network control dialog, select the Configuration tab (95/98) or the Protocols tab 

(NT) and double-click the TCP/IP network item to view the TCP/IP Properties dialog. 

d. In the TCP/IP Properties dialog, select the IP Address tab, select “Specify an IP Address”, 

type in 192.168.10.31 in the “IP Address” field, and type in 255.255.255.0 in the “Subnet 

Mask” field. 

e. Click the OK buttons in both dialogs to finish setting up your computer’s IP address. 

If you are using 

Windows NT, select 

the “Protocols” tab. 

Make sure this number is different 

from the one in the 6K’s IP address. 

If the 6K’s default IP address is 

unchanged (192.168.10.30), then 

select a number other than 30. 

NOTE 

If you are using a computer (Ethernet card) that is 

normally connected to a network, you should write 

down the existing IP Address and Subnet Mask 

values, so that you may restore them later. 

3. Establish an RS-232 communication link between the Gem6K and your computer (connect to 

the Gem6K’s “RS-232” connector according to the instructions in the Gem6K Installation 


4. Install Motion Planner on your computer, and launch Motion Planner. Click on the Terminal 

tab to view the terminal emulator. 

5. In the Terminal window, click on the button to view the Communications Settings dialog. 

Select the Port tab and select the COM port that is connected to the Gem6K’s “RS-232” 

connector (see Step 4 above). Click OK. 

6. In the Terminal window, enable Ethernet communication with the appropriate NTFEN 


a. If you are using the Gem6K as a server or client, type the NTFEN2 command and press 

ENTER, then type the RESET command and press ENTER. 

b. If you are using the 6K in a peer-to-peer connection with another 6K or Gem6K, type the 

NTFEN1 command and press ENTER, then type the RESET command and press ENTER. 

7. Use the following sub-procedure to statically map the Gem6K’s Ethernet MAC address to 

IP address of the Ethernet card in your PC. Static mapping eliminates the need for the PC 


to ARP the Gem6K controller, thereby reducing communication overhead. 

a. In Motion Planner’s Terminal window, type TNT and press ENTER. The response 

includes the Gem6K IP address, and the Gem6K Ethernet address value in hex (this is 

also known as the “MAC” address). Write down the IP address and the Ethernet 

address (hex value) for later use in the procedure below. 

b. Start a DOS window. The typical method to start a DOS window is to select MS-DOS 

Prompt from the Start/Programs menu (see illustration below). 

c. At the DOS prompt, type the arp –s command (see example below) and press ENTER. 

arp –s 192.168.10.30 0-90-55-0-0-1 192.168.10.31 

Spaces 

(press the space bar) 

6K’s IP Address 

(from TNT report) 

6K’s Ethernet Address 

(from TNT report) 

IP Address of Ethernet Card 

d. To verify the mapped addresses, type the arp –a command and press ENTER. 

If you receive the response “No ARP Entries Found”: 

1) Switch to the Motion Planner Terminal window, type NTFEN2 (or NTFEN1 if using a 

peer-to-peer network) and press ENTER, then type RESET and press ENTER. 

2) Switch to the DOS window, type the ping command and press ENTER: 

ping 192.168.10.30 

(space) 

6K’s IP Address (from TNT report) 

3) Repeat the arp –s command as instructed above. Use arp –a to verify. 

If your PC responds with “Request 

Timed Out”, check your Ethernet 

wiring and IP address setting. 

4) Switch to the Motion Planner Terminal window, type NTFEN2 (or NTFEN1 if using a 

peer-to-peer network) and press ENTER, then type RESET and press ENTER. 

e. (OPTIONAL) Automate the arp –s static mapping command. This allows your PC 

to automatically perform the static mapping when it is booted; otherwise, you will 

have to manually perform static mapping every time you boot your PC. 

• Windows 95/98: Add the arp –s command to the Autoexec.bat file. 

• Windows NT: Create a batch file that contains the arp –s command. Save the file 

(name the file “GEM6KARP.BAT”) to the root directory on the C drive. Using 

Windows Explorer, locate the Gem6KARP.BAT file, create a shortcut, then cut and 

paste the shortcut into the StartUp directory. Windows NT has several StartUp 

directories to accommodate various user configurations. We recommend using the 

Administrators or All Users locations. For example, you can paste the shortcut into the 

WinNt\Profiles\AllUsers\StartMenu\Programs\StartUp directory, allowing all users to 

statically map the IP and Mac addresses whenever the PC is booted. 


Ethernet Connection Status 

LEDs (located on the RJ-45 

“ETHERNET” connector): 

• Green LED turns on to 

indicate the Ethernet 

physical connection is OK. 

• Yellow LED flashes to 

indicate the Gem6K is 

transmitting over the 

Ethernet interface. 

f. Connect the Gem6K Controller to your computer using a cross-over 10Base-T cable (5-foot 

cable provided in ship kit). 

g. In Motion Planner’s Terminal window, click on the button to view the Communications 

Settings dialog. Select the Port tab, select “Network” and type the IP address (192.168.10.30) 

in the text field. Click OK. 

h. You may now communicate to the Gem6K controller over the Ethernet interface. Reminder: 

You cannot communicate to the Gem6K with simultaneous transmissions over both the 

“ETHERNET” and “RS-232” (PORT1) connections. 

8. Connect the Gem6K Controller to your computer using a cross-over 10Base-T cable (5-foot 

cable provided in ship kit). 

9. In Motion Planner’s Terminal window, click on the button to view the Communications 

Settings dialog. Select the Port tab, select “Network” and type the IP address (192.168.10.30) 

in the text field. Click OK. 

10. You may now communicate to the Gem6K controller over the Ethernet interface. 

Reminder: You cannot communicate to the Gem6K with simultaneous transmissions over both 

the “ETHERNET” and “RS-232” (PORT1) connections. 

Ethernet Connection Status LEDs (located on the RJ-45 “ETHERNET” connector): 

• Green LED turns on to indicate the Ethernet physical connection is OK. 

• Yellow LED flashes to indicate the Gem6K is transmitting over the Ethernet interface. 

Networking with Other 6K or Gem6K Products (Peer-to-Peer) 

This feature is used to communicate information between 6Ks and Gem6Ks over Ethernet. 

This is not a client or server; this feature uses UDP broadcasting over the subnet to transfer 

data, so no client/server connection is needed. 

There can be up to 8 different 6K or Gem6K devices sharing information, with each device 

having access to each shared data from the 7 other device. Each device can broadcast 8 pieces 

of information by way of “shared output” variables (VARSHO1 through VARSHO8). These 

variables can share with other devices the values of its motion attributes, controller status, 

variables, etc. (see list below). 

A..........Acceleration NMCY... Master cycle number SS..........System status 

AD........Deceleration OUT..... Output status SWAP......Task swap assignment 

ANI .....Analog input voltage PANI... Analog input position TASK......Task number 

ANO .....Analog output voltage PC....... Commanded position TIM........Timer value 

AS........Axis status PCC..... Captured command pos. TRIG......Trigger interrupt status 

ASX .....Extended axis status PCE..... Captured encoder pos. US..........User-defined status 

D..........Distance PCME... Captured master enc. pos. V............Velocity 

DAC .....DAC output value PE....... Encoder position VARI......Integer variable 

DKEY ...RP240 keypad value PER..... Position error VARB......Binary variable 

ER........Error status PMAS... Position of Master VEL........Commanded velocity 

FB........Feedback device pos. PME..... Master encoder pos. VELA......Actual velocity 

FS........Following status PSHF... Net position shift VMAS......Velocity of the master 

IN........Input status PSLV... Follower pos. command VARSHI .Shared input variable 

INO .....Enable input status SC....... Controller status 

LIM .....Limit input status SCAN... PLC scan time 

MOV .....Axis moving status SEG..... Free segment buffers 

The type of data can be either binary, as in the AS (axis status) operand, or a 32-bit unscaled 

integer, as in PE (encoder position) operand. The data stored in the VARSHO is not scaled. 


Each unit will re-broadcast its updated VARSHO data at a rate set with the NTRATE command. 

RECOMMENDATION: Set all devices to broadcast at the same NTRATE rate of 50 

milliseconds. 

Setup 

Example 

For 6K or Gem6K sending and/or receiving information via the Peer to Peer feature: 

1. Connect the 6K/Gem6K products to the network and configure each 6K/Gem6K for 

Ethernet communication according to the procedures on page 43. 

2. Set the broadcasting rate with NTRATE command, preferably the same for each unit. 

3. If the unit is to receive data only (not send) you are finished with the setup for that unit. 

If the unit is to send also, complete steps 4 and 5. 

4. Assign a unique unit number (1-8) with the NTID command. 

5. Assign data to the eight broadcast variables with the VARSHO command. 

6. Repeat steps 2-5 for each unit in the peer-to-peer network. 

First 6K or Gem6K: 

NTID1 ; Assign this unit a peer-to-peer unit number of 1 

VARSHO1 = 1A ; Shared variable #1 contains axis 1's acceleration 

VARSHO2 = 1PE ; Shared variable #2 contains axis 1's encoder 

;position 

; ****************************************************************** 

; * Use this space to define shared output variables VARSHO3 – ;VARSHO7. * 

; ****************************************************************** 

VARSHO8 = VARI1 ; Shared variable #8 contains the value of VARI1 

NTRATE50 

; Set the broadcasting rate to 50 milliseconds 

Second 6K or Gem6K: 

NTID2 ; Assign this unit an ID of 2 

VARSHO1 = 1D ; Shared variable #1 contains axis 1's programmed 

;distance 

VARSHO2 = 3PE ; Shared variable #2 contains axis 3's encoder 

position 

; ****************************************************************** 

; * Use this space to define shared output variables VARSHO3 – VARSHO7. * 

; ****************************************************************** 

VARSHO8 = 1ANI.1 ; Shared variable #8 contains the voltage value at 

;analog 

; input 1 on I/O brick 1 

NTRATE50 ; Set the broadcasting rate to 50 milliseconds 

Third 6K or Gem6K: 

NTRATE50 ; Set the broadcasting rate to 50 milliseconds 

; This third unit will receive data only. Therefore, it does not 

;require 

; a unit ID number or VARSHO data assignment 


Program 

Interaction 

Each Unit can read the broadcast variables of each other unit with the nVARSHIi command. 

The “n” specifies the ID number (NTID) of the unit you want to read from, the “i” is the 

VARSHO number of that unit to be read. For example, if you want unit 1 to read unit 2’s 

VARSHO8 data, then use 2VARSHI8. 

Using the VARSHI command, you can process data from the VARSHO variable of another peerto-peer 

unit in these ways: 

• Assign the VARSHO data to a VAR (numeric), VARI (integer), or VARB (binary) variable. 

For example, the command VARI1=2VARSHI8 assigns the value of VARSHO8 on unit 2 

to the VARI1 integer variable. 

• Assign the VARSHO data to a virtual input (IN). For example, 3IN=2VARSHI3 assigns 

the binary value of VARSHO3 from unit 2 to virtual input brick 3. 

• Use the VARSHO data in a conditional expression for an IF, WAIT, WHILE, or UNTIL 

statement. For example, if VARSHO5 on unit 2 is assigned is assigned the status of 

onboard trigger input 3 (VARSHO5=IN.3), then you could use this command to make 

unit 1 wait until trigger input 3 on unit 2 was on: WAIT(2VARSHI5=b1). 

Example First 6K or Gem6K (unit 1): 

VARI1 = 2VARSHI8; Assign Unit 2's VARSHO8 (which is the voltage 

; value at analog input 1 on I/O brick 1) to VARI1. 

Second 6K or Gem6K (unit 2): 

VARI100 = 1VARSHI2; Assign Unit 1's VARSHO2 (which is the encoder 

;position of axis 1) to VARI100. 

Third 6K or Gem6K (reading data only): 

VARI90 = 1VARSHI1; Assign Unit 1's VARSHO1 (which is the 

;acceleration of axis 1) to VARI90. 

Networking with OPTO22 SNAP I/O 

The Gem6K client can communicate with the OPTO22 SNAP I/O server to read digital and 

analog inputs and outputs, and write digital and analog outputs. The Gem6K supports up to 

eight modules per OPTO22. 

Setup 1. Follow the manufacturer’s setup procedure for the OPTO22 Ethernet I/O rack. 

2. Connect the Gem6K and OPTO22 products in a network and configure the Gem6K for 


3. Choose a Server Connection Number for this device. The Gem6K can support up to 6 

simultaneous server connections. Pick a number (1-6) that has not been used already for 

another connection. This will be used to reference the OPTO22 unit from now on. 

4. Enter the IP address of the OPTO22 and specify a 2 for connection type with the NTIP 

command. For example, if the OPTO22 is Server #3 and its IP address is 172.20.34.170, 

then the command would be 3NTIP2,172,20,34,170. 

5. Attempt a connection to the device with NTCONN. For example, if the server number is 3, 

the command would be 3NTCONN1. If the connection is successful, Network Status bit #1 

is set (see NTS, TNTS, TNTSF). If the connection is unsuccessful, Error Status bit #23 is 

set (see ER, TER, TERF). 

6. Inform the Gem6K of the configuration of the OPTO22. For each module position, use 

the NTIO command to specify the type of module in that position. 


n \ m NTIO 

Example 

Program 

Interaction 

Network Server # 

Range: 1-6 

Module # on Server “n” 

Range: 0-7 

Module Type. Options are: 

1 = Digital/Discrete Inputs 

2 = Digital/Discrete Outputs 

3 = Analog Inputs 

4 = Analog Outputs 

For example, if there is a digital input module in slot 0, then the command would be 

3\0NTIO1. If there is an Analog Input module in slot 7, then the command would be 

3\7NTIO3. 

7. Set the polling rate with the NTPOLL command. 50 milliseconds is recommended. For 

example, to set the polling rate to 50 ms on server #3, use the 3NTPOLL50 command. If 

there is an error during polling, then Error Status bit #24 will be set. 

NTADDR172,34,54,123 ; Set the IP address of the Gem6K 

OPTEN0 

; Disable the option card (for Fieldbus units only) 

RESET 

NTFEN2 

; Enable network function on Gem6K 

RESET 

DEL OPTOSU 

DEF OPTOSU 

2NTIP2,172,34,54,124; Identify an OPTO22 device as Server #2, which is 

; located at IP address 172.34.54.124 

2NTCONN1 

; Attempt connection to Server #2 (OPTO22) 

2\1NTIO2 

; Configure OPTO22 module 1 as digital output 

2\2NTIO2 

; Configure OPTO22 module 2 as digital output 

2\3NTIO1 

; Configure OPTO22 module 3 as digital input 

2\4NTIO3 

; Configure OPTO22 module 4 as analog input 

2NTPOLL50 

; Begin polling, set polling interval to 50 ms 

END 

Once the OPTO22 is configured and a connection is made, you can then set outputs and check 

inputs. 

How the Gem6K addresses OPTO22 I/O locations: 

The Gem6K addresses each I/O bit by its location on a specific module. (NOTE: I/O 

points are not addressed by an absolute 32-bit location on the OPTO22.) Digital input and 

output modules have four I/O points, or channels, and are numbered 1-4. Analog input and 

output modules have two I/O points, or channels, and are numbered 1-2. 

EXAMPLE: OPTO22 is Network Server #3 

0 

1 

2 

3 

4 

5 

6 

7 

Digital 

Input 

Module 

Digital 

Input 

Module 

Digital 

Output 

Module 

Digital 

Output 

Module 

Analog 

Output 

Module 

Analog 

Output 

Module 

Analog 

Input 

Module 

Analog 

Input 

Module 

Input 

1 

Input 

2 

Input 

3 

Input 

4 

Input 

1 

Input 

2 

Input 

3 

Input 

4 

Output 

1 

Output 

2 

Output 

3 

Output 

4 

Output 

1 

Output 

2 

Output 

3 

Output 

4 

Output 

1 

Output 

2 

Output 

1 

Output 

2 

Input 

1 

Input 

2 

Input 

1 

Input 

2 

3\0IN.3 3\3OUT.2 3\5ANO.1 3\7ANI.2 

• To verify the I/O configuration (as per NTIO) and to check the status of each module’s 

inputs and outputs, type n\TIO, where “n” is the server number. 

• To set a digital output, type n\mOUT.i-b, where “n” is the server number, “m” is the 


module number, “i” is the point number on that module and “b” is the state (1 = on, 

0 = off). To set multiple digital outputs on the same module, type n\mOUTbbbb: 

Output #1 

Output #2 

Output #3 

Output #4 


Range: 1-6 

Module # on Server “n” 

Range: 0-7 

n \ m OUT b b b b 

Options for “b” are: 

1 = Turn on 

0 = Turn off 

x = Don’t Change 

For example (Server #3), to turn on outputs #1 and #4 and leave outputs #2 and #3 unchanged 

on module #2, type 3\2OUT1XX1. To turn off only output #4, type 3\2OUT.4-0. 

• To set an analog output voltage, type n\mANO.i-r, where “n” is the server number, “m” is 

the module number, “i” is the output number on that module and “r” is the voltage. For 

example, to set analog output #1 on module #5 of Server #3 to 6.4V, type 3\5ANO.1=6.4. 

• To read a digital input or output module, use the assignment/comparison operands (n\mIN 

or n\mOUT) or the transfer commands (n\mTIN or n\mTOUT). Examples are: 

- IF(3\0IN=b1100) is an IF condition that reads all four digital inputs on module #0. 

IF(3\0IN.2=b1) is an IF condition that reads only digital input #2 on module #0. 

- IF(3\2OUT=b1100) is an IF condition that reads all four outputs on module #2. 

IF(3\2OUT.3=b1) is an IF condition that reads only digital output #3 on module #2. 

- 3\0TIN transfers the binary status of all four digital inputs on module #0. 

3\0TIN.2 transfers the binary status of only digital input #2 on module #0. 

- 3\2TOUT transfers the binary status of all four digital outputs on module #2. 

3\2TOUT.3 transfers the binary status of only digital output #3 on module #2. 

• To read an analog input or output module, use the assignment/comparison operands 

(n\mANI or n\mANO) or the transfer commands (n\mTANI or n\mTANO). Examples are: 

- WAIT(3\7ANI.2=1.0) is an IF condition that reads analog output #1 on module #5. 

- 3\6TANI transfers the voltage status of both analog inputs on module #6. 

3\6TANI.2 transfers the voltage status of only analog input #2 on module #6. 

- 3\4TANO transfers the voltage status of both analog outputs on module #4. 

3\4TANO.1 transfers the voltage status of only analog output #1 on module #4. 

Networking with a DVT Vision System 

The DVT client can send trigger commands to the camera. The camera should send back 

ASCII strings of the form VARn = 123.456, VARm = 234.567. The strings will be VAR 

assignments delineated by commas. These values will then be written to the Gem6K’s VARs. 

This data can represent anything, such as an x-y coordinate. 

Setup 1. Follow the manufacturer’s setup procedure for the DVT camera. 

2. Connect the Gem6K and DVT camera in a network and configure the Gem6K for 


3. Choose a Server Connection Number for this device. The Gem6K can support up to 6 

simultaneous client connections. Pick a number (1-6) that has not been used already for 

another server connection. This will be used to reference the device from now on. 

4. Enter the IP address of the camera and specify a 3 for connection type with the NTIP 

command. For example, if the DVT camera is Server #6 and its IP address is 


Example 

172.20.34.150, then the command would be 6NTIP3,172,20,34,150. 


the command would be 6NTCONN1. If the connection is successful, Network Status bit 

#1 is set (see NTS, TNTS, TNTSF). If the connection is unsuccessful, Error Status bit #23 

is set (see ER, TER, TERF). 

6NTIP3,172,34,54,150 ; Identify a DVT camera as Server #6, located at 

; IP address 172.34.54.150. 

6NTCONN1 ; Attempt the connection to Server #6 

Program 

Interaction 

Example 

Once a connection has been established, you can write trigger commands to the camera using 

the NTWRIT command. 

DEL DVT 

DEF DVT 

6NTCONN1 

; Attempt connection to DVT camera 

6NTWRIT"DVT commands" ; Write the text "DVT commands" to camera 

END 

Networking with an Allen-Bradley SLC 5/05 PLC 

The Allen-Bradley SLC 5/05 exchanges integer and binary data with the Gem6K. The data 

exchange is accomplished by mapping integer variables (VARI) and binary variables (VARB) in 

the Gem6K with data elements in the PLC’s integer and binary data files. The Gem6K limits 

the amount of variable mapping to 100 binary variables (50 write, 50 read) and 100 integer 

variables (50 write, 50 read). 

Setup 1. Follow the manufacturer’s setup procedure for each Allen-Bradley PLC, DVT camera 

and OPTO22 Ethernet I/O rack. 

2. Connect the Gem6K and Allen-Bradley PLC in a network and configure the Gem6K for 


3. Choose a connection number for this device. The Gem6K can support up to 6 

simultaneous client connections. Pick a number (1-6) that has not been used already for 

another client connection. This will be used to reference the device from now on. 

4. Enter the IP address of the PLC and specify a 1 for connection type with the NTIP 

command. For example, if the PLC is Server #5 and its IP address is 172.20.34.124, then 

the command would be 3NTIP1,172,20,34,124. 


the command would be 5NTCONN1. If the connection is successful, Network Status bit 

#1 is set (see NTS, TNTS, TNTSF). If the connection is unsuccessful, Error Status bit #23 

is set (see ER, TER, TERF). 

6. Map the required integer and binary variables between the Gem6K and the data files in 

the Allen-Bradley PLC. There are four mappings possible (a programming example is 

provided below). 

• Use the NTMPRB command to read up to 50 binary elements from a PLC’s binary file 

and write them to VARB variables in the Gem6K. 



Range: 1-6 

n NTMPRB i, i, i, i 

# of Allen-Bradley data file 

# of first element in AB data file 

(beginning of range) 

# of elements in range 

# of first binary variable (VARB) in 6K 

(beginning of range, max value is 125) 

EXAMPLE: 

IF: 

• Allen-Bradley PLC is server #5 

• The PLC’s binary data file 3 has 30 

elements. Use data elements 15-29 

(15 elements total) for binary data 

that is to be shared with the 6K. 

• Use the 6K’s binary variables 35-49 

(15 variables total) to store the data 

from the PLC. 

The required mapping command is: 

5NTMPRB3,15,15,35 

• Use the NTMPRI command to read up to 50 integers elements from a PLC’s Integer 

file and write them to VARI variables in the Gem6K. 


Range: 1-6 

n NTMPRI i, i, i, i 





# of first integer variable (VARI) in 6K 


EXAMPLE: 

IF: 


• The PLC’s integer data file 9 has 30 


(15 elements total) for integer data 

that is to be shared with the 6K. 

• Use the 6K’s integer variables 35-49 


from the PLC. 


5NTMPRI9,15,15,35 

• Use the NTMPWB command to write up to 50 binary values from VARB variables in the 

Gem6K to binary elements in a PLC’s binary file. 


Range: 1-6 

n NTMPWB i, i, i, i 





# of first binary variable (VARB) in 6K 


EXAMPLE: 

IF: 


• In the PLC’s binary data file 3, use 

data elements 0-14 (15 elements 

total) for binary data that is to be 

transmitted from the 6K. 

• Use the 6K’s binary variables 20-34 


to be transmitted to the PLC. 


5NTMPWB3,0,15,20 

• Use the NTMPWI command to write up to 50 integers values from VARI variables in 

the Gem6K to a integer elements in a PLC’s integer file. 


Range: 1-6 

n NTMPWI i, i, i, i 





# of first integer variable (VARI) in 6K 


EXAMPLE: 

IF: 


• The PLC’s integer data file 9 has 30 


(15 elements total) for integer data 

to be transmitted from the 6K. 

• Use the 6K’s integer variables 20-34 


to be transmitted to the PLC. 


5NTMPWI9,0,15,20 

7. Set the polling rate with the NTPOLL command. 50 milliseconds is recommended. For 

example, to set the polling rate to 50 ms on Server #5, use the 5NTPOLL50 command. If 

there is an error during polling, Error Status bit #24 will be set (see ER, TER or TERF). 


Example 

NTADDR172,34,54,123 ; Set the IP address of the Gem6K 

OPTEN0 

; Disable the option card (for Fieldbus units 

only) 

RESET 

NTFEN2 

; Enable network function on Gem6K 

RESET 

5NTIP1,172,34,54,124 ; Identify network server #5 as an Allen Bradley 

PLC 

; at IP address 172.34.54.124 

5NTCONN1 ; Connect to network server #5 

5NTMPRB11,7,1,106 ; File 11, element 7 in the AB PLC is mapped to 

the Gem6K's 

; binary variable VARB106 

5NTMPRI20,5,2,128 ; File 20, elements 5-6 in the AB PLC are mapped 

to 

; the Gem6K's integer variables VARI128-VARI129, 

respectively 

5NTMPWB11,3,4,100 ; File 11, elements 3-6, in the AB PLC are 

mapped to 

; the Gem6K's binary variables VARB100-VARB103 

5NTMPWI20,3,2,120 ; File 20, elements 3-4, in the AB PLC are 

mapped to 

; the Gem6K's integer variables VARI120-VARB121 

5NTPOLL50 

; Start polling network server #5, set interval 

to 50 ms. 

; 

********************************************* 

************************ 

; The Gem6K's VARB106 will read from the PLC's File 11, element 7. 

; The Gem6K's VARI128-VARI129 will read from the PLC's File 20, 

elements 5-6. 

; The PLC's File 11, elements 3-6 will read from the Gem6K's 

VARB100-VARB103. 

; The PLC's File 20, elements 3-4 will read from the Gem6K's 

VARI120-VARB121. 

; 

********************************************* 

************************ 

Program 

Interaction 

After the connection is established, mapping has been set up, and polling enabled, the Gem6K 

starts exchanging data automatically with the PLC. Here is how to: 

• Write a binary variable to the PLC: Simply write a value to one of the VARB variables in 

the NTMPWB mapping. The new data will be written to the binary file during the next poll. 

• Write an integer variable to the PLC: Simply write a value to one of the VARI variables in 

the NTMPWI mapping. The new data will be written to the integer file during the next poll. 

• Read a binary variable from the PLC: The VARB variables in the NTMPRB mapping 

correspond to the values in the binary file in the PLC. 

• Read an integer variable from the PLC: The VARI variables in the NTMPRI mapping 

correspond to the values in the integer file in the PLC. 


Example VARB100 = HAB79 ; Element 3 in file 10 of the AB PLC will be 

equal to VARB100 

if(VARB106 = B1111111111111111) ; VARB106 will be equal to 

variable 7 in 

; file 10 of the AB PLC 

if(VARI129 = 17) ; Element 6 in file 20 of the AB PLC will be 

equal to VARI129 

VARI121 = 17 

; Element 4 in file 20 of the AB PLC will be 

equal to VARI121 

Error Conditions 

Error Messages 

The 6K will transmit error message to alert you of certain error conditions. Below is a list of 

the error messages related to Ethernet networking. 

Error Response 

CONNECTION COULD NOT BE CLOSED OR 

ALREADY CLOSED 

CONNECTION COULD NOT BE OPENED 

CONNECTION ERROR, CONNECTION IS 

NOW BEING CLOSED 

CONNECTION IS NOT OPEN 

CONNECTION IS OPEN - MUST CLOSE 

FIRST 

ERROR, INVALID FILE TYPE, NUMBER 

OR SIZE. SETTING NTMP COMMANDS 

TO 0 ELEMENTS. CHECK MAPPING. 

ERROR, INVALID STRING 

ETHERNET CAN NOT BE USED WITH 

OPTION CARD - SEE OPTEN 

ETHERNET COMMUNICATION MUST BE 

ENABLED BEFORE MAKING 

CONNECTION - SEE NTFEN 

INVALID CONNECTION NUMBER 

INVALID I/O POINT 

INVALID POINT TYPE OR NUMBER, 

Possible Cause 

Tried to close the network server connection (nNTCONNØ) 

when the connection was already closed. 

Tried NTCONN1 and failed. Problem could be invalid IP 

address or it refused a connection. 

Connection error or timeout with server. When polling and 

get timeout or message aborted. This condition also sets 

Error Status bit #23 (see ER, TER, TERF). 

Tried a NTWRIT when connection is not open; or tried a 

\TANI or \TANO or \TIN or \TOUT or \TIO when 

connection is not open. 

Tried to open a network server connection (nNTCONN1) 

when the connection was already open. 

Tried to read the wrong Allen-Bradley PLC file type, there 

are not enough elements in the file, or the file doesn’t exist. 

The 6K automatically stop polling all mapped binary and 

integer variables (equivalent to executing the 

NTMPRBi,i,0,i, NTMPWBi,i,0,i, NTMPRIi,i,0,i, 

and NTMPWIi,i,0,i, commands). 

The DVT camera sent an invalid string response. 

Tried to enable Ethernet communication (NTFEN) on a 

Fieldbus version of the 6K (part number is 6Kn-PB for 

PROFIBUS units, 6Kn-DN for DeviceNet units). You must 

disable the internal option card with OPTENØ before 

enabling Ethernet communication. The 6K cannot 

communicate over a Fieldbus connection and Ethernet 

connection simultaneously. 

Tried to connect to an Ethernet server (nNTCONN1) before 

you enabled Ethernet communication in the 6K with the 

NTFEN command. 

Tried to make an NTS assignment or comparison using an 

invalid server number (e.g., VARB1 = 7NTS).Tried to 

address an Ethernet command to a server connection 

number outside of the range 1-6. What’s the difference 

between this and the “INVALID SERVER TYPE” error 

Tried to read or write an OPTO22 I/O point that is not 

configured according to the NTIO command. 

Tried to set or read an I/O point (with an \IN, \OUT, \ANI, 



SEE NTIO 

INVALID SERVER TYPE 

NETWORK INPUTS AND OUTPUTS CANNOT 

BE ASSIGNED TO A VARSHO 

NETWORK IP ADDRESS CANNOT BE 

CHANGED WHILE CONNECTION IS 

OPEN, SEE NTCONN 

NO NETWORK IP ADDRESS SPECIFIED 

FOR CONNECTION, SEE NTIP 

NTFEN MUST BE 1 TO USE THIS 

COMMAND 

NTRATE MUST BE 0 TO CHANGE NTFEN 

NTSELP ALREADY ENABLED ON THIS 

TASK 

OPTION CARD CAN NOT BE USED WITH 

ETHERNET - SEE NTFEN 

VARB USED BY OPTION CARD 

VARIABLE MAPPING CONFLICT, SEE 

NTMPRB, NTMPRI, NTMPWI, NTMPWB 

MAPPINGS 


\ANO, \TANI, \TANO, \TIN, or \TOUT command), but that 

I/O point was configured with the NTIO command to be 

different I/O type. 

Tried an OPTO22-related command (\TANI, \TANO, \TIN, 

\TOUT, \TIO, \IN, \OUT, \ANI, \ANO, etc.) for a non- 

OPTO22 connection. 

Tried to assign the status of OPTO22 I/O to a VARSHO 

variable. 

Tried to execute an NTIP command while the connection is 

open. 

Tried to connect (nNTCONN1) to a server # that has not yet 

been established with the NTIP command, or tried to 

connect to a server in an incompatible subnet. 

(Peer-to-peer connection only) Tried to execute an NTRATE 

command while NTFEN is set to a value other than NTFEN1. 

(Peer-to-peer connection only) Tried to execute an NTFEN 

command while NTRATE is set to a non-zero value. 

NTSELP, which enables program selection via OPTO22 

inputs, has already been enabled (if multitasking, it has 

been enabled for this specific Task). 

Tried to enable the internal Fieldbus Option card for 

PROFIBUS or DeviceNet communication (6Kn-PB and 6Kn- 

DN products only) with the OPTEN1 command. You must 

disable Ethernet communications with the NTFENØ 

command before enabling the Option card. The 6K cannot 

communicate over a Fieldbus connection and Ethernet 

connection simultaneously. 

Tried to map a binary variable to read from or write to an 

Allen-Bradley data file, but the variable is already used for 

Fieldbus (PROFIBUS or DeviceNet) data transfer functions. 

Tried to map the same 6K VARB or VARI variables for read 

and write functions. Or tried to map the same 6K VARB or 

VARI variables to another PLC. 

Error Handling 

The 6K has a Error Status register for logging certain error conditions. If you enable checking 

for an error condition (see ERROR command), the 6K will branch to the designated error 

program (see ERRORP command) when it detects the error condition. The Ethernet networking 

related Error Status register bits are noted below. 

ERROR 

Bit # 

Cause of the Error 

23 Ethernet Client 

Connection Error. 

(Can’t connect.) 

Gosub 

24 Ethernet Client Polling Gosub 

Error. (After connect and 

polling device for data, 

polling timeout occurred. 

Cause could be 

disconnect, client lost 

power, etc.) 

Branch Type How to Remedy the Error 

to ERRORP 

Clear the error bit (ERROR.23-0), reestablish 

the Ethernet connection 

(nNTCONN1), and then issue ERROR.23-1. 

Clear the error bit (ERROR.24-0), reestablish 

the Ethernet connection 

(nNTCONN1), and then issue ERROR.24-1. 


Serial Communication 

Controlling Multiple Serial Ports 

In this section: 

• Controlling Multiple Serial Ports 

• RS-232 Daisy Chaining 

• RS-485 Multi-Drop 

Every Gem6K Series product has two serial ports. The “RS-232” connector is referenced as the 

“COM2” serial port, and the “RS-232/485” connector is referenced as the “COM1” serial port. 

XON/XOFF 

The XONOFF command was created to enable or disable XON/XOFF ASCII handshaking. 

(XONOFF1 enables XON/XOFF, XONOFFØ disables XON/XOFF) Defaults: XONOFF1 for the 

COM1 port, XONOFF1 for the COM2 port. 

Controllers on a multi-drop do not support XON/XOFF; to ensure that XON/XOFF is disabled 

for COM1, send the PORT1 command followed by the XONOFFØ command. 

Configuring the 

COM Port 

To control the applicable port for setting up serial communication and transmitting ASCII text 

strings, use the PORT command. PORT1 selects COM1 and PORT2 selects COM2. 

• Serial communication setup commands (see list below) affect the COM port selected 

with the last PORT command. For example, to configure the COM1 port for Gem6K 

language commands only (e.g., to communicate to the Gem6K product over an RS-485 

interface), execute the PORT1 command, then execute the DRPCHKØ command. (refer 

to the Gem6K Series Command Reference to details on each command) 

DRPCHK........ RP240 Check 

E.................... Enable Serial Communication 

ECHO............. Enable Communication Echo 

BOT............... Beginning of Transmission Characters 

BAUD............. Serial Communication Baud Rate 

EOT............... End of Transmission Characters 

EOL............... End of Line Terminating Characters 

ERRBAD........ Error Prompt 

ERRDEF........ Program Definition Prompt 

ERRLVL........ Error Detection Level 

ERRORK........ Good Prompt 

XONOFF........ Enable or disable XON/XOFF 

• The PORT command also selects the COM port through which the WRITE and READ 

commands transmit ASCII text strings. If an RP240 is connected, the DWRITE 

command (and all other RP240 commands) will affect the RP240 regardless of the 

PORT command setting. If no RP240 is detected, the commands are sent to the COM2 

port. DWRITE text strings are always terminated with a carriage return. 


Setup for Gem6K 

Language or RP240 

Selecting a 

Destination Port for 

Transmitting from 

the Controller 

To configure the COM ports for use with Gem6K language commands or an RP240, use the 

DRPCHK command. The DRPCHK command affects the COM port selected with the last PORT 

command. The default for COM1 is DRPCHKØ; the default for COM2 is DRPCHKØ. The 

DRPCHK setting is automatically saved in non-volatile memory. NOTE: Only one COM port 

may be set to DRPCHK2 or DRPCHK3 at any given time. 

DRPCHKØ......Use the COM port for Gem6K language commands only. This is the default 

setting for COM1 and COM2, and if using RS-485 half duplex on COM1. 

Power-up messages appear on all ports set to DRPCHKØ. 

DRPCHK1......Check for the presence of an RP240 at power-up/reset. If an RP240 is 

present, initialize the RP240. If an RP240 is not present, use the port only 

for Gem6K language commands. NOTE: RP240 commands will be sent at 

power-up and reset. 

DRPCHK2......Check for the presence of an RP240 every 5-6 seconds. If an RP240 is 

plugged in, initialize the RP240. 

DRPCHK3......Check for the presence of an RP240 at power-up/reset. If an RP240 is 

present, the initialize the RP240. If an RP240 is not present, use the COM 

port for DWRITE commands only, and ignore received characters. 

To define the port (COM port) through which the Gem6K product sends its responses, you 

have 3 options: 

• Do nothing different. The response will be sent to the COM port through which the 

request was made. If the command is in a stored program, the report will be sent to the 

COM port selected by the most recent PORT command. 

• Prefix the command with [. This causes the response to be sent to both COM ports. 

(e.g., the [TFS command response will be sent through both COM ports) 

• Prefix the command with ]. This causes the response to be sent to the alternative COM 

port. For example, if a report back (e.g., ]TAS) is requested from COM1, the response 

is sent through COM2. If the command is in a stored program, the report will be sent 

out the alternate port from the one selected by the most recent PORT command. 

RS-232C Daisy-Chaining 

Up to ninety-nine stand-alone Gem6K Series products may be daisy-chained. There are two 

methods of daisy-chaining: one uses a computer or terminal as the controller in the chain; the 

other uses one Gem6K product as the master controller. Refer to you product’s Installation 

Guide for daisy-chain connections. 

Step 1 

Follow these steps to implement daisy-chaining: 

To enable and disable communications on a particular controller unit in the chain, you must use 

the Daisy-Chain Address (ADDR) command to establish a unique device address for each the 

unit. The ADDR command automatically configures unit addresses for daisy chaining. This 

command allows up to 99 units on a daisy chain to be uniquely addressed. 

Sending ADDRi to the first unit in the daisy chain sets its address to be (i). The first unit in turn 

transmits ADDR(i + 1) to the next unit to set its address to (i + 1). This continues down 

the daisy chain until the last unit of (n) daisy-chained units has its address set to (i + n). 

Note that a controller with the default device address of zero (0) will send an initial power-up 

start message similar to the following: 

*PARKER Gem6K MOTION CONTROLLER 

*NO REMOTE PANEL 

NOTE: For daisy chaining , you can use either PORT1 (COM1 RS232/484 connector), or 

PORT2 (COM1 RS 232 connector). 


Step 2 

Connect the daisy-chain with a terminal as the master (see diagram in the product’s Installation 


It is necessary to have the error level set to 1 for all units on the daisy-chain (ERRLVL1). 

When the error level is not set to 1, the controller sends ERROK or ERRBAD prompts after 

each command, which makes daisy-chaining impossible. Send the ERRLVL1 command to 

each unit in the chain. (NOTE: To send a the ERRLVL1 command to one specific unit on the 

chain, prefix the command with the appropriate unit's device address and an underline.) 

Commands PORT1 (or PORT2 if that port is being used): 

0_ERRLVL1 ; set error level to Ø for unit #Ø 

1_ERRLVL1 ; Set error level to 1 for unit #1 



After this has been accomplished, a carriage return sent from the terminal will not cause any 

controller to send a prompt. Verify this. Instructions below (step 3) show how to set the error 

level to 1 automatically on power-up by using the controller's power-up start program (highly 

recommended). 

After the error level for all units has been set to ERRLVL1, send a Gem6K series command to 

all units on the daisy-chain by entering that command from the master terminal. 

Commands: 

OUT1111 

A50 

; Turn on onboard outputs 1-4 on all units 

; Set accel to 50 (all units) 

To send a Gem6K series command to one particular unit on the chain, prefix the command 

with the appropriate unit's device address and an underline: 


2_OUT0 ; Turn off onboard output 1 on unit #2 

4_OUT0 ; Turn off onboard output 1 on unit #4 

To receive data from a particular controller on the chain, you must prefix the command with 

the appropriate unit's device address and an underline: 


1_A ; Request acceleration information from unit #1 

*A50 ; Response from unit #1 

Use the E command to enable/disable RS-232C communications for an individual unit. If all 

Gem6K controller units on the daisy chain are enabled, commands without a device address 

identifier will be executed by all units. Because of the daisy-chain's serial nature, the 

commands will be executed approximately 1 ms per character later on each successive unit in 

the chain (assuming 9600 baud). 

Units with the RS-232C disabled (EØ) will not respond to any commands, except E1; 

however, characters are still echoed to the next device in the daisy chain. 


3_E0 ; Disable RS-232C on unit #3 

VAR1=1 ; Set variable #1 to 1 on all other units 

3_E1 ; Enable RS-232C on unit #3 

3_VAR1=5 ; Set variable #1 to 5 on unit #3 

Verify communication to all units by using the techniques described above. 

Step 3 

Now that communication is established, programming of the units can begin (alternatively, 

units can be programmed individually by connecting the master terminal to one unit at a time). 

To allow daisy-chaining between multiple controllers, the ERRLVL1 command must be used 

to prevent units from sending error messages and command prompts. In every daisy-chained 


unit, the ERRLVL1 command should be placed in the program that is defined as the STARTP 

program: 

Program: 

DEF chain ; Begin definition of program chain 

ERRLVL1 ; Set error level to 1 

GOTO main ; Go to program main 

END 

; End definition of program chain 

STARTP chain ; Designates program chain as the power-up program 

To define program main for unit #0: 

Program: 

0_DEF main ; Begin definition of program main on unit #0 

0_GO 

; Start motion 

0_END ; End definition of program main on unit #0 

Step 4 

After all programming is completed, program execution may be controlled by either a master 

terminal, or by a Gem6K Series controller used as a master. 

Daisy-Chaining 

from a Computer or 

Terminal 

Controlling the daisy-chain from a master computer or terminal follows the examples above: 


0_RUN main ; Run program main on unit #0 

1_RUN main ; Run program main on unit #1 

2_GO1 ; Start motion on unit #2 

3_A ; Get A command response from unit #3 

Daisy-Chaining 

from a Master 

Gem6K Controller 

Controlling the daisy-chain from a master Gem6K controller (the first unit on the daisy-chain) 

requires the programs stored in the master controller to control program and command 

execution on the slave controllers. The example below demonstrates the use of the WRITE 

command to send commands to other units on the daisy chain. 

NOTE 

The last unit on the daisy-chain must have RS-232C echo disabled (ECHOØ command). 

Master controller's main program: 

Program: 

DEF main 

L 

WHILE (IN.1 = b0) 

NWHILE 

GO 

WHILE (IN.1 = b1) 

NWHILE 

WRITE"2_D2000" 

WRITE"2_ACK" 

LN 

END 

Controller unit #2 ack program: 

Program: 

DEF ack 

GO1 

END 

; Program main 

; Indefinite loop 

; Wait for input #1 to go active 

; Initiate move 

; Wait for input #1 to go inactive 

; Send message "2_D2000" down daisy chain 

; Send message "2_ACK" down the daisy chain 

; End of loop 

; End of program main 

; Program ack 

; Start motion 

; End of program ack 


Daisy-Chaining and RP240s 

RS-485 Multi-Drop 

RP240s cannot be placed in the drive/controller daisy chain; RP240s can only be connected to 

the designated RP240 port on a drive/controller. It is possible to use only one RP240 with a 

drive/controller daisy-chain to input data for multiple units on the chain. The example below 

(for the drive/controller master with an RP240 connected) reads data from the RP240 into 

variables #1 (data1) & #2 (data2), then sends the messages 3_Ddata1,data2 and 

3_GO. 

Sample portion of code: 

L 

; Indefinite loop 

VAR1=DREAD ; Read RP240 data into variable #1 

VAR2=DREAD ; Read RP240 data into variable #2 

EOT0,0,0,0 

; Turn off 

WRITE"3_D" 

; Send message "3_D" down the daisy chain 

WRVAR1 

; Send variable #1 data down the daisy chain 

WRITE"," 

; Send message "," down the daisy chain 

EOT13,0,0,0 

; Turn on 

WRVAR2 

; Send variable #2 data down the daisy chain 

WRITE"3_GO" 

; Send message "3_GO" down the daisy chain 

LN 

; End of loop 

Up to 99 Gem6K Series products may be multi-dropped. Refer to your product's Installation 

Guide for multi-drop connections. 

To establish device addresses, using the ADDR command: 

The ADDR command allows you to establish up to 99 unique addresses. To use the ADDR 

command, you must address each unit individually before it is connected on the multi drop. 

For example, given that each product is shipped configured with address zero, you could set 

up a 4-unit multi-drop with the commands below, and then connect them in a multi drop: 

1. Connect the unit that is to be unit #1 and transmit the Ø_ADDR1 command to it. 




If you need to replace a unit in the multi drop, send the Ø_ADDRi command to it, where 

"i" is the address you wish the new unit to have. 

To send a Gem6K command from the master to a specific unit in the multi-drop, prefix the 

command with the unit address and an underscore (e.g., 3_OUTØ turns off output #1 on unit 

#3). The master unit (if it is not a Gem6K product) may receive data from a multi-drop unit. 

The ECHO command was enhanced with options 2 and 3. The purpose is to accommodate an 

RS-485 multi-drop configuration in which a host computer communicates to the “master” 

Gem6K controller over RS-232 (COM2 port) and the master Gem6K controller communicates 

over RS-485 (COM1 port) to the rest of the units on the multi-drop. For this configuration, 

the echo setup should be configured by sending to the master the following commands 

executed in the order shown. In this example, it is assumed that the master's device address is 

set to 1. Hence, each command is prefixed with “1_” to address only the master unit. 


1_PORT2........... Subsequent command affects COM1, the RS-485 port 

1_ECHO2........... Echo characters back through the other port, COM2 

1_PORT1........... Subsequent command affects COM2, the RS-232 port 

1_ECHO3........... Echo characters back through both ports, COM1 and COM2 

NOTES 

Controllers on a multi-drop do not support XON/XOFF. To ensure that XON/XOFF is disabled 

for COM1, send the PORT1 command followed by the XONOFFØ command. 

Only ECHOØ or ECHO2 can be used. 


Basic Operation Setup 

3C HAPTER THREE 

Basic Operation 

Setup 


This chapter will enable you to understand and implement these basic operation features: 

• Before You Begin (setup programs, Motion Planner, resetting, etc.).................64 

• Memory Allocation (CAUTION: Do not place in “setup” program)........................ 65 

• Drive Setup (fault level, resolution, disable drive on kill)......................................... 66 

• Scaling ................................................................................................................ 67 

• Positioning Modes .............................................................................................. 71 

• End-of-Travel Limits.......................................................................................... 74 

• Homing............................................................................................................... 79 

• Encoder-Based Stepper Operation (stepper axes only).......................................84 

• Tuning Procedures (servos only) ........................................................................ 85 

• Target Zone Mode (servo axes only)..................................................................84 

• Programmable Inputs and Outputs (incl. triggers and auxiliary outputs) ...........90 

• Variable Arrays (teaching variable data)........................................................... 110

Before You Begin 

WARNING 

The Gem6K Product is used to control your system's electrical and mechanical components. 

Therefore, you should test your system for safety under all potential conditions. Failure to do so 

can result in damage to equipment and/or serious injury to personnel. 

Setup Parameters Discussed in this Chapter 

Below is a list of the setup parameters discussed in this chapter. You can check the status of each parameter setting by 

entering the respective setup command without any command fields (e.g., typing LIMFNC displays the current 

function and state of each limit input). Some setup parameters are also reported with the TSTAT and TASF status 

commands (these and other status commands are described on page 222). 

Setup Parameter Command See Pg. Setup Parameter Command See Pg. 

Memory (status with TDIR & TMEM) ...........MEMORY.............11 & 65 

Drive Setup............................................................................66 

Drive resolution (stepper only) ..............DRES 

Drive disable on kill................................KDRIVE 

Drive stall detection ...............................DSTALL 

Scaling...................................................................................67 

Enable scaling factor .............................SCALE 

Acceleration scaling factor.....................SCLA 

Distance scaling factor ..........................SCLD 

Velocity scaling factor............................SCLV 

Positioning Mode...................................................................71 

Continuous or preset .............................MC 

Preset: absolute or incremental.............MA 

Encoder Based Stepper Operation (stepper only) ................84 

Encoder resolution.................................ERES 

Encoder capture/counting enable..........ENCCNT 

Use encoder as counter ........................ENCSND ((keep)) 

Stall detection........................................ESTALL 

Kill when stall is detected ......................ESK 

Stall deadband.......................................ESDB 

Tuning Procedures (servos only) ..........................................85 

Current loop bandwidth .........................DIBW 

Torque/force limit...................................DMTLIM 

Velocity limit...........................................DMVLIM 

Notch filter A depth................................DNOTAD 

Notch filter A frequency .........................DNOTAF 

Notch filter A quality factor.....................DNOTAQ 

Notch filter B depth................................DNOTBF 

Notch filter B quality factor.....................DNOTBQ 

Notch filter B frequency ........................DNOTBF 

Notch lead filter break frequency ..........DNOTLD 

Notch lag filter break frequency ............DNOTLG 

Position loop bandwidth ........................DPBW 

Velocity loop bandwidth ........................DVBW 

Load damping .......................................LDAMP 

Load-to-rotor inertia ratio 

or load-to-force mass ratio ....................LJRAT 

Acceleration feed forward gain .............DNOTBF 

Servo control signal offset .....................SGAF 

Integrator enable ..................................SGINTE 

Current damping ratio ...........................SGIRAT 

Target Zone end-of-move settling criteria (servo axes)........ 84 

Target zone mode enable..................................................... STRGTE 

Target distance zone ...................................................... STRGTD 

Target velocity zone........................................................ STRGTV 

Target settling timeout period ......................................... STRGTT 

Programmable Input Functions ............................................ 90 

Define input functions ........................... INFNC & LIMFNC 

Input active level................................... INLVL & LIMLVL 

Input debounce ..................................... INDEB 

Trigger interrupt - special functions ...... TRGFN 

Trigger interrupt - lockout time.............. TRGLOT 

Virtual Inputs......................................... IN 

Programmable Output Functions.......................................... 90 

Define output functions......................... OUTFNC 

Output active level ................................ OUTLVL 

End-of-travel limits................................................................ 74 

Limit function assignments ................... LIMFNC & INFNC 

Hardware – enabled ............................. LH 

Hardware – deceleration....................... LHAD 

Hardware – s-curve decel..................... LHADA 

Hardware – active level of input............ LIMLVL 

Software – enabled............................... LS 

Software – deceleration........................ LSAD 

Software – s-curve decel ...................... LSADA 

Software – negative direction limit ....... LSNEG 

Software – positive direction limit ........ LSPOS 

Homing ................................................................................. 79 

Limit function assignments ................... LIMFNC & INFNC 

Acceleration.......................................... HOMA 

S-curve acceleration............................. HOMAA 

Deceleration.......................................... HOMAD 

S-curve deceleration............................. HOMADA 

Backup to home.................................... HOMBAC 

Final approach direction ....................... HOMDF 

Stopping edge of switch........................ HOMEDG 

Home switch active level ...................... LIMLVL 

Velocity ................................................ HOMV 

Velocity of final approach...................... HOMVF 

Home to Z channel input....................... HOMZ 

Variable Arrays (teaching variable data) .............................. 110 

Initialize numeric variable for data ........ VAR or VARI 

Define data program and program size DATSIZ 

Set data pointer & establish increment. DATPTR 

Reset data pointer to specific location.. DATRST 


Position loop ratio .................................SGPRAT 

Velocity/position bandwidth ratio ..........SGPSIG 

Velocity feed forward gain ....................SGVP 

Velocity damping ratio ..........................SGVRAT 

Using a Setup Program 

The features described in this chapter are configured with certain Gem6K Series commands, 

commonly referred to as “setup commands.” We recommend placing these commands (except 

MEMORY) into a special “setup program” that is executed to prepare the Gem6K Series 

product for subsequent controller operations. Further details about setup programming are 

provided in the Creating and Executing a Setup Program section, page 13. 

USE THE START WIZARD IN MOTION PLANNER 

The easiest way to get started with your setup program is to use the Start Wizard in Motion 

Planner’s Wizard Editor. After the Start wizard is finished, you can include additional setup 

code according to your programming needs. The Start wizard also defines which program is 

your start-up (STARTP) program. If you do not wish to program you entire application with 

the Wizards, you can use the Start wizard to get the basic setup accomplished, and then 

copy the generated code into the Program Editor. (Wizard version 4.2 or later required) 

Resetting the Controller 

There are two primary ways to reset the Gem6K controller (listed below). 

• Cycle power. 

• Execute the RESET command. 

When the controller is reset, most of the previously entered command parameters are returned 

to their original factory default values. All programs and variables, as well as certain 

command values, are retained in non-volatile memory (see page 35). If a start-up program is 

assigned with the STARTP command, resetting the controller will automatically execute that 

program. If you are using an RP240, the RESET function is available if you use the default 

menu system (see page 130). 

Memory Allocation 

For details about memory allocation, refer to Storing Programs on page 11. 

CAUTION 

Issuing a new MEMORY command (e.g., MEMORY200000,100000) will erase all existing 

programs and compiled profiles residing in the Gem6K product’s memory. To determine the 

status of memory allocation, use the TMEM command. 

Do not place the MEMORY command in the program assigned as the startup (STARTP) 

program. Doing so would erase all programs and segments upon cycling power or issuing 

the RESET command. 

Chapter 3. Basic Operation Setup 65

Drive Setup 

Drive Stall Detection (stepper only) 

The DSTALL command determines if the encoderless stall feature will be checked as Drive 

Stall indicator. 

The state of the encoderless stall feature can be monitored at all times with Extended Axis 

Status bit #17 (reported with TASX, TASF, and the ASX assignment/comparison operand). 

When a Drive Stall is detected, the Gem6K responds as follows: (this response is the same as 

that for Encoder Stall Detection, which is enabled with the ESTALL command) 

• The stall is reported with Axis Status bit #12 (reported with TAS, TASF, and AS). 

• If ERROR error-checking bit #1 is enabled (ERROR.1-1): 

- The stall is reported with Error Status bit #1 (reported with TER, TERF, and ER). 

- The Gem6K branches to the assigned ERRORP program. 

• If the Kill-on-Stall feature is enabled (ESK1), the Gem6K immediately kills motion. 

Drive Resolution (stepper only) 

The drive resolution controls the number of steps the Gem6K controller considers as a full 

revolution for the motor drive. The drive’s resolution is set with the DRES command (default 

is 25,000 steps/rev). 

Disable Drive On Kill (servo only) 

Normally, when you issue a Kill command (K, !K, or K) or activate an input 

configured as a kill input (see INFNCi-C or LIMFNCi-C command), motion is stopped at 

the hard limit (LHAD/LHADA) deceleration setting and the drives are left in the enabled state 

(DRIVE1). 

However, your application may require you to disable (shut down or de-energize) the drives in 

a Kill situation to, for example, prevent damage to the motors or other system mechanical 

components. If so, set the controller to the Disable Drive on Kill mode with the KDRIVE1 

command. In this mode, a kill command or kill input will shut down the drives immediately, 

letting the motors free wheel (without control from the drives) to a stop. 


Scaling 

Units of Measure without Scaling 

Scaling is disabled (SCALEØ) as the factory default condition: 

• Steppers: When scaling is disabled, all distance values entered are in commanded counts 

(sometimes referred to as motor steps), and all acceleration, deceleration and velocity 

values entered are internally multiplied by the DRES command value. 

• Servos: 

Units of Measure (per feedback source) 

Motion Attribute Encoder Resolver 

Accel/Decel Revs/sec/sec * revs/sec/sec 

Velocity Revs/sec * revs/sec 

Distance Counts (steps) ** Counts (steps) ** 

* All accel/decel & velocity values are internally multiplied by the ERES value. 

** Distance is measured in the counts received from the feedback device. 

What is Scaling 

Scaling allows you to program acceleration, deceleration, velocity, and position values in 

units of measure that are appropriate for your application. The SCALE command is used to 

enable or disable scaling (SCALE1 to enable, SCALEØ to disable). The motion type(s) you are 

using in your application determines which scale factor commands you need to configure: 

Type of Motion 

Accel/Decel 

Scaling 

Velocity 

Scaling 

Distance 

Scaling 

Standard Point-to-Point Motion SCLA SCLV SCLD 

Following SCLA SCLV SCLD for follower distances 

SCLMAS for master distances 

* A separate description of implementing scaling for Following is provided on page 70. 

When Should I Define Scaling Factors 

Scaling calculations are performed when a program is defined or downloaded. Consequently, 

you must enable scaling (SCALE1) and define the scaling factors (SCLD, SCLA, SCLV, 

SCLMAS) prior to defining (DEF), uploading (TPROG), or running (RUN) the program. 

NOTE 

All scaling parameters 

are saved in batterybacked 

RAM 

RECOMMENDATION: Place the scaling commands at the beginning of your program file, 

before the location of any defined programs. This ensures that the motion parameters in 

subsequent programs in your program file are scaled correctly. When you use Motion Planner’s 

Setup Generator wizard, the scaling commands are automatically placed in the appropriate 

location in your program file. 

ALTERNATIVE: Scaling factors could be defined via a terminal emulator just before defining 

or downloading a program. Because scaling command values are saved in battery-backed 

RAM (remembered after you cycle power or issue a RESET command), all subsequent program 

definitions and downloads will be scaled correctly. 

NOTES 

• Scaling commands are not allowed in a program. If there are scaling commands in a 

program, the controller will report an error message (“COMMAND NOT ALLOWED IN 

PROGRAM”) when the program is downloaded. 

• If you intend to upload a program with scaled motion parameters, be sure to use 

Motion Planner. Motion Planner automatically uploads the scaling parameters and 

places them at the beginning of the program file containing the uploaded program from 

the controller. This ensures correct scaling when the program file is later downloaded. 


Acceleration & Deceleration Scaling (SCLA) 

Steppers: 

Servos: 

If scaling is enabled (SCALE1), all accel/decel values entered are internally 

multiplied by the acceleration scaling factor to convert user units/sec/sec to 

commanded counts/sec/sec. The scaled values are always in reference in 

commanded counts, regardless of the existence of an encoder. 

If scaling is enabled (SCALE1), all accel/decel values entered are internally 

multiplied by the acceleration scaling factor to convert user units/sec/sec to 

encoder or analog input counts/sec/sec. 

All accel/decel commands for point-to-point motion (e.g., A, AA, AD, HOMA, HOMAD, JOGA, 

etc.) are multiplied by the SCLA command value. 

As the accel/decel scaling factor (SCLA) changes, the 

resolution of the accel and decel values and the 

number of positions to the right of the decimal point 

also change (see table at right). An accel/decel value 

with greater resolution than allowed will be truncated 

(e.g., if scaling is set to SCLA10, the A9.9999 

command would be truncated to A9.9). 

SCLA value 

(steps/unit 2 ) 

1 - 9 

10 - 99 

100 - 999 

1000 - 9999 

10000 - 99999 

100000 - 999999 

Decimal 

Places 

0 

1 

2 

3 

4 

5 

Use the following equations to determine the range of acceleration and deceleration values for 

your product. 

Axis Type Min. Accel or Decel (resolution) 

Stepper 0.001 ∗ DRES 

SCLA 

Servo 

0.001 ∗ ERES 

Encoder feedback: 

SCLA 

Resolver 

Max. Accel or Decel 

999.9999 ∗ DRES 

SCLA 

999.9999 ∗ ERES 

Encoder feedback: 

SCLA 

Resolver 

Velocity Scaling (SCLV) 

Steppers: 

Servos: 

If scaling is enabled (SCALE1), all velocity values entered are internally 

multiplied by the velocity scaling factor to convert user units/sec to 

commanded counts/sec. The scaled values are always in reference to 

commanded counts (sometimes referred to as “motor steps”). 

If scaling is enabled (SCALE1), all velocity values entered are internally 

multiplied by the velocity scaling factor to convert user units/sec to encoder or 

analog input counts/sec. 

All velocity commands for point-to-point motion (e.g., V, HOMV, HOMVF, JOGVH, JOGVL, 

etc.) are multiplied by the SCLV command value. 

As the velocity scaling factor (SCLV) changes, the velocity command's range and its decimal 

places also change (see table below). A velocity value with greater resolution than allowed 

will be truncated. For example, if scaling is set to SCLV10, the V9.9999 command would 

be truncated to V9.9. 

SCLV Value 

(counts/unit) 

1 - 9 

10 - 99 

100 - 999 

1000 - 9999 

10000 - 99999 

100000 - 999999 

Velocity Resolution 

(units/sec) 

1 

0.1 

0.01 

0.001 

0.0001 

0.00001 

Decimal Places 

0 

1 

2 

3 

4 

5 


Use the following equations to determine the maximum velocity range for your product type. 

Max. Velocity for Steppers 

6,5000,000 

SCLV 

n = maximum velocity as set 

by the PULSE command. 

Max. Velocity for Servos 

(determined by feedback source selected for axis #1) 

Encoder Feedback: 6,5000,000 

SCLV 

Resolver 

Distance Scaling (SCLD and SCLMAS) 

Steppers: 

Servos: 

If scaling is enabled (SCALE1), all distance values entered are internally 

multiplied by the distance scaling factor to convert user units to commanded 

counts (“motor steps”). 

If scaling is enabled (SCALE1), all distance values entered are internally 

multiplied by the distance scaling factor to convert user units to encoder or 

analog input counts. 

All distance commands for point-to-point motion (e.g., D, PSET, REG, SMPER) are multiplied 

by the SCLD command value. 

Scaling for Following Motion: The SCLD command defines the follower’s distance scale factor, and 

the SCLMAS command defines the master's distance scale factor. The Following-related commands that 

are affected by SCLD and SCLMAS are listed in the table below. 

Commands Affected by Master Scaling (SCLMAS) 

FMCLEN: Master Cycle Length 

FMCP: Master Cycle Position Offset 

FOLMD: Master Distance 

FOLRD: Follower-to-Master Ratio (Denominator) 

GOWHEN: Conditional GO (left-hand variable is PMAS) 

TPMAS & [ PMAS ]: Position of Master Axis 

TVMAS & [ VMAS ]: Velocity of Master Axis 

Commands Affected by Follower Scaling (SCLD) 

FOLRN: Follower-to-Master Ratio (Numerator) 

FSHFD: Preset Phase Shift 

GOWHEN: Conditional GO (left-hand variable ≠ PMAS) 

TPSHF & [ PSHF ]: Net Position Shift of Follower 

TPSLV & [ PSLV ]: Position of Follower Axis 

Fractional Step Truncation 

If you are operating in the 

incremental mode (MAØ), or 

specifying master distance 

values with FOLMD, when the 

distance scaling factor (SCLD or 

SCLMAS) and the distance value 

are multiplied, a fraction of one 

step may be left over. This 

fraction is truncated when the 

distance value is used in the 

move algorithm. This truncation 

error can accumulate over a 

period of time, when performing 

incremental moves continuously 

in the same direction. To 

eliminate this truncation 

problem, set SCLD or SCLMAS to 

1, or a multiple of 10. 

As the SCLD or SCLMAS scaling factor changes, the distance command's range and its 

decimal places also change (see table below). A distance value with greater resolution than 

allowed will be truncated. For example, if scaling is set to SCLD400, the D105.2776 

command would be truncated to D105.277. 

SCLD or SCLMAS Value 

(counts/unit) 

Distance Resolution 

(units) 

Distance Range 

(units) 

1 - 9 1.0 0 - ±999999999 0 

10 - 99 0.10 0.0 - ±99999999.9 1 

100 - 999 0.010 0.00 - ±9999999.99 2 

1000 - 9999 0.0010 0.000 - ±999999.999 3 

10000 - 99999 0.00010 0.0000 - ±99999.9999 4 

100000 - 999999 0.00001 0.00000 - ±9999.99999 5 

Decimal 

Places 


Scaling Example — 

Steppers 

User has a 25,000 step/rev motor/drive attached to 5-pitch leadscrew. The user wants to program motion 

parameters in inches; therefore the scale factor calculation is: 25,000 steps/rev x 5 revs/inch = 125,000 

steps/inch. For instance, with a scale factor of 125,000, the operator could enter a move distance value of 

2.000 and the controller would send out 250,000 pulses, corresponding to two inches of travel. 

SCALE1 

DRES25000 

SCLD125000 

SCLV125000 

SCLA125000 

; Enable scaling 

; Set drive resolution to 25,000 steps/rev 

; Allow entering distance in inches 

; Allow entering velocity in inches/sec 

; Allow entering accel/decel in inches/sec/sec 


Servos 

User has a 4,000 count/rev servo motor/drive system (using a 1000-line encoder) attached to a 5-pitch 

leadscrew. The user wants to position in inches; therefore, the scale factor calculation is 4,000 counts/rev 

x 5 revs/inch = 20,000 counts/inch. 

ERES4000 

SCALE1 

SCLD20000 

SCLV20000 

SCLA20000 

; Set encoder resolution to 4000 steps/rev (post quadrature) 


; Allow entering distance values in inches 

; Allow entering velocity values in inches/sec 

; Allow entering accel/decel values in inches/sec/sec 

; Select ANI feedback for axis #1 


; Allow entering distance values in volts 

; Allow entering velocity values in volts/sec 

; Allow entering accel/decel values in volts/sec/sec 

; Select encoder feedback for both axes (prepare for motion) 


Following 

Typically, the master and follower scale factors are programmed so that master and follower units are the 

same, but this is not required. Consider the scenario below as an example. 

The master is a 1000-line encoder (4000 counts/rev post-quadrature) mounted to a 50 teeth/rev pulley 

attached to a 10 teeth/inch conveyor belt, resulting in 80 counts/tooth (4000 counts/50 teeth = 80 

counts/tooth). To program in inches, you would set up the master scaling factor with the SCLMAS800 

command (80 counts/tooth ∗ 10 teeth/inch = 800 counts/inch). 

The follower axis is a servo motor with position feedback from a 1000-line encoder (4000 counts/rev). 

The motor is mounted to a 4-pitch (4 revs/inch) leadscrew. Thus, to program in inches, you would set 

up the follower scaling factor with the SCLD16000 command (4000 counts/rev ∗ 4 revs/inch = 16000 

counts/inch). 

SCALE1 


SCLMAS800 

; Master scaling: 

; (80 counts/tooth * 10 teeth/inch = 800 counts/inch) 

SCLD16000 

; Follower scaling: 

; (4000 counts/rev ∗ 4 revs/inch = 16000 counts/inch) 


Positioning Modes 

The Gem6K controller can be programmed to position in either the preset (incremental or 

absolute) mode or the continuous mode. You should select the mode that will be most 

convenient for your application. For example, a repetitive cut-to-length application requires 

incremental positioning. X-Y positioning, on the other hand, is better served in the absolute 

mode. Continuous mode is useful for applications that require constant movement of the load 

based on internal conditions or inputs, not distance. 

Refer also to the 

Scaling section on 

page 67. 

Positioning modes require acceleration, deceleration, velocity, and distance commands 

(continuous mode does not require distance). The table below identifies these commands and 

their units of measure, and which scaling command affects them. 

Parameter Units (Unscaled), Stepper Units (Unscaled), Servo Unit Scaling Command * 

Acceleration revs/sec 2 encoder/resolver: revs/sec 2 SCLA 

Deceleration revs/sec 2 encoder/resolver: revs/sec 2 SCLA 

Velocity revs/sec encoder/resolver: revs/sec SCLV 

Distance steps counts SCLD *** 

* Scaling must first be enabled with the SCALE1 command. For details on scaling, refer to page 67. 

*** An axis assigned as a master (for Following) is scaled by the SCLMAS command. 

On-The-Fly (Pre-emptive Go) Motion Profiling 

While motion is in progress (regardless of the positioning mode), you can change these 

motion parameters to affect a new profile: 

• Acceleration (A) — s-curve acceleration not allowed during on-the-fly changes 

• Deceleration (AD) — s-curve deceleration not allowed during on-the-fly changes 

• Velocity (V) 

• Distance (D) 

• Preset or Continuous Positioning Mode Selection (MC) 

• Incremental or Absolute Positioning Mode Selection (MA) 

• Following Ratio Numerator and Denominator (FOLRN and FOLRD, respectively) 

The motion parameters can be changed by sending the respective command (e.g., A, V, D, 

MC, etc.) followed by the GO command. If the continuous command execution mode is 

enabled (COMEXC1), you can execute buffered commands; otherwise, you must prefix each 

command with an immediate command identifier (e.g., !A, !V, !D, !MC, etc., followed by 

!GO). The new GO command pre-empts the motion profile in progress with a new profile 

based on the new motion parameter(s). 

For more information, see On-The-Fly Motion Profiling on page 155. 


Preset Positioning Mode 

Incremental Mode 

Moves 

Example 

A preset move is a point-to-point move of a specified distance. You can select preset moves by 

putting the Gem6K controller into preset mode (canceling continuous mode) using the MCØ 

command. Preset moves allow you to position the motor/load in relation to the previous stopped 

position (incremental mode—enabled with the MAØ command) or in relation to a defined zero 

reference position (absolute mode—enabled with the MA1 command). 

The incremental mode is the controller's default power-up mode. When using the Incremental 

Mode (MAØ), a preset move moves the motor/load the specified distance from its starting 

position. For example, if you start at position N, executing the D6ØØØ command in the MAØ 

mode will move the motor/load 6,000 units from the N position. Executing the D6ØØØ 

command again will move the motor/load an additional 6,000 units, ending the move 12,000 

units from position N. 

You can specify the direction of the move by using the optional sign + or - (e.g., D+6ØØØ or 

D-6ØØØ). Whenever you do not specify the direction (e.g., D6ØØØ), the unit defaults to the 

positive (+) direction. 

SCALE0 ; Disable scaling 

MA0 ; Set to Incremental Position Mode 

A2 ; Set acceleration to 2 units/sec/sec 

V5 ; Set velocity to 5 units/sec 

D4000 ; Set distance to 4,000 positive units 

GO ; Initiate motion on (move 4,000 positive units) 

GO ; Repeat the move 

D-8000 ; Set distance to 8,000 negative units 

; (return to original position) 

GO ; Initiate motion on (move 8,000 units in the negative 

; direction and end at its original starting position) 

Absolute Mode 

Moves 

A preset move in the Absolute Mode (MA1) moves the motor/load the distance that you specify 

from the absolute zero position. 

Establishing a Zero Position 

One way to establish the zero position is to issue the PSET command when the load is at the 

location you would like to reference as absolute position zero (e.g., PSETØ defines the current 

position as absolute position zero). Steppers with encoder feedback can use the PESET command 

set the absolute encoder position in ENCCNT1 mode. 

The zero position is also established when the Go Home (HOM) command is issued, the absolute 

position register is automatically set to zero after reaching the home position, thus designating the 

home position as position zero. 

Example 

The direction of an absolute preset move depends upon the motor's/load's position at the 

beginning of the move and the position you command it to move to. For example, if the 

motor/load is at absolute position +12,500, and you instruct it to move to position +5,000 

(e.g., with the D5ØØØ command), it will move in the negative direction a distance of 7,500 

steps to reach the absolute position of +5,000. 

The Gem6K controller retains the absolute position, even while the unit is in the incremental 

mode. To ascertain the absolute position, use the TPC and PC commands. 


MA1 ; Set the controller to the absolute positioning mode 

PSET0 ; Set current absolute position to zero 

A5 ; Set acceleration to 5 units/sec/sec 

V3 ; Set velocity to 3 units/sec 

D4000 ; Set move to absolute position 4,000 units 

GO ; Initiate move (move to absolute position +4,000) 

D8000 ; Set move to absolute position +8,000 

GO ; Initiate move (starting from position +4,000, move 4,000 

; additional units in the positive direction to position +8,000) 

D0 ; Set move to absolute position zero 

GO ; Initiate move (starting at absolute position +8,000, 

; move 8,000 units in the negative direction to position zero) 


Continuous Positioning Mode 

The Continuous Mode (MC1) is useful in these situations: 

• Applications that require constant movement of the load 

• Synchronize the motor to external events such as trigger input signals 

• Changing the motion profile after a specified distance or after a specified time period 

(T command) has elapsed 

You can manipulate the motor movement with either buffered or immediate commands. After 

you issue the GO command, buffered commands are not executed unless the continuous 

command execution mode (COMEXC1 command) is enabled. Once COMEXC1 is enabled, 

buffered commands are executed in the order in which they were programmed. More 

information on the COMEXC mode is provided on page 14. 

The command can be specified as immediate by placing an exclamation mark (!) in front of 

the command. When a command is specified as immediate, it is placed at the front of the 

command queue and is executed immediately. 

Example A COMEXC1 ; Enable continuous command processing mode 

COMEXS1 

; Allow command execution to continue after stop 

MC1 

; Sets mode to continuous 

A10 ; Sets acceleration to 10 


GO 

; Initiates move (Go) 

WAIT(VEL=1) ; Wait to reach continuous velocity 

T5 

; Time delay of 5 seconds 

S1 

; Initiate stop 

WAIT(MOV=b0) ; Wait for motion to completely stop 

COMEXC0 

; Disable continuous command processing mode 

; When the move is executed, the load will accelerate to 1 unit/sec, 

; continue at that rate for 5 seconds, and then decelerate to a stop. 

Example B DEF prog1 ; Begin definition of program prog1 

COMEXC1 

; Enable continuous command processing mode 

COMEXS1 

; Allow command execution to continue after stop 

MC1 

; Set to continuous positioning mode 

A10 ; Set acceleration to 10 

V1 ; Set velocity to 1 

GO 

; Initiate move (Go) 

WAIT(VEL=1) ; Wait for motor to reach continuous velocity 

T3 


A50 ; Set acceleration to 50 

V10 ; Set velocity to 10 

GO 

; Initiate acceleration and velocity changes 

T5 


S1 

; Initiate stop 

WAIT(MOV=b0) ; Wait for motion to completely stop 

COMEXC0 

; Disable continuous command processing mode 

END 

; End definition of program prog1 

While in continuous mode, motion can be stopped if: 

• You issue an immediate Stop (!S) or Kill (!K or ctrl/K) command. 

• The load trips an end-of-travel limit switch or encounters a software end-of-travel limit. 

• The load trips a registration input (a trigger input configured with the INFNCi-H 

command to function as a registration input). 

• The load trips an input configured as a kill input (INFNCi-C or LIMFNCi-C) or a 

stop input (INFNCi-D or LIMFNCi-D). 

NOTE 

While the axis is moving, you cannot change the parameters of some commands (such as DRIVE 

and HOM). This rule applies during the COMEXC1 mode and even if you prefix the command with an 

immediate command identifier (!). For more information, refer to Restricted Commands During 

Motion on page 17. 


Linear Motion 

All Gemini drives operate internally in rotary units. If you use a linear motor, 

you must convert some of the motion parameters to their rotary equivalents: 

A .................... Acceleration 

AA .................. Acceleration (S-Curve) 

AD .................. Deceleration 

ADA ................ Deceleration (S-Curve) 

D .................... Distance/Position 

HOMA .............. Home Acceleration 

HOMV .............. Home Velocity 

HOMVF ............ Home Final Velocity 

LHAD .............. Hardware EOT Limit Decel 

LHADA ............ Hardware EOT Limit Decel (S-Curve) 

LSAD .............. Software EOT Limit Decel 

LSADA ............ Software EOT Limit Decel (S-Curve) 

PSET .............. Absolute Position Reference 

REG ................ Registration Distance 

REGLOD .......... Registration Lockout Distance 

STRGTD .......... Target Zone Distance 

STRGTV .......... Target Zone Velocity 

V .................... Velocity 

NOTE: Motor setup is handled differently. If you use the Motion Planner 

setup wizard, you may enter the motor data in linear units and the software 

converts them to rotary units before they are downloaded to the drive. 

To make the conversion from linear to rotary and vice versa, the motor electrical 

pitch, or DMEPIT, must be known. The electrical pitch relates the linear distance 

required for the equivalent of one rotary motor revolution. Mechanically, the 

definition of the electrical pitch is the linear distance between two magnets 

comprising a full magnetic cycle. The illustration (below) shows an example of 

an electrical pitch of 42mm (DMEPIT42). NOTE: Parker linear motors have an 

electrical pitch of 42mm. 

Linear motor track 

;N S;N ;;N 

S 

S 

;N S 

; 

;;; 

42 mm 

Definition of DMEPIT (Electrical Pitch) 

The feedback resolution (ERES) value must be set to the number of counts for 

the electrical pitch (1 rev). 

# counts 1 m DMEPIT( 

mm) 

# counts 

ERES = × × 

= 

1 m 1000 mm 1 ( rev) 

1 ( rev) 

14243 

14243 144 

2443 

from encoder 

conversion 

from motor 

Most linear encoders are metric, and most of those are 1 micron (1 µm): 

1 count 1,000,000 counts 

1 micron encoder = = 

1 µ m m 

Use the following formulas to convert from linear to rotary units. An sample 

conversion for position, acceleration, and velocity is provided on page 76. 


Linear Position 

• D (distance) 

• PSET (absolute 

position reference) 

• REG (registration 

distance) 

• REGLOD (registration 

lockout distance) 

• STRGTD (target zone 

distance) 

Metric: 

English: 

Position 

Position 

# counts 

( counts) 

= 

( m) 

14243 

rotary × 

from encoder 

Position 

# counts .0254 ( m) 

( counts) 

= × 

( m) 

1 ( in) 

14243 

from encoder 

linear 

rotary × 

( m) 

Position 

linear 

( in) 

Position 

# counts .0254 ( m) 

12 ( in) 

( counts) 

= × × 

( m) 

1 ( in) 

1 ( ft) 

14243 

rotary × 

from encoder 

Position 

linear 

( ft) 

Linear Velocity 

• V (velocity) 

• HOMV (home velocity) 

• HOMVF (home final 

velocity) 

• STRGTV (target 

velocity) 

Metric: 

English: 

Velocity 

Velocity 

1 1000 ( mm) 

( rps) 

= 

× 

Velocitylinear 

( m / s) 

DMEPIT( 

mm) 

1 ( m) 

rotary × 

1 25.4 ( mm) 

( rps) 

= 

× 

Velocitylinear 

( in / s) 

DMEPIT( 

mm) 

1 ( in) 

rotary × 

Velocity 

1 25.4 ( mm) 

12 ( in) 

( rps) 

= 

× × Velocitylinear 

( ft / s) 

DMEPIT( 

mm) 

1 ( in) 

1 ( ft) 

rotary × 

Linear Acceleration 

• A (acceleration) 

• AA (s-curve accel) 

• AD (deceleration) 

• AD (s-curve decel) 

• HOMA (home accel) 

• LHAD (hard limit decel) 

• LHADA (hard limit 

s-curve decel) 

• LSAD (soft limit decel) 

• LSADA (soft limit 

s-curve decel) 

Metric: 

Accel 

English: 

Accel 

Accel 

1 1000 ( mm) 

( rpss) 

= 

× 

DMEPIT( 

mm) 

1 ( m) 

rotary × 

1 25.4 ( mm) 

( rpss) 

= 

× 

DMEPIT( 

mm) 

1 ( in) 

rotary × 

Accel 

Accel 

1 25.4 ( mm) 

12 ( in) 

( rpss) 

= 

× × 

DMEPIT( 

mm) 

1 ( in) 

1 ( ft) 

linear 

linear 

rotary × 

( m / s 

( in / s 

Accel 

2 

2 

) 

) 

linear 

( ft / s 

2 

) 


Conversion 

Example 

Using a Parker 406-LXR-M-D15-E2 linear motor, the electrical pitch is 42mm 

(DMEPIT42) and the encoder is 1 micron. Here, we will convert an acceleration of 

10 inches/sec 2 , a velocity of 5 inches/sec, and a distance of 20 inches: 

1. Calculate ERES in counts/rev (result is ERES42000): 

1000 000 counts 1 ( m) 

42 ( mm) 

42 000 counts 

ERES = 

× × = 

1 ( m) 

1000 ( mm) 

( rev) 

1 ( rev) 

144244 

3 14243 14243 

from encoder 

conversion 

from motor 

2. Convert an acceleration of 10 inches/sec 2 to its rotary equivalent in revs/sec 2 : 

1 25.4 ( mm) 

Accel rotary ( rpss) 

= × × 10 ( in / s 

2 ) = 6. 0476 rpss 

42( mm) 

1 ( in) 

3. Convert a velocity of 5 inches/sec to its rotary equivalent in revs/sec: 

1 25.4 ( mm) 

Velocity rotary ( rps) 

= × × 5 ( in / s) 

= 3. 0238 rps 

42 ( mm) 

1 ( in) 

4. Convert a distance of 20 inches to its rotary equivalent in counts: 

1000000 counts .0254 ( m) 

Position rotary ( counts) 

= × × 20.0 ( in) 

= 508000 

1 ( m) 

1 ( in) 

144244 

3 

from encoder 

The program values resulting from these conversions are: 

ERES42000 ; Set encoder resolution to 42000 counts/rev 

A6.0476 ; Set acceleration to 6.0476 revs/sec/sec 

; (10 inches/sec/sec) 

V3.0238 ; Set velocity to 3.0238 revs/sec (5 inches/sec) 

D508000 ; Set distance to 508,000 counts (20 inches) 


End-of-Travel Limits 

Related Commands: 

LH .............Hard limit enable 

LHAD .........Hard limit decel 

LHADA .......Hard limit decel (s) 

LIMLVL.....Limit switch polarity 

LS .............Soft limit enable 

LSAD .........Soft limit decel 

LSADA .......Soft limit decel (s) 

LSNEG .......Soft limit (negative) 

LSPOS .......Soft limit (positive) 

TLIM .........Hard limit status 

TASF .........Bits 15-18 indicate if 

..................hard or soft limit 

..................was encountered 

TERF .........Bit 2: hard limit hit 

..................Bit 3: soft limit hit 

..................(must enable ERROR 

..................checking bits 2 & 3) 

ERROR .......Bit 2 or 3 is enabled, 

..................the Gem6K will 

branch to 

..................the ERRORP program 

..................if a hard or soft limit 

..................is encountered 

The Gem6K controller can respond to both hardware and software end-of-travel limits. The 

purpose of hardware and software end-of-travel limits is to prevent the motor’s load from 

traveling past defined limits. Software and hardware limits are typically positioned in such a 

way that when the software limit is reached, the motor/load will start to decelerate toward the 

hardware limit, thus allowing for a much smoother stop at the hardware limit. Software limits 

can be used regardless of incremental or absolute positioning. When a hardware or software 

end-of-travel limit is reached, the Gem6K controller stops that axis using the respective 

hardware deceleration rate (set with LHAD & LHADA) or software limit deceleration rate (set 

with LSAD & LSADA). 

How to set up hardware end-of-travel limits (for each axis): 

1. Connect the end-of-travel limit inputs according to the instructions in your Gem6K 

product’s Installation Guide. To help assure safety, connect normally-closed switches 

and leave the active level at default “active low” setting (set with the LIMLVL 

command). 

2. (Optional) Define the inputs to be used as end-of-travel inputs for the respective axes. 

NOTE: When the Gem6K product is shipped from the factory, the inputs on the 

“LIMITS/HOME” connectors are factory-configured with the LIMFNC command to 

function as end-of-travel and home limits for their respective axes. If you intend to use 

digital inputs on an external I/O brick as limit inputs: 

a. Assign the limit function to the external input with the INFNC command. 

For example, 1INFNC9-1R assigns the “axis 1 positive end-of-travel limit” 

function to the 1 st input on SIM2 (I/O point 9) of I/O brick 1. 

b. Reassign the respective “LIMITS/HOME” input to a non-limit function with the 

LIMFNC command. For example, LIMFNC1-A assigns the “general-purpose 

input” function to limit input 1 (normally assigned the “axis 1 positive end-oftravel 

limit” function). 

3. Set the hard limit deceleration rate (LHAD & LHADA) to be used when the limit switch 

is activated. The LHADA command allows you to define an s-curve deceleration. 

Steppers: If your system is moving heavy loads or operating at high velocities, you may 

need to decrease the LHAD command value (deceleration rate) to prevent the motor 

from stalling. 

NOTES ON HARDWARE LIMITS 

• Gem6K controllers are shipped from the factory with the hardware end-of-travel limits 

enabled, but not connected. Therefore, motion will not be allowed until you do 

one of the following: 

- Install limit switches or jumper the end-of-travel limit terminals to the GND terminal 

(refer to your product's Installation Guide for wiring instructions). 

- Disable the limits with the LH command (recommended only if the load is not 

coupled). 

- Reverse the active level of the limits by executing the LIMLVL0 command for the 

respective axis. 


How to set up software end-of-travel limits (for each axis): 

1. Use the LS command to enable the software end-of-travel limits/ 

2. Define the positive-direction limit with the LSPOS command, and define the negativedirection 

limit with the LSNEG command. If you have scaling enabled (SCALE1), these 

limit values are scaled by the SCLD command. Both software limits may be defined 

with positive values. 

NOTES ON SOFTWARE LIMITS 

• The software limits (LSPOS & LSNEG) are referenced from a position of absolute 

zero. or negative values. Care must be taken when performing incremental moves 

because the software limits are always defined in absolute terms. They must be 

large enough to accommodate the moves, or a new zero reference position must be 

defined (using the PSET command) before each move. 

• To ensure proper motion when using soft end-of-travel limits, be sure to set the 

LSPOS value to an absolute value greater than the LSNEG value. 

Programming 

Example 

In this sample of code (not a complete program), the hardware and software limits are enabled. 

The distance scaling command (SCLD) is used to define software limit locations in revolutions 

from the absolute zero position (assumes a 4000 step/rev resolution). Deceleration rates are 

specified for both software and hardware limits. If a limit is encountered, the motor will 

decelerate to a stop. 

; ********************************************************* 

; These scaling setup commands are downloaded before the 

; limit setup commands are executed: 

SCALE1 ; Enable scaling 

SCLD4000 ; Program soft limit distance in revs 

SCLA4000 ; Program soft limit accel/decel in revs/sec/sec 

ERES4000 ; Set encoder resolution to 4000 steps/rev 

; ********************************************************* 

LH3 ; Enable limits 1 and 2, disable limits 3 and 4 

LHAD10 ; Set hard limit deceleration 

LSAD5 ; Set soft limit deceleration 

LSNEG0 ; Set negative direction soft limit 

; (0 revs) 

LSPOS10 ; Establish positive soft limit 

; (10 revs) 

LS3 

; Enable soft limits 


Homing (Using the Home Inputs) 

Refer to the product's 

Installation Guide for 

instructions to wire a 

hardware home limit 

switch. 

The homing operation is a sequence of moves that position an axis using the Home Limit input 

and/or the Z Channel input of an incremental encoder. The goal of the homing operation is to 

return the load to a repeatable initial starting location. 

Zero Reference After Homing: As soon as the homing operation is successfully completed, 

the absolute position register is reset to zero, thus establishing a zero reference position. 

The homing operation has several potential homing functions you can customize to suit the 

needs of your application (illustrations of the effects of these commands are presented below): 

Command Homing Function (see respective command descriptions for further details) Default 

Homing Status: 

Status of homing moves 

is stored in bit #5 of the 

axis status register 

(indicates whether or not 

the home operation was 

successful). To display 

the status, use the TASF 

command or the TAS 

command. To use the 

status in a conditional 

expression (e.g., for an 

IF statement), use the 

AS assignment/comparison 

operator. 

HOM ...............Initiate the homing move. To start the homing move in the positive 

direction, use HOMØ; to home in the negative direction, use HOM1. 

HOMA.............Acceleration while homing. 

HOMAA...........S-curve acceleration while homing. 

HOMAD...........Deceleration while homing. 

HOMADA.........S-curve deceleration while homing. 

HOMBAC.........Back up to home. The load will decelerate to a stop after encountering 

the active edge of the home region, and then will move in the opposite 

direction at the HOMVF velocity until the active edge of the home region 

is encountered. Allows the use of HOMEDG and HOMDF. 

HOMDF...........Final approach direction —during backup to home (HOMBAC) or during 

homing to the Z channel input of an incremental encoder (HOMZ). 

HOMEDG.........Specify the side of the home switch on which to stop (either the 

positive-travel side or the negative-travel side). 

LIMLVL.........Define the home limit input active level (i.e., the state, high or low, 

which is to be considered an activation of the input). To use a normallyopen 

switch, select active low (LIMLVL0); to use a normally-closed 

switch, select active high (LIMLVL1). 

HOMV.............Velocity while seeking the home position (see also HOMVF). 

HOMVF...........Velocity while in final approach to home position—during backup to 

home (HOMBAC) or during homing to the Z channel input of an 

incremental encoder (HOMZ). 

HOMZ.............Home to the Z channel input from an incremental encoder. NOTE: The 

home limit input must be active prior to homing to the Z channel. 

HOMx 

(do not home) 

HOMA1Ø 

(10 units/sec 2 ) 

HOMAA10 


HOMAD10 


HOMADA10 


HOMBAC0 

(function disabled) 

HOMDF0 

(positive direction) 

HOMEGD0 

(positive-travel 

side of switch) 

LIMLVL0 

(active-low, use a 

normally-open 

switch) 

HOMV1 

(1 unit/sec) 

HOMVF.1 

(0.1 unit/sec) 

HOMZ0 

(function disabled) 

NOTES ABOUT HOMING 

• Avoid using pause and resume functions during the homing operation. A pause command 

(PS or !PS) or pause/resume input (input configured with the INFNCi-E or LIMFNCi-E 

command) will pause the homing motion. However, when the subsequent resume 

command (C or !C) or pause/resume input occurs, motion will resume at the beginning of 

the homing motion sequence. 

• Relevance of positive and negative direction: 

 

 

 

 

 

 

 

 

 

 

• If an end-of-travel limit is encountered during the homing operation, the motion will be 

reversed and the home switch will be sought in the opposite direction. If a second limit is 

encountered, the homing operation will be terminated, stopping motion at the second limit. 


Figures A and B show the homing operation when HOMBAC is not enabled. “CW” refers to 

the positive direction and “CCW” refers to the negative direction. 

Figure A: 

 

 

 

Home Profile Attributes (commands): 

• Start home move in positive 

direction (HOM0) 

• Backup To Home disabled 

(HOMBAC0) 

 

 

 

 

 

 

 

 

 

 

 

Figure B: 

 

 

 


• Start home move in negative 


• Backup To Home disabled 

(HOMBAC0) 

 

 

 

 

 

 

 

 

 

 

 

Positive Homing, 

Backup to Home 

Enabled 

The seven steps below describe a sample homing operation when HOMBAC is enabled (see 

Figure C). The final approach direction (HOMDF) is CW and the home edge (HOMEDG) is the 

CW edge. “CW” refers to the positive direction and “CCW” refers to the negative direction. 

NOTE 

To better illustrate the direction changes in the backup-to-home operation, the illustrations in 

the remainder of this section show the backup-to-home movements with varied velocities. In 

reality, the backup-to-home movements are performed at the same velocity (HOMVF value). 

Step 1 

Step 2 

Step 3 

Step 4 

Step 5 

Step 6 

Step 7 

A CW home move is started with the HOMØ command at the HOMA and HOMAA 

accelerations. Default HOMA is 10 revs (or inches) per sec 2 . 

The HOMV velocity is reached (move continues at that velocity until home input goes 

active). 

The CCW edge of the home input is detected, this means the home input is active. 

At this time the move is decelerated at the HOMAD and HOMADA command values. It 

does not matter if the home input becomes inactive during this deceleration. 

After stopping, the direction is reversed and a second move with a peak velocity 

specified by the HOMVF value is started. 

This move continues until the CCW edge of the home input is reached. 

Upon reaching the CCW edge, the move is decelerated at the HOMAD and HOMADA 

command values, the direction is reversed, and another move is started in the CW 

direction at the HOMVF velocity. 

As soon as the home input CW edge is reached, this last move is immediately 

terminated. The load is at home and the absolute position register is reset to zero. 


Figure C: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 




• Backup To Home enabled 

(HOMBAC1) 

• Final approach direction is 

positive (HOMDF0) 

• Stop on the positive-travel side 

of the home switch active region 

(HOMEDG0) 

Figures D through F show the homing operation for different values of HOMDF and HOMEDG, 

when HOMBAC is enabled. “CW” refers to the positive direction and “CCW” refers to the 

negative direction. 

Figure D: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 





(HOMBAC1) 


positive (HOMDF0) 

• Stop on the negative-travel side 


(HOMEDG1) 

Figure E: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 





(HOMBAC1) 


negative (HOMDF1) 

• Stop on the positive-travel side 


(HOMEDG0) 

Figure F: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 





(HOMBAC1) 


negative (HOMDF1) 

• Stop on the negative-travel side 


(HOMEDG1) 


Negative Homing, 

Backup to Home 

Enabled 

Figures G through J show the homing operation for different values of HOMDF and HOMEDG, 

when HOMBAC is enabled. “CW” refers to the positive direction and “CCW” refers to the 

negative direction. 

Figure G: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 





(HOMBAC1) 

• Final approach direction is negative 

(HOMDF1) 

• Stop on the negative-travel side of 

the home switch active region 

(HOMEDG1) 

Figure H: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 





(HOMBAC1) 


(HOMDF1) 

• Stop on the positive-travel side of 


(HOMEDG0) 

Figure I: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 





(HOMBAC1) 

• Final approach direction is positive 

(HOMDF0) 

• Stop on the negative-travel side of 


(HOMEDG1) 

Figure J: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 





(HOMBAC1) 


(HOMDF0) 

• Stop on the positive-travel side of 


(HOMEDG0) 


Homing Using 

The Z-Channel 

Figures K through O show the homing operation when homing to an encoder index pulse, or Z 

channel, is enabled (HOMZ1). The Z-channel will only be recognized after the home input is 

activated. It is desirable to position the Z channel within the home active region; this reduces 

the time required to search for the Z channel. “CW” refers to the positive direction and 

“CCW” refers to the negative direction. 

Figure K: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


• Z-Channel homing enabled (HOMZ1) 

• Start home move in negative direction 

(HOM1) 

• Backup To Home enabled (HOMBAC1) 


(HOMDF1) 

• Stop on the negative-travel side of the 

z-channel active region (HOMEDG1) 

Figure L: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 




(HOM1) 



(HOMDF0) 

• Stop on the positive-travel side of the 


Figure M: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 




(HOM1) 



(HOMDF0) 



Figure N: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



• Start home move in positive direction 

(HOM0) 

• Backup To Home disabled (HOMBAC0) 


(HOMDF0) 



Figure O: 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



• Start home move in positive direction 

(HOM0) 



(HOMDF0) 




Encoder-Based Stepper Operation (stepper only) 

Encoder Resolution 

When using an encoder in a stepper application, you may configure the following: 

• Encoder resolution 

• Stall Detection & Kill-on-Stall, Stall Deadband 

• Encoder-based position reference and position capture 

You must specify the encoder resolution with the ERES command. 

Stall Detection & Kill-on-Stall 

To detect stalls without 

an encoder, refer to 

Drive Stall Detection on 

page 66. 

The ESTALL1 command enables the drive to detect encoder-based stall conditions. 

NOTE: Encoder count reference must be enabled (ENCCNT1) before stall detect (ESTALL) 

can be used. 

If used with Kill-on-Stall enabled (ESK1 command), the move in progress will be aborted upon 

detecting a stall. If queried with the ER or the AS commands, the user may branch to any other 

section of program when a stall is detected. Refer to the ER, and AS command descriptions in 

the Gem6K Series Command Reference for more information. 

Kill-on-Stall functions only if the stall detection is enabled (ESTALL1). 

WARNING 

Disabling the Kill-on-Stall function with the ESKØ command will allow the controller to finish 

the move regardless of a stall detection, even if the load is jammed. This can potentially 

damage user equipment and injure personnel. 

Stall Deadband 

Another encoder set-up parameter is the Stall Backlash Deadband (ESDB) command. This 

command sets the number of commanded counts of error allowed, after a change in direction, 

before a stall will be detected. This is useful for situations in which backlash in a system can 

cause false stall situations. 

Encoder Set Up Example 

Examples for 4 Axes 

(command line samples) 

The example below illustrates the features discussed in the previous paragraphs. The DRES 

statement defines the motor resolutions. The ERES statement defines the number of encoder 

steps per encoder revolution. A standard 1000-line encoder is used that produces 4000 

quadrature steps/rev. Encoder counting (ENCCNT), stall detect (ESTALL) and kill-on-stall 

(ESK1) are enabled. If a stall is detected (more than 10 steps out without an encoder step 

back), the motor's movement is killed. The ESDB statement defines the stall deadband. 

DRES25000 

ERES4000 

ESK1 

ENCCNT1 

ESTALL1 

ESDB0 

; Set drive resolution 

; Set encoder resolution 

; Enable kill motion on stall 

; Enable encoder counting (this is 

; required for ESTALL to work) 

; Enable stall detection 

; Set stall deadband 


Encoder Count/Capture Referencing 

Use ENCCNT to configure steppers to reference either the encoder position or the commanded 

position when capturing the position (see INFNCi-H) and checking the encoder position (PE 

and TPE). When checking the actual velocity (VELA and TVELA), ENCCNT determines whether 

the velocity, in units of revs/sec, is derived with the encoder resolution (ERES) or the drive 

resolution (DRES). The default setting (ENCCNT0) references the commanded position. 

Example INFNC1-H ; Configure trigger 1A as position capture input 

ENCCNT10 ; Capture encoder position when trigger 1A is activated 

Tuning Procedures (servos only) 

During the Express Setup procedure shown in the Hardware Installation Guide, Chapter 2 

Installation, the drive uses default values for tuning parameters, based upon the motor 

information you entered. That procedure assumes that the motor is unloaded. In the following 

tuning procedures, you will enter in system information that will characterize the load on the 

motor. Before you continue with the tuning procedures you must have first configured 

your drive for the motor being used. See the Express Setup section in the Hardware 

Installation Guide, Chapter 2: Installation. 

Entering Load Settings 

Position Mode Tuning 

The main load setting you will adjust is LJRAT, which is the load-to-rotor inertia value for 

your system. The more accurately you know this value, the closer your tuning bandwidth 

settings will correspond to the actual dynamic performance of your system. If you only know 

this value approximately, you can adjust this value until you achieve the system performance 

you desire. The total system inertia is given by the following formula: 

Total system inertia = motor rotor inertia*(1 + LJRAT) 

If your system has significant mechanical damping, you will also want to adjust the LDAMP 

setting which specifies system damping provided by the load. If you know that you have 

significant damping in your system from your load but do not know its exact value, you can 

adjust this value until you achieve the system performance that you desire. 

Both the LJRAT and the LDAMP values can be set in the Full Setup section of the GV6K 

wizard in Motion Planner. These values can also be set in the terminal mode of Motion 

Planner. During the tuning process you may want to use the terminal emulator to establish 

appropriate values for these parameters and then upload and save the drive’s full configuration 

settings for use with other units. 

For most applications, the default tuning parameters for position mode are set to provide 

good, stiff motor shaft performance for a given load setting. With the default tuning 

parameters set in the Express Setup procedure, you need only set the system load-to-rotor 

inertia ratio and your system will be tuned. If your system has significant mechanical 

damping, you may need to set the system damping as well. Should you wish to modify the 

default values and fine tune your system for position mode, use the following procedures: 

WARNING 

This procedure causes the motor shaft to move. Make sure that shaft motion will not damage 

equipment or injure personnel. 


Position Mode Tuning Procedure 

Primary Tuning Procedure 

1. Disable the drive. 

2. Configure the drive for position tuning mode (DMODE17). In this mode, the drive 

commands an alternating 1/4 revolution step change in position at a one second 

repetition rate. 

3. Enable the drive and observe your system’s response. (If necessary, you can connect an 

oscilloscope as described in Advanced Tuning below.) 

Ringing or an oscillating response indicates that the position loop bandwidth is too 

high. To eliminate oscillations: 

• decrease bandwidth using the DPBW command. 

A sluggish response indicates that position loop bandwidth is too low. To improve the 

response: 

• increase bandwidth by using the DPBW command. 

NOTE: Ringing, oscillations, or a sluggish response can also indicate inaccurate drive 

settings for LJRAT or LDAMP. 

4. After you achieve a satisfactory system response, reconfigure the drive for position 

mode (DMODE12). This completes the primary tuning procedure. 

If you are unable to achieve a satisfactory response, proceed to the advanced tuning 

procedure below. 

Advanced Tuning Procedure 

1. Disable the drive. 

2. Configure the drive for position tuning mode (DMODE17). In this mode, the drive 

commands an alternating 1/4 revolution step change in position at a one second 

repetition rate. 

(In some applications a different move profile may give better results. Choose a move 

similar to that required by your application, but using fast acceleration and deceleration 

rates. Be sure the maximum velocity of your move is well below the rated speed of 

your drive/motor combination. 

3. Configure ANALOG MONITOR A to show position error (DMONAV3). 

4. Connect one channel of your oscilloscope to the drive’s ANALOG MONITOR A (pin 

21). Connect your oscilloscope’s ground to the drive’s ANALOG GROUND (pin 25). 

5. Adjust your oscilloscope to display position error. (The analog monitor can be scaled, 

in percent, with the DMONAS command.) 

6. Enable the drive and observe your system’s response. Position error will increase 

during acceleration, but should decay smoothly to near zero without significant ringing 

or instability. 

Ringing or an oscillating response indicates that the position loop bandwidth is too 

high, or the position loop damping is too low. To eliminate ringing or oscillations: 

• decrease bandwidth using the DPBW command; then, if necessary: 

• adjust damping by using the SGPRAT command. Use the value that gives the best 

performance. 

• in applications with backlash or high static friction, disabling the velocity integrator 

(SGINTE0) can help improve stability. 

• NOTE: In position mode, the velocity loop bandwidth tracks changes in position loop 

bandwidth by a ratio set by the SGPSIG command. 

A sluggish response indicates that position loop bandwidth is too low, or position loop 

damping is too high. To improve the response: 

• increase bandwidth by using the DPBW command; then, if necessary: 

• adjust damping by using the SGPRAT command. Use the value that gives the best 

performance. 

NOTE: Ringing or a sluggish response can also indicate inaccurate drive settings for 

LJRAT or LDAMP. 

7. After you achieve a satisfactory system response, reconfigure the drive for position 

mode (DMODE12). This completes the advanced tuning procedure. 

If ringing or oscillations persist, and do not seem to be affected by the above adjustments, you 

may need to use notch filters or lead/lag filters. See the Filter Adjustments procedure below. 


Filter Adjustments 

If the previous tuning procedures did not eliminate ringing or oscillations, then mechanical 

resonances may be causing problems with your system’s response. 

Before trying the procedure below, we recommend that you check your mechanical system, 

especially the mechanical stiffness and mounting rigidity of your system. Use bellows or disk 

style couplers, not helical couplers. Once you have optimized your mechanical system, filters 

may allow increased performance, without causing system instability. 

Filters can improve response by reducing system gain over the same frequencies that contain 

resonances. You can then increase the gain for frequencies outside this range, without exciting 

the resonance and causing instability. 

The first procedure below describes how to set the drive’s two notch filters, to reduce 

resonance and improve your system’s response. The second and third procedures describe 

how to set the drive’s lead and lag filters. 

WARNING 

These procedures cause the motor shaft to move. Make sure that shaft motion will not damage 

equipment or injure personnel. 

Notch Filter Adjustment Procedure 

1. Configure the analog monitor to show q-axis current (DMONAV19). 

2. Configure the drive for position tuning mode (DMODE17). 

3. Configure DMTLIM to approximately 1/3 of the default value for your Compumotor 

motor. 

4. Connect one channel of your oscilloscope to the drive’s ANALOG MONITOR A (pin 

21). Connect your oscilloscope’s ground to the drive’s ANALOG GROUND (pin 25). 

5. From the oscilloscope display, observe the system’s response to the tuning mode’s step 

input. Note the frequency of the oscillatory current waveform that is superimposed on 

the 1 Hz step command signal. 

6. Using the DNOTAF command, set the notch filter to the frequency noted in Step 5. 

7. Using the DNOTAD command, slowly increase the depth of the notch filter from 0.0 to 

1.0 until the ringing decreases. 

8. Continue to observe the response to step command signal. Ringing should be reduced 

or eliminated. 

9. Adjust the Q of the filter (DNOTAQ command). Use the following guidelines: 

• Set Q as low as possible. Resonances change with load; therefore, your system 

will be more robust with a lower Q value. (Default = 1) 

• If Q is too low, system stiffness will be reduced outside the resonant range. 

• If Q is too high, the response peak may shift in frequency. 

10. After reducing the resonance, you may notice a second resonance. Use the second 

notch filter (DNOTBF, DNOTBD and DNOTBQ) to reduce the second resonance. 

Follow the same procedure as outlined in steps 1 – 9 above. 

11. If you are done adjusting filters, reconfigure DMTLIM to its default value. 

Otherwise, proceed to the Lag Filter Adjustment procedure below. 


Lag Filter Adjustment Procedure 

The lag filter can act as a low pass filter, and reduce the effects of electrical noise on the 

commanded torque. (It can also reduce the effects of resonance at low frequencies— 

below 60 Hz—where the notch filters are not effective.) 

1. As described in Steps 2 – 3 in the Notch Filter Adjustment procedure above, reduce 

DMTLIM and connect an oscilloscope. 

2. Verify that the lead filter is turned off (DNOTLDØ). 

3. Configure the drive for position tuning mode. Observe the system’s response to the 

tuning mode’s step input. 

4. Choose a value for the lag filter (DNOTLG) that reduces low frequency resonance and 

provides satisfactory system performance. 

5. If you are done adjusting filters, reconfigure DMTLIM to its default value. Otherwise, 

proceed to the Lead /Lag Filter Adjustment procedure below. 

Lead/Lag Filter Adjustment Procedure 

The lead filter can counteract the effects of the lag filter at higher frequencies. Do not use 

the lead filter by itself—if you use the lead filter, you must also use the lag filter. 

1. As described in Steps 2 – 3 in the Notch Filter Adjustment procedure above, reduce 

DMTLIM and connect an oscilloscope. 

2. Set the lag filter (DNOTLG) as described above. 

3. Configure the drive for position tuning mode. Observe the system’s response to the 

tuning mode’s step input. 

4. Choose a value for the lead filter (DNOTLD) that improves system performance. This 

value will typically be higher in frequency than the lag filter setting. 

5. You must choose a value for the lead filter that is higher in frequency than the lag filter 

value. However, do not set the lead filter higher than four times the lag filter frequency, 

or a drive configuration warning will result, and the drive will use the previous filter 

settings. 

6. If you are done adjusting filters, reconfigure DMTLIM to its default value. 


Target Zone Mode (move completion criteria for servos only) 

Under default operation (Target Zone Mode 

not enabled), the Gem6K product's move 

completion criteria is simply derived from the 

move trajectory. The Gem6K product 

considers the current preset move to be 

complete when the commanded trajectory has 

reached the desired target position; after that, 

subsequent commands/moves can be executed. 

Consequently, the next move or external 

operation can begin before the actual position 

has settled to the commanded position (see 

diagram). 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

To prevent premature command execution before the actual position settles into the 

commanded position, use the Target Zone Mode. In this mode, enabled with the STRGTE 

command, the move cannot be considered complete until the actual position and actual 

velocity are within the target zone (that is, within the distance zone defined by STRGTD and 

less than or equal to the velocity defined by STRGTV). If the load does not settle into the 

target zone before the timeout period set with the STRGTT command, the Gem6K product 

detects a timeout error (see illustration below). 

If the timeout error occurs, you can prevent subsequent command/move execution only if you 

enable the ERROR command to continually check for this error condition, and when it occurs 

to branch to a programmed response you can define in the ERRORP program. (Refer to the 

Error Handling section, page 30, for error program examples.) 

As an example, setting the distance zone to ±5 counts (STRGTD5), the velocity zone to ≤0.5 

revs/sec (STRGTV0.5), and the timeout period to 1/2 second (STRGTT500), a move with a 

distance of 8,000 counts (D8000) must end up between position 7,995 and 8,005 and settle 

down to ≤0.5 rps within 500 ms (1/2 second) after the commanded profile is complete. 

Damping is critical 

To ensure that a move settles within the distance zone, it must be damped to the point that it 

will not move out of the zone in an oscillatory manner. This helps ensure the actual velocity 

falls within the target velocity zone set with the STRGTV command (see illustration below). 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Checking the 

Settling Time 

Checking the Actual Settling Time: Using the TSTLT command, you can display the actual 

time it took the last move to settle into the target zone (that is, within the distance zone defined 

by STRGTD and less than or equal to the velocity defined by STRGTV). The reported value 

represents milliseconds. The TSTLT command is usable whether or not the Target Zone 

Settling Mode is enabled with the STRGTE command. 


Programmable Inputs and Outputs (onboard and external inputs & outputs) 

Programmable inputs and outputs allow the controller to detect and respond to the state of 

switches, thumbwheels, electronic sensors, and outputs of other equipment such as drives and 

PLCs. The I/O that may be used as programmable inputs and outputs are: 

• Onboard I/O: 

− Limit inputs on the Drive I/O connector (pins 28, 29, and 31) 

− Trigger inputs on the Drive I/O connector (pins 37 and 38). A “master trigger” is 

also available on the Drive I/O connector (pin 35). These are general purpose on 

board digital inputs but can be redefined as trigger inputs. 

− Digital outputs on the Drive I/O connector (pins 41, 43, 45, 46, 48, and 49) 

− Relay output on the +24VDC power input connector (screw terminals) 

• Expansion I/O located on I/O bricks connected to the Gem6K controller’s “EXPANSION 

I/O” connector. Each I/O brick can hold from 1 to 4 of these I/O SIM modules in any 

combination (each SIM module provides 8 inputs or outputs, for a total of 32 I/O points 

per I/O brick): 

− Digital inputs 

− Digital outputs 

− Analog inputs 

− Analog outputs 

USING THE STATE OF I/O TO CONTROL PROGRAMMED EVENTS: Based on the 

binary state of the inputs and outputs (binary status can be used in assignment/comparison 

operations using the LIM, IN and OUT operators), the controller can make program flow 

decisions and assign values to binary variables for subsequent mathematical operations. These 

operations and the associated program flow, branching, and variable commands are listed below. 

Operation based on I/O State Associated Commands See Also* 

I/O state assigned to a binary variable LIM, [IN], [OUT], VARB Variables (page 18) 

I/O state used as a basis for 

comparison in conditional branching & 

looping statements 

Input state used as a basis for a 

conditional GO 

I/O state used as a basis for a 

program interrupt (GOSUB) 

conditional statement 

Mimic PLC functionality by scanning 

I/O states with a compiled program 

LIM, [IN], [OUT], IF, 

ELSE, NIF, REPEAT, 

UNTIL, WAIT, WHILE, 

NWHILE 

Program Flow Control (page 23) 

[IN], GOWHEN, LIM Synchronizing Motion (page 163) 

ONIN Program Interrupts (page 29) 

PLCP, SCANP PLC Scan Mode (page 120) 

* Refer also to the respective command descriptions in the Gem6K Series Command Reference. 

I/O UPDATE RATE: The programmable inputs and outputs are sampled at the “system 

update rate,” which is every 2 ms. 

EXPANSION I/O BRICKS: If the I/O brick is disconnected or if it loses power, the 

controller will perform a kill (all tasks) and set error bit #18 (see ERROR). (If you disable the 

“Kill on I/O Disconnect” mode with KIOENØ, the Gem6K will not perform the kill.) The 

controller will remember the brick configuration (volatile memory) in effect at the time the 

disconnection occurred. When you reconnect the I/O brick, the controller checks to see if 

anything changed (SIM by SIM) from the state when it was disconnected. If an existing SIM 

slot is changed (different SIM, vacant SIM slot, or jumper setting), the controller will set the 

SIM to factory default INEN and OUTLVL settings. If a new SIM is installed where there was 

none before, the new SIM is auto-configured to factory defaults. 


Programmable I/O Bit Patterns 

The Gem6K has programmable inputs and outputs. The total number of onboard inputs and outputs (analog inputs, digital 

inputs, and digital outputs) is fixed. The total number of expansion inputs and outputs (analog inputs, analog outputs, 

digital inputs and digital outputs) depends on your configuration of expansion I/O bricks. 

These programmable I/O are represented by binary bit patterns, and it is the bit pattern that you reference when 

programming and checking the status of specific inputs and outputs. The bit pattern is referenced 1 to n, from left to right. 

• Onboard I/O. For example, the status command to check all onboard digital inputs is TIN. 

An example response is: *TIN0100_0. 

• Expansion I/O. For example, the status command to check all digital inputs on I/O brick 2 is 2TIN. 

An example response is: *2TIN0010_0110_1100_0000_XXXX_XXXX_XXXX_XXXX. 

I/O Brick 2 

Bit 1 

Bit 1 

Bit 5 

Bit 32 

Onboard Programmable I/O 

I/O Location Programming Status Report, Assignment 

Limit Inputs “DRIVE I/O” connector LIMFNC, LIMEN, LIMLVL TLIM, LIM 

Digital Inputs “DRIVE I/O” connector INFNC, INLVL, INEN, ONIN, 

INPLC, INSTW 

Outputs (digital) “DRIVE I/O” connector OUT, OUTFNC, OUTLVL, 

OUTEN, OUTALL, OUTPLC, 

OUTTW, POUT 

Analog Input “DRIVE I/O” connector JOYAXH, JOYCDB, 

JOYCTR, JOYEDB, 

ANIRNG, ANIMAS 

TIN, IN 

TOUT, [OUT] 

TANI, [ANI] 

Limit Inputs (“DRIVE I/O” connector) 

Input bit pattern for LIM, TLIM, LIMEN, LIMFNC, and LIMLVL: 

Bit # Pin # Function * 

1 28 Positive end-of-travel limit 

2 29 Negative end-of-travel limit 

3 31 Home limit 

* The functions listed are the factory default functions; other 

functions may be assigned with the LIMFNC command. 

Sample response to TLIM (limit inputs status) command: 

*TLIM110 


Digital Inputs (“DRIVE I/O” connector) 

Input bit pattern for TIN, IN, INFNC, INLVL, INEN, INPLC, INSTW, ONIN: 

Bit # Pin # Function * 

1 37 Input 1 (if assigned, TRIG-A) 

2 38 Input 2 (if assigned, TRIG-B) 

3 39 Input 3 

4 34 Input 4 

5 35 Input 5 (if assigned, TRIG-M) 

* If the input is assigned the “trigger interrupt” function with the INFNCi-H 


TRIG-A must be on Input 1 

TRIG-B must be on Input 2 

TRIG-M must be on input 5 

Sample response to TIN (input status) command: 

*TIN0010_1 

Digital Outputs (“DRIVE I/O” connector) 

Output bit pattern for TOUT, [OUT], OUT, OUTFNC, OUTLVL, OUTEN, OUTALL, 

OUTPLC, OUTTW, POUT: 

Bit # Pin # Function 

1 41 Output 1. 






7 Relay Output 7. 

Sample response to TOUT 

(onboard outputs status) command: 

*TOUT0000_000 


Expansion I/O Bricks 

The Gem6K product allows you to expand your system I/O by connecting up to 8 I/O bricks (see Installation Guide for 

connections). Expansion I/O bricks may be ordered separately (referred to as the “EVM32”). Each I/O brick can hold from 

1 to 4 of these I/O SIM modules in any combination: 

SIM Type Programming Status Report, Assignment 

Digital Inputs SIM (8 inputs) INFNC, INLVL, INEN, ONIN, INPLC, INSTW TIN, IN, TIO 

Digital Outputs SIM (8 outputs) 

Analog Inputs SIM (8 inputs) 

OUT, OUTFNC, OUTLVL, OUTEN, OUTALL, 

OUTPLC, OUTTW, POUT 

• Enable/Disable: ANIEN. 

• Voltage range: ANIRNG. 

• Joystick setup: JOYAXH, JOYAXL, JOYCDB, 

JOYCTR, JOYEDB, JOYZ. 

• Following master source: ANIMAS, FOLMAS 

TOUT, [OUT], TIO 

• Voltage: TANI, ANI, TIO 

• Servo position: TPANI, PANI, 

FB, TFB 

Analog Outputs SIM (8 outputs) ANO TANO, [ANO], TIO 

Each I/O brick has a unique “brick address”, denoted with the “” symbol in the command syntax. The I/O bricks are 

connected in series to the “EXPANSION I/O” connector on the Gem6K. The 1 st I/O brick has address #1, the next brick has 

address #2, and so on. (NOTE: If you leave out the brick address in the command, the Gem6K product assumes you are 

addressing the command to the onboard I/O.) Each I/O brick has 32 I/O addresses, referenced as absolute I/O point 

locations: 

• SIM slot 1 = I/O points 1-8 




Example: 

Gem6K 

Controller 

I/O Brick #1 

Slot #1 (I/O points 1-8) 

Digital Inputs SIM 






Analog Inputs SIM 

I/O Brick #2 


Digital Outputs SIM 




No SIMM installed 


Digital Outputs SIM 

Sample response to 1TIN (digital inputs status) command: 

*1TIN0000_0010_1100_0000_0100_0001_XXXX_XXXX 

Sample response to 2TOUT (digital outputs status) command: 

*2TOUT0000_0000_XXXX_XXXX_XXXX_XXXX_0000_0000 

The TIO command identifies the connected I/O bricks (and installed SIMs), including the status of each I/O point: 

*BRICK 1: SIM Type Status Function 

1-8: DIGITAL INPUTS 0000_0000 AAAA_AAAA 



25-32: ANALOG INPUTS 0.000,0.000,0.000,0.000,0.000,0.000,0.000,0.000 

*BRICK 2: SIM Type Status Function 

1-8: DIGITAL OUTPUTS 0000_0000 AAAA_AAAA -- SINKING 


17-24: NO SIM PRESENT 

25-32: DIGITAL OUTPUTS 0000_0000 AAAA_AAAA -- SOURCING 


Input Functions 

Programmable input functions may be assigned to the digital inputs on the Gem6K, as well as 

to digital inputs on an expansion I/O brick connected to the Gem6K product. The appropriate 

input function command (LIMFNC or INFNC) depends on which input you are configuring: 

• Onboard limit inputs — use LIMFNC: 

Syntax: 

LIMFNCi-c 

Number of the input. 

(see page 141 for input bit assignments) 

Letter that selects the desired 

function (see list below). 

• Onboard digital inputs and digital inputs installed on an expansion I/O brick — use 

INFNC: 

Syntax: 

INFNCi-c 

I/O Brick number. 

Trigger inputs are considered 

collectively as I/O brick 0 (zero), 

and are addressed of the I/O brick 

number is left off the command. 



Number of the input. 

(see page 143 for input bit assignments) 

Virtual Inputs 

Virtual Inputs provide programming input functionality for data or external events that are 

not ordinarily represented by inputs. The Virtual Input Override (IN) command allows you 

to substitute almost any 32-bit data operand as a virtual input brick of 32 inputs (integer 

values are converted to binary). Page 8 provides a list of the data operands; the only data 

operands that are not allowed are: SIN, COS, TAN, ATAN, VCVT, SQRT, VAR, TW, READ, 

DREAD, DREADF, DAT, DPTR, and PI. 

The virtual inputs behave similar to real inputs in that they are affected by INEN and 

INLVL, and they affect INFNC, INPLC, INSTW, INDUST, ONIN, and GOWHEN(IN=b) 

commands. Unlike real inputs, virtual inputs are not affected by the INDEB debounce 

setting. 

NOTE: A virtual input can only be defined for expansion I/O bricks that are not connected 

on the serial I/O network (remember that up to 8 I/O bricks are allowed). For example, if 

your Gem6K unit has two I/O bricks, you can designate I/O bricks 3-8 as virtual I/O bricks. 

EXAMPLE: Suppose a PLC is sending binary data via the VARB1 command to the Gem6K. 

If the binary state of VARB1 is assigned to input brick 2 (2IN=VARB1), the Gem6K can 

respond based on programmable input functions set up with the INFNC command. 

2TIN 

; Brick 2 is not connected; therefore, the Gem6K will 

; respond with an error message: "*INCORRECT I/O BRICK" 

2IN=VARB1 ; Map the binary state of VARB1 to be the input state 

; of "virtual" input brick 2 (2IN) 

VARB1=b10100000 ; Change "virtual" input brick 2IN to a new VARB1 value 

2TIN 

; Check the input status. The response will be: 

; "*2IN1010_0000_0000_0000_0000_0000_0000_0000" 


Letter Designator 

Function 

A .................General-purpose input (default function for onboard and expansion digital inputs 

on I/O bricks) 

B .................BCD program select 

C .................Kill 

D .................Stop 

E .................Pause/Continue 

F .................User fault 

G ................. 

H .................Trigger Interrupt for position capture or registration (trigger inputs only). Special 

trigger functions can be assigned with the TRGFN command (see page 166). 

I .................Cause an “Alarm Event” over the Ethernet interface 

J .................Jog in the positive-counting direction 

K .................Jog in the negative-counting direction 

L .................Jog velocity select 

M .................Joystick release 

O .................Joystick velocity select 

P .................One-to-one program select 

Q .................Program security 

R .................End-of-travel limit for positive-counting direction * 

S .................End-of-travel limit for negative-counting direction * 

T .................Home limit * 

* Limit inputs are factory-set to their respective end-of-travel or home limit function (see page 74). 

NOTES 

• Multi-tasking: If the LIMFNC or INFNC command does not include the task identifier (%) prefix, 

the function affects the task that executes the LIMFNC or INFNC command. The only functions 

that may be directed to a task with % are: C, D, E, F, and P (e.g., 2%INFNC3-F assigns onboard 

input 3 as a user fault input for task 2). Multiple tasks may share the same input, but the input 

may only be assigned one function. 

Input Status 

* The purpose of the IN 

and LIM operators is to 

use the state of the inputs 

as a basis for conditional 

statements (IF, REPEAT, 

WHILE, GOWHEN, etc.) or 

for binary variable 

assignments (VARB). For 

examples, refer to the 

Conditional Looping and 

Branching section on 

page 25. 

Below is a list of the status commands you may use to ascertain the current state and/or defined 

function of the limit inputs (LIMFNC) and trigger and I/O brick inputs (INFNC). 

Limit inputs (LIMFNC): 

• Status display commands: 

- LIMFNC.............. Active state and programmed function of all limit inputs 

- LIMFNCi............ Same as LIMFNC display, but only for the input number (“i”) 

- TLIM................... Hardware state of all limit inputs (binary report); 

use TLIM.i to check the state of only one input (“i”) 

• Status assignment/comparison operator: * 

- LIM ..................... Hardware state (binary) of all limit inputs; 

use LIM.i to check the state of only one input (“i”) 

Trigger inputs and digital inputs on expansion I/O bricks (INFNC): 


- TIO ..................... I/O brick configuration (which SIMs are present) 

- INFNC ................ Active state and programmed function of all trigger inputs 

- INFNCi.............. Same as INFNC display, but only for the trigger input number (“i”) 

- INFNC ......... Active state and programmed function of all inputs on I/O brick B 

- INFNCi....... Same as INFNC display, but only for the input number (“i”) on brick B 

- TIN ..................... Hardware state of all onboard trigger inputs (binary report); 

use TIN.i to check the state of only one input (“i”) 

- TIN.............. Hardware state of all digital inputs on I/O brick B (binary report) ; 

use TIN.i to check the state of only one input (“i”) on brick B 


- IN ................ Hardware state (binary) of triggers and expansion digital inputs; 

use IN.i to check the state of only one input (“i”) on brick B 


Input Active Levels 

Many people refer to a voltage level when referencing the state of programmable inputs and 

outputs. Using LIMLVL (for limit inputs) and INLVL (for triggers and I/O brick inputs), you 

can define the logic levels of the programmable inputs as positive or negative. The Gem6K 

product defaults to an input level of zero volts as its active level (referred to as “active low”); 

thus, a “1” will appear in a status command (TLIM & LIM, or TIN & IN) referencing an input 

state when the voltage level is zero volts. 

Active Level Setting State LIM/TLIM or IN/TIN Report 

Active Low, the default setting 

• LIMLVL0 for limits 

• INLVL0 for triggers/I/O bricks 

Active High 

• LIMLVL1 for limits 

• INLVL1 for triggers/I/O bricks 

Grounded — sinking current 

(device drive the input is on) 

------------------------------------------------ 

Not Grounded — not sinking current 

(device drive the input is off) 

Grounded — sinking current 

(device drive the input is on) 

------------------------------------------------ 

Not Grounded — not sinking current 

(device drive the input is off) 

1 (active) 

-------------------------------------- 

- 

0 (inactive) 

0 (inactive) 

-------------------------------------- 

- 

1 (active) 

Input Debounce 

Time 

Using the INDEB command, you can change the input debounce time for programmable 

inputs. The debounce is the period of time that the input must be held in a certain state before 

the controller recognizes it. This directly affects the rate at which the inputs can change state 

and be recognized. The default setting is 4 ms. For example, to set the debounce for all digital 

inputs on I/O brick 2 to 5 ms, use the 2INDEB6 command. 

Exception for Trigger Inputs: For trigger inputs that are assigned the “Trigger Interrupt” 

function (INFNCi-H), the debounce is instead governed by the TRGLOT setting. The TRGLOT 

setting applies to all trigger inputs defined as “Trigger Interrupt” inputs. The TRGLOT debounce 

time is the time required between a trigger’s initial active transition and its secondary active 

transition. This allows rapid recognition of a trigger, but prevents subsequent bouncing of the 

input from causing a false position capture. The default TRGLOT setting is 24 ms. 

Limit Inputs. The limit inputs found on the connectors are not normally debounced; however, 

if a limit is assigned a different function with the LIMFNC command (other than LIMFNCi-R, 

LIMFNCi-S, or LIMFNCi-T), the input is debounced using the INDEB setting for the on-board 

trigger inputs (I/O brick 0). If a I/O brick input or an onboard trigger input is assigned a limit 

input function (INFNCi-R, INFNCi-S, or INFNCi-T), the input will not be debounced. 

“General Purpose” 

• LIMFNCi-A 

• INFNCi-A 

This is the default function for INFNC inputs (onboard digital inputs and I/O brick inputs). 

When an input is defined as a General Purpose input, the input is used as a standard input. 

You can then use this input to synchronize or trigger program events, through the use of the 

LIM or IN operator. 

Example DEL prog1 ; Precaution: Delete a program before defining it 

DEF prog1 ; Begin definition of program prog1 

INFNC1-A ; No function (general purpose) for input 1 

INFNC2-A ; No function (general purpose) for input 2 

INFNC3-D ; Input 3 is a stop input 

A10 

; Set acceleration 

V10 

; Set velocity 

D5 

; Set distance 

WAIT(IN=b1XX) ; Wait for onboard input 1 

GO 

; Initiate motion 

IF(IN=bX1) ; If onboard input 2 

TFB 

; Transfer feedback device position 

NIF 

; End IF statement 

END 



BCD Program Select 

• LIMFNCi-B 

• INFNCi-B 

The BCD program select function allows you to execute defined 

programs by activating the program select inputs. 

BCD program select inputs are assigned BCD weights, with the least 

weight on the smallest numbered input. The next BCD weight is 

assigned to the next input defined as a BCD input. For example, the 

table to the right shows the BCD weights if inputs 1-8 are configured 

as program select inputs. 

Input # 

Input 1 

Input 2 

Input 3 

Input 4 

Input 5 

Input 6 

Input 7 

Input 8 

BCD Weight 

To execute a particular program, you activate the combination of inputs to achieve the BCD 

weight that corresponds to the number of the program (see note below). For example, if inputs 

1-8 are defined as BCD inputs (as in the example above), activating inputs 4 and 6 would 

execute program #28, activating inputs 1 and 4 would execute program #9, and so on. 

1 

2 

4 

8 

10 

20 

40 

80 

Program Numbers 

A program's number is determined by the order in which the program was downloaded to 

the controller. The number of each program stored in the controller's memory can be 

obtained through the TDIR command — refer to the number reported in front of each 

program name. When selecting programs with BCD Program Select inputs, a program is 

executed when the total BCD weight of the active BCD inputs equals the program's number. 

Before you can execute programs using the BCD program select inputs, you must first enable 

scanning with the INSELP1 command. Once enabled, the controller will continuously scan 

the BCD inputs and execute the program (by number) according to the weight of the currently 

active BCD inputs. After executing and completing the selected program, the controller will 

scan the inputs again. NOTE: To disable scanning, enter !INSELPØ or place INSELPØ in a 

program that can be selected. 

The INSELP command also determines how long the BCD program select input level must 

be maintained before the controller executes the program. This delay is referred to as 

debounce time (but is not affected by the INDEB setting). 

Example 

☞ 

The number in front of 

each program name is 

the BCD weight required 

to execute the program. 

RESET ; Return controller to power-up conditions 

ERASE ; Erase all programs 

DEF PROG1 ; Begin definition of program PROG1 

TPE 

; Transfer position of encoder 

END 

; End program 


TREV ; Transfer software revision 

END 

; End program 


TSTAT ; Transfer statistics 

END 

; End program 

INFNC1-B ; Assign onboard input 1 as a BCD program select input 

INFNC2-B ; Assign onboard input 2 as a BCD program select input 

INSELP1,50 ; Enable scanning inputs, levels must be maintained for 50ms 

TDIR ; Display number and name of programs stored in memory 

; response from TDIR should be similar to following: 

; *1 - PROG1 USES 6 BYTES 



; *32877 OF 33000 BYTES (98%) PROGRAM MEMORY REMAINING 

; *500 OF 500 SEGMENTS (100%) COMPILED MEMORY REMAINING 

You can now execute the programs by activating the correct combination of inputs: 

• Activate digital input 1 (BCD weight of 1) to execute program #1 (PROG1) 

• Activate digital input 2 (BCD weight of 2) to execute program #2 (PROG2) 

• Activate digital inputs 1 & 2 (BCD weight of 3) to execute program #3 (PROG3) 


Kill 

• LIMFNCi-C 

• INFNCi-C 

When an input defined as a Kill input goes active: 

• Motion stops (using the LHAD and LHADA decel rate). 

• Program currently in progress is terminated. 

• Commands currently in the command buffer are eliminated. 

• Drive is left in the enabled state (@DRIVE1), unless the “disable drive on kill” function 

is enabled with the KDRIVE command (see description on page 66). 

• If error-checking bit 6 is enabled (e.g., ERROR.6-1), the error status is reported by bit 

6 of the TERF, TER and ER commands and the error program (assigned with the 

ERRORP command) will be executed to respond to the error condition. 

NOTE: Kill is not intended as a means to temporarily inhibit motion; use the Pause/Continue 

input function instead (LIMFNCi-E or INFNCi-E). 

Stop 

• LIMFNCi-D 

• INFNCi-D 

An input defined as a Stop input will stop motion (see examples below). Deceleration is 

controlled by the programmed AD/ADA deceleration ramp. If error-checking bit 8 is enabled 

(e.g., ERROR.8-1), the error status is reported by bit 8 of the TERF, TER and ER commands 

and the error program (assigned with the ERRORP command) will be executed to respond to 

the error condition. 

After the Stop input is received, further program execution is dependent upon the COMEXS 

command setting: 

COMEXSØ: (default setting) Upon receiving a stop input, motion will stop, program 

execution will be terminated and cannot be resumed, and every command in the 

buffer will be discarded. 

COMEXS1: Upon receiving a stop input, motion will stop, program execution will pause, and 

all commands following the command currently being executed will remain in 

the command buffer (but the move in progress will not be saved). 

You can resume program execution (but not the move in progress) by issuing an 

immediate Continue (!C) command or by activating a pause/resume input (i.e., a 

general-purpose input configured as a pause/continue input with the INFNCi-E 

command—see below). You cannot resume program execution while the move 

in progress is decelerating. 

COMEXS2: Upon receiving a stop input, the Gem6K responds as it does in the COMEXS0 

mode, with the exception that you can still use the program-select inputs to 

select programs (INSELP value is retained). The program-select input functions 

are: BCD select (INFNCi-B or LIMFNCi-B; see page 97), and one-to-one select 

(INFNCi-P or LIMFNCi-P; see page 103). For further details on program 

selection with inputs, refer to INFNC (or LIMFNC) and INSELP. 

Example: The 3INFNC2-D command assigns the “stop” function to the 2 nd input on SIM1 of 

I/O brick #3. When this input is activated, motion will stop. 


Pause/Continue 

• LIMFNCi-E 

• INFNCi-E 

An input defined as a Pause/Continue input will affect motion and program execution 

depending on the COMEXR command setting, as described below. In both cases, when the 

input is activated, the current command being processed will be allowed to finish executing 

before the program is paused. 

COMEXRØ: Upon receiving a pause input, only program execution will be paused; any motion 

in progress will continue to its predetermined destination. Releasing the pause 

input or issuing a !C command will resume program execution. 

COMEXR1: Upon receiving a pause input, both motion and program execution will be paused; 

the motion stop function is used to halt motion. Releasing the pause input or 

issuing a !C command will resume motion and program execution. You cannot 

resume program execution while the move in progress is decelerating. 

User Fault 

• LIMFNCi-F 

• INFNCi-F 

An input defined as a User Fault input acts as an immediate Kill (!K) command, stopping 

motion and terminating program execution. Motion is stopped at the rate set with the hard limit 

(LHAD & LHADA) commands. 

If error-checking bit #7 is enabled (e.g., ERROR.7-1), then a user fault input will cause a 

branch to the ERRORP error program (for more information, see Error Handling on page 30) 

and the occurrence of a user fault input will be reported by error bit #7 (see TERF, TER and ER 

commands). 

Trigger Interrupt 

(INFNCi-H) 

This function is available only for onboard trigger inputs. Any trigger input may be defined 

as a Trigger Interrupt input and can be used for these functions: 

• Position Capture (see below) 

• Special trigger functions assigned with the TRGFN command (see below) 

• Registration (see discussion on page 159) 

Notes About Trigger Interrupt Inputs 

• The trigger interrupt input is debounced for 24 ms (default) before another input on the 

same trigger is recognized. If your application requires a different debounce time, you can 

change it with the TRGLOT command (refer to Input Debounce Time on page 96). 

• When configured as Trigger Interrupts, the triggers cannot be affected by the input enable 

(INEN) command. 

• Status: Use the TTRIG and TRIG commands to ascertain if a trigger interrupt input has 

been activated. TTRIG displays the status as a binary report, and TRIG is an 

assignment/comparison operator for using the status information in a conditional 

expression (e.g., in an IF statement). Each TTRIG/TRIG bit is cleared when the 

respective captured position value is read with the PCC, PCE, PCME, PCMS, TPCC, TPCE, 

TPCME, or TPCMS commands, but the position information is still available from the 

respective register until it is overwritten by a subsequent position capture by the same 

trigger input. 

Position Capture 

The Gem6K has two dedicated trigger inputs, referred to as “TRIG-A” and “TRIG-B.” These 

trigger inputs are located on the DRIVE/10 connector. When either trigger input (TRIG-A or 

TRIG-B) is assigned the Trigger Interrupt function, activating the input performs a hardware 

capture of the position. If the Gem6K is used as a follower in Following, activating the trigger 

also performs an interpolated capture of the associated master axis position. 

An additional trigger, labeled “TRIG-M”, may be used to perform a hardware capture of the 

Master Encoder (the encoder connected to the “MASTER ENCODER” connector), as well as the 

motor position (encoder position on servo axes; commanded or encoder position for steppers, 

depending on the ENCCNT setting). To assign TRIG-M as a trigger interrupt input, use the 


INFNC17-H command. 

When a Trigger Interrupt input is activated, the controller captures the relevant positions and 

stores them in registers that are available at the next system update (2 ms) through the use of 

these transfer and assignment/comparison commands: 

Captured Information Transfer Assignment/Comparison Offset * Scale Factor ** 

Commanded position TPCC PCC PSET SCLD 

Encoder position TPCE PCE PSET SCLD 

Master encoder position TPCME PCME PMESET SCLMAS 

Master cycle position TPCMS PCMS PSET SCLMAS 

* Captured values are offset by any existing PSET or PMESET offset. 

** If scaling is enabled, the captured position is scaled by SCLD or SCLMAS. 

Notes About Position Capture 

• Hardware Capture: The encoder position is captured within ± 1 encoder count. The 

commanded position capture accuracy is ± 1 count. 

• Interpolated Capture: There is a time delay of up to 50 µs between activating the trigger 

interrupt input and capturing the position; therefore, the accuracy of the captured position 

is equal to 50 µs multiplied by the velocity at the time the input was activated. 

• Servo vs. Stepper. The nature of the position captured with a Trigger Interrupt input may 

be different, depending on whether the drive is a servo or stepper. For servos, both the 

commanded and encoder positions are captured. Analog input feedback cannot be 

captured. For steppers, if the ENCCNT command is set to ENCCNT0 (default condition), 

only the commanded position is captured. If ENCCNT1 mode is enabled, only the encoder 

position is captured. 

Trigger Functions 

The Trigger Functions command (TRGFN) allows you to assign additional functions to trigger 

inputs that have been defined as trigger interrupt inputs with the INFNCi-H command. These 

trigger functions are cleared once the function is triggered. Command syntax is: 

TRGFNcbb 

Start New Master Cycle (FMCNEW) function 

Conditional GO (GOWHEN) function 

Trigger letter. Two triggers are available (A or B). 

The “Master Trigger” (letter M) may also be used. 

• “Conditional GO” Function (TRGFNc1x): Suspend execution of the next start-motion 

command until the specified trigger input goes active. Start-motion commands are: 

- GO (standard command to begin motion) 

- FSHFC (begin continuous shift – for Following motion) 

- FSHFD (begin preset shift – for Following motion) 

Axis status bit #26 (reported with TASF, TAS, or AS) is set to one (1) when there is a 

pending “Conditional GO” condition initiated by a TRGFN command; this bit is cleared 

when the trigger is activated or when a stop command or a kill command is issued. If you 

need execution to be triggered by other factors (e.g., input state, master position, encoder 

position, etc.) use the GOWHEN command; refer to GOWHEN command or page 163 for 

details. 

• “New Master Cycle” Function (TRGFNcx1): This is equivalent to executing the 

FMCNEW command. When the specified trigger input goes active, the controller begins 

a new Following master cycle. Refer to the FMCNEW command or to page 183 for 

more on master cycles. 


Code Examples INFNC1-H ; Assign trigger A (onboard input 1) to function as 

; a trigger interrupt input. 

INFNC2-H ; Assign trigger B (onboard input 2) to function as 

; a trigger interrupt input. 

TRGFNAx1 ; When trigger A goes active, begin a new master cycle 

TRGFNB1 

; When trigger B goes active, execute the move commanded 

; with the GO command. 

GO 

; The move is commanded, but will not execute until 

; trigger B becomes active. 

Registration 

If registration is enabled (with the RE command), activating a trigger interrupt input will 

initiate a registration move defined with the REG command. Refer to page 159 for details on 

the Registration feature. 

Alarm Event 

• LIMFNCi-I 

• INFNCi-I 

An input specified as an Alarm Event input will cause the Gem6K controller to set an Alarm 

Event in the Communications Server over the Ethernet interface. You must first enable the 

Alarm checking bit for this input-driven alarm (INTHW.23-1). For details on using alarms 

and other Communications Server features, refer to the COM6SRVR Programmer’s Guide or to 

the Motion Planner help system. 

Jogging the Motor 

• LIMFNCi-J 

• LIMFNCi-K 

• LIMFNCi-L 

• INFNCi-J 

• INFNCi-K 

• INFNCi-L 

In some applications, you may want to manually move (jog) the load. You can configure these 

jog-related input functions: 

“J” ....Jog in the positive counting direction when the input is active, stop when the input is 

inactive. 

“K” ....Jog in the negative counting direction when the input is active, stop when the input is 

inactive. 

“L” ....Select the high (JOGVH) or low (JOGVL) velocity setting for jog motion. Activating 

the input selects high velocity, deactivating the input selects low velocity. 

The jog profile is defined with these commands listed below. NOTE: If scaling is enabled 

(SCALE1) the velocity is scaled by SCLV and accel/decel is scaled by SCLA. 

JOGVH....... High velocity range for jogging. The high velocity is used when the jogging 

speed-select input (configured with INFNCi-L) is active. 

JOGVL....... Low velocity range for jogging. The low velocity is used when the jogging 

speed-select input (configured with INFNCi-L) is inactive. 

JOGA......... Jog acceleration 

JOGAA....... Jog acceleration (s-curve profile) 

JOGAD....... Jog deceleration 

JOGADA .... Jog deceleration (s-curve profile) 

Once you set up the jog functions and move profile, you can attach a switch to the designated 

jog inputs and perform jogging. (Jog motion will not occur unless Jog Mode is enabled with 

the JOG command.) The example below shows you how to define a program to set up jogging. 


Example Step 1 Define program for jog setup: 

Step 2 

Step 3 

Step 4 

Step 5 

Step 6 


JOGA25 ; Jog acceleration to 25 units/sec/sec 

JOGAD25 ; Jog deceleration to 25 units/sec/sec 

JOGVL.5 ; Low-speed jog velocity to 0.5 units/sec 

JOGVH5 ; High-speed jog velocity to 5 units/sec 

INFNC1-J ; Trigger input 1 is a positive-direction jog input, axis 1 

INFNC2-K ; Trigger input 2 is a negative-direction jog input, axis 1 

INFNC3-L ; Trigger input 3 is a speed-select input, axis 1 

JOG1 ; Enable Jog function for axis 1 

END 


Download and run the prog1 program. 

Activate input 1 to move the load in the positive direction at a velocity of 0.5 units/sec (until 

trigger input 1 is released). Deactivate the input to stop the axis. 

Activate input 2 to move the load in the negative direction at a velocity of 0.5 units/sec (until 

input 2 is released). Deactivate the input to stop the axis. 

Activate input 3 to switch to high-speed jogging. 

Repeat steps 3 and 4 to perform high-speed jogging at the JOGVH value (5 rps). 

Joystick Functions 

• LIMFNCi-M 

• LIMFNCi-N 

• LIMFNCi-O 

• INFNCi-M 

• INFNCi-N 

• INFNCi-O 

As part of the joystick setup process, you can configure programmable inputs to serve the 

joystick input functions listed below. Full details on joystick setup and operation are provided 

on page 130. 

“M” ....The Joystick Release input signals the controller to end joystick operation and resume 

program execution with the next statement in your program. When the input is open 

(high, sinking current), the joystick mode is disabled (joystick mode can be enabled 

only if the input is closed, and only with the JOY command). When the input is closed 

(low, not sinking current), joystick mode can be enabled with the JOY command. The 

general process of using Joystick mode is: 

1. Assign the “Joystick Release” input function to a programmable input. 

2. At the appropriate place in the program, enable joystick control of motion (with the JOY 

command). (Joystick mode cannot be enabled unless the "Joystick Release" input is 

closed.) When the JOY command enables joystick mode, program execution stops 

(assuming the Continuous Command Execution Mode is disabled with the COMEXCØ 


3. Use the joystick to move as required. 

4. When you are finished using the joystick, open the “Joystick Release” input to disable the 

joystick mode. This allows program execution to resume with the next statement after the 

initial JOY command that started the joystick mode. 

“O” ...The Joystick Velocity Select input allows you to select the velocity for joystick 

motion. The JOYVH and JOYVL commands establish the high-speed velocity and the 

low-speed velocity, respectively. Opening the Velocity Select input (input is high, 

sinking current) selects the JOYVH configuration. Closing the Velocity Select input 

(input is low, not sinking current) selects the JOYVL configuration. The high range 

could be used to quickly move to a location, the low range could be used for accurate 

positioning. NOTE: When this input is not connected, joystick motion always uses 

the JOYVL velocity setting. 


One-to-One 

Program Select 

• LIMFNCi-iP 

• INFNCi-iP 

An input defined as a One-to-One Program Select input is assigned to execute one specific 

program. The targeted program is reference by its number (see note). 

Program Numbers 

A program’s number is determined by the order in which the program was downloaded to the 

controller. The number of each program stored in the controller's memory can be obtained 

through the TDIR command — refer to the number reported in front of each program name. 

When selecting programs with One-to-One Program Select inputs, the program number is 

assigned to one specific input and is executed when the input is activated (see example 

below). 

Before you can execute programs using the One-to-One program select inputs, you must first 

enable scanning with the INSELP2 command. Once enabled, the controller will continuously 

scan the inputs and execute the program (by number) according to the program number 

assigned to the input. After executing and completing the selected program, the controller will 

scan the inputs again. NOTE: To disable scanning, enter !INSELPØ or place INSELPØ in a 

program that can be selected. 

The INSELP command also determines how long the program select input level must be 

maintained before the controller executes the program. This delay is referred to as debounce 

time (but is not affected by the INDEB setting). 

Example RESET ; Return controller to power-up default conditions 

DEF proga ; Begin definition of program proga 

TFB 

; Transfer position of feedback devices 

END 

; End program 

DEF progb ; Begin definition of program progb 

TREV ; Transfer software revision 

END 

; End program 

DEF progc ; Begin definition of program progc 

TSTAT ; Transfer statistics 

END 

; End program 

TDIR ; Response should show: *1 - PROGA USES 36 BYTES 

; *2 - PROGB USES 70 BYTES 

; *3 - PROGC USES 133 BYTES 

INFNC4-1P ; input 4 will select proga 

INFNC5-2P ; input 5 will select progb 

INFNC6-3P ; input 6 will select progc 

INSELP2,50 ; Enable scanning of inputs with a strobe time of 50 ms 

You can now execute programs by making a contact closure from an input to ground to 

activate the input: 

• Activate input #4 to execute program #1 (proga) 

• Activate input #5 to execute program #2 (progb) 

• Activate input #6 to execute program #3 (progc) 


Program Security 

• LIMFNCi-Q 

• INFNCi-Q 

Once an input is assigned the Program Security function, the Program Security feature is 

enabled. The program security feature denies you access to the DEF, DEL, ERASE, MEMORY, 

LIMFNC and INFNC commands until you activate the Program Security input. Being denied 

access to these commands effectively restricts altering the user memory allocation. If you try 

to use these commands when program security is active (program security input is not 

activated), you will receive the error message *ACCESS DENIED. 

For example, once you issue the 2INFNC7-Q command, input #7 on I/O brick #2 (2IN.7) is 

assigned the program security function and access to the DEF, DEL, ERASE, MEMORY, 

LIMFNC and INFNC commands will be denied until you activate 2IN.7. 

To regain access to the DEF, DEL, ERASE, MEMORY, LIMFNC or INFNC commands without 

the use of the program security input, you must issue the INEN command to disable the 

program security input, make the required user memory changes, and then issue the INEN 

command to re-enable the input. For example, if input 3 on brick 2 is assigned as the Program 

Security input, use 2INEN.3=1 to disable the input and leave it activated, make the necessary 

user memory changes, and then use 2INEN.3=E to re-enable the input. 

NOTE: If you wish the Program Security feature to be enabled on power-up, place the 

INFNCi-Q or LIMFNCi-Q command in the start-up program (STARTP). 

Limit Functions 

• LIMFNCi-aR 

• LIMFNCi-aS 

• LIMFNCi-aT 

• INFNCi-aR 

• INFNCi-aS 

• INFNCi-aT 

Input numbers are factory-configured with the LIMFNC command to function as end-of-travel 

and home limits (see illustration on page 91). The limit functions are: 

“R” .... Positive-Direction End-of-Travel Limit input, axis specific. 

“S” .... Negative-Direction End-of-Travel Limit input, axis specific. 

“T” .... Home Limit input, axis specific. 

If you intend to use digital inputs on an external I/O brick as limit inputs: 

1. Assign the limit function to the external input with the INFNC command. For example, 

1INFNC9-1R assigns the “axis 1 positive end-of-travel limit” function to the 1 st input 

on SIM2 (I/O point 9) of I/O brick 1. 

2. Reassign the respective “LIMITS” input to a non-limit function with the LIMFNC 

command. For example, LIMFNC1-A assigns the “general-purpose input” function to 

limit input 1 (normally assigned the “axis 1 positive end-of-travel limit” function). 

NOTE: Once an input or I/O brick input is assigned a limit function, it is no longer debounced 

(INDEB has no effect), and it must be enabled/disabled with the LH command instead of the 

INEN command. 


Output Functions 

The Gem6K product provides programmable digital outputs, found on the drive I/O connect. 

Additional digital outputs may be installed on expansion I/O bricks (see example on page 93). 

You can turn the controller's programmable outputs on and off with the Output (OUT, POUT 

or OUTALL) commands, or you can use the Output Function (OUTFNC) command to 

configure them to activate based on seven different situations. The OUTFNC syntax is as 

follows: 

OUTFNCi-c 

I/O Brick number. 

Onboard outputs are considered 

collectively as I/O brick 0 (zero), and 

are addressed of the I/O brick 

number is left off the command. 



Number of the output. 

(see page 78-79 for output bit assignments) 

Letter Designator Function 

A .................General-purpose output (default function) 

B .................Moving/not moving 

C .................Program in progress 

D .................Hardware or software end-of-travel limit encountered 

E .................Stall indicator — stepper only 

F .................Fault indicator (indicates drive fault input or user fault input is active) 

G .................Position error exceeds max. limit set with SMPER — servo only 

H .................Output on position 

NOTES 

• Multi-tasking: If the OUTFNC command does not include the task identifier (%) prefix, the 

function affects the task that executes the OUTFNC command. “Program in progress” 

(function C) is only function that may be directed to a specific task with %. Multiple tasks 

may share the same output, but the output may only be assigned one function. 

• Limit of 32 output functions: You may assign a maximum of 32 OUTFNC functions. This 

excludes function A (“general-purpose”). 


Output Status 

Below is a list of the status commands you may use to ascertain the current state and/or defined 

function of the outputs. 


- TIO........................I/O brick configuration (which SIMs are present, including sinking/sourcing) 

- OUTFNC.................Active state and programmed function of all onboard outputs 

- OUTFNCi ..............Same as OUTFNC display, but only for the output number (“i”) 

- OUTFNC..........Active state and programmed function of all outputs on I/O brick B 

- OUTFNCi .......Same as OUTFNC display, but only for the output number (“i”) on I/O brick B 

- TOUT .....................Hardware state of all onboard outputs (binary report); 

use TOUT.i to check the state of only one output (“i”) 

- TOUT ..............Hardware state of all outputs (binary report) on I/O brick B; 

use TOUT.i to check the state of only one output (“i”) on brick B 


- OUT........................Hardware state (binary) of all onboard outputs; 

use OUT.i to check the state of only one output (“i”) 

- OUT.................Hardware state (binary) of all outputs on I/O brick B; 

use OUT.i to check the state of only one output (“i”) on I/O brick B 

* The purpose of the OUT operator is to use the state of the outputs as a basis for conditional 

statements (IF, REPEAT, WHILE, GOWHEN, etc.) or for binary variable assignments (VARB). 

Output Active 

Levels 

Using OUTLVL, you can define the logic levels of the programmable outputs as positive or 

negative. OUTLVL0 selects active low (default setting); OUTLVL1 selects active high. 

Onboard Digital Outputs 

OUTLVL Setting OUT State * Current TOUT Status 

OUTLVL0 (default) OUT1 Sinking current 1 

OUTLVL0 (default) OUT0 No current flow 0 

OUTLVL1 OUT1 No current flow 1 

OUTLVL1 OUT0 Sinking current 0 

* The output is “active” when it is commanded by the OUT, OUTPA, or POUTA commands 

(for example, OUTxx1 activates output #3). 

Outputs on Expansion I/O Bricks: 

• Sinking vs. Sourcing Outputs. On power up, the Gem6K controller auto-detects the type 

of output SIM installed on each external I/O brick, and automatically changes the OUTLVL 

setting accordingly. If sinking (NPN) outputs are detected, OUTLVL is set to active low 

(OUTLVL0); if sourcing (PNP) outputs are detected, OUTLVL is set to active high 

(OUTLVL1). 

• Disconnect I/O Brick. If the I/O brick is disconnected (or if it loses power), the controller 

will perform a kill (all tasks) and set error bit #18. (If you disable the “Kill on I/O 

Disconnect” mode with KIOENØ, the Gem6K will not perform the kill.) The controller 

will remember the brick configuration (volatile memory) in effect at the time the 

disconnection occurred. When you reconnect the I/O brick, the controller checks to see if 

anything changed (SIM by SIM) from the state when it was disconnected. If an existing 

SIM slot is changed (different SIM, vacant SIM slot, or jumper setting), the controller 

will set the SIM to factory default INEN and OUTLVL settings. If a new SIM is installed 

where there was none before, the new SIM is auto-configured to factory defaults. 


• Relationships: 

Output Type OUTLVL Setting OUT State * Current OUT/TOUT status LED 

NPN (sinking) OUTLVL0 (default) OUT1 Sinking current 1 ON 

NPN OUTLVL0 (default) OUT0 No current flow 0 OFF 

NPN OUTLVL1 OUT1 No current flow 1 OFF 

NPN OUTLVL1 OUT0 Sinking current 0 ON 

PNP (sourcing) OUTLVL0 OUT1 No current flow 1 OFF 

PNP OUTLVL0 OUT0 Sourcing current 0 ON 

PNP OUTLVL1 (default) OUT1 Sourcing current 1 ON 

PNP OUTLVL1 (default) OUT0 No current flow 0 OFF 

* The output is “active” when it is commanded by the OUT, OUTP, or POUT command 

(for example, OUTxx1 activates output #3). 

“General Purpose” 

(OUTFNCi-A) 

The default function for the outputs is General Purpose. As such, the output is used as a 

standard output, turning it on or off with the OUT, OUTP or OUTALL commands to affect 

processes external to the controller. To view the state of the outputs, use the TOUT command. 

To use the state of the outputs as a basis for conditional branching or looping statements (IF, 

REPEAT, WHILE, etc.), use the [ OUT ] command. 

Moving/Not Moving 

(In Position) 

(OUTFNCi-B) 

Example 

When assigned the Moving/Not Moving function, the output will activate when motion is 

commanded. As soon as the move is completed, the output will change to the opposite state. 

Servos: If the target zone mode is enabled (STRGTE1), the output will not change state until 

the move completion criteria set with the STRGTD and STRGTV commands has been met. 

(For more information, refer to the Target Zone section on page 84.) In this manner, the 

Moving/Not Moving output functions as an In Position output. 

The code example below defines onboard outputs 1 and 2 as General Purpose outputs and 

output 3 as a Moving/Not Moving output. Before the motor moves 4,000 steps, output 1 turns 

on and output 2 turns off. These outputs remain in this state until the move is completed, then 

output 1 turns off and output 2 turns on. While the motor/load is moving, output 3 remains on. 


MC0 

; Set axis 1 to preset positioning mode 

MA0 

; Select incremental positioning mode 

A10 ; Set axis 1 acceleration to 10 

V5 ; Set axis 1 velocity to 5 

D4000 

; Set axis 1 distance to 4,000 counts 

OUTFNC1-A ; Set onboard output 1 as a general purpose output 

OUTFNC2-A ; Set onboard output 2 as a general purpose output 

OUTFNC3-B ; Set onboard output 3 as axis 1 Moving/Not Moving output 

OUT10 

; Turn onboard output 1 on and output 2 off 

GO 

; Initiates axis 1 move 

OUT01 

; Turn onboard output 1 off and output 2 on 

Program in 

Progress 

(OUTFNCi-C) 

When assigned the Program in Progress function, the output will activate when a program is 

being executed. After the program is finished, the output's state is reversed. The action of 

executing a program is also reported with system status bit 3 (see TSSF, TSS and SS 

commands). 


Limit Encountered 

(OUTFNCi-D) 

When assigned the Limit Encountered function, the output will activate when a hard or soft 

end-of-travel limit has been encountered. 

If a hard or soft limit is encountered, you will not be able to move the motor/load in that same 

direction until you clear the limit by changing direction (D) and issuing a GO command. (An 

alternative is to disable the limits with the LHØ command, but this is recommended only if the 

motor is not coupled to the load.) The event of encountering an end-of-travel limit is also 

reported with axis status bits 15-18 (see TASF, TAS and AS commands, summary on page 222). 

Stall Indicator 

(OUTFNCi-E) 

Stepper Axis Only 

When assigned the Stall Indicator function, the output will activate when a stall is detected. To 

detect a stall, you must first connect an encoder and enable stall detection with the ESTALL1 

command. Refer to Encoder-Based Stepper Operation on page 84 for further discussion on 

stall detection. 

Fault Output 

(OUTFNCi-F) 

When assigned the Fault Output function, the output will activate when either the user fault 

input or the drive fault input becomes active. The user fault input is a general-purpose input 

defined as a user fault input with the LIMFNCi-F or INFNCi-F command (see page 99). 

Maximum Position 

Error Exceeded 

(OUTFNCi-G) 

Servos Only 

When assigned the Max. Position Error Exceeded function, the output will activate when the 

maximum allowable position error, as defined with the SMPER command, is exceeded. 

The position error (TPER) is defined as the difference between the commanded position (TPC) 

and the actual position as measured by the feedback device (TFB). When the maximum 

position error is exceeded (usually due to lagging load, instability, or loss of position 

feedback), the controller shuts down the drive and sets error status bit #12 (reported by the 

TERF, TER and ER commands if bit #12 of the ERROR command is enabled). 

NOTE 

If the SMPER command is set to zero (SMPERØ — the default value), the position error will not 

be monitored; thus, the Maximum Position Error Exceeded function will not be usable. 


Output on Position 

(OUTFNCi-H) 

The Output on Position feature activates the designated output when the motor or load has 

reached a specified position. To use this feature, you must first assign the Output on Position 

function to output #1, and define the Output on Position characteristics with the OUTP 

command. Note: this is a firmware feature (not hardware) and the output on position is 

only updated every 1msec. 

OUTPA 

, , , 

Enable Bit: 

1 ... Enable the output-on-position function 

0 ... Disable the output-on-position function 

Servo Axes: If an SFB command is executed, 

the function is disabled. 

Increment or Absolute Position Comparison: 

1 ... Set position comparison to incremental 

...... (measured from the last start-motion 

...... command, such as GO, GOWHEN, etc.) 

0 ... Set position comparison to absolute 

Time (milliseconds): 

Time (milliseconds) the output is to stay active. 

The output activates when the specified 

position () is reached or exceeded, and 

stays active for the specified time. 

If this field is set to zero, the output will stay 

active for as long as the actual distance equals 

or exceeds the position comparison distance 

(this is possible only for an absolute position 

comparison). 

Position: 

Scalable distance (distance is either 

incremental or absolute, depending on the 

second data field). 

Servos: Only the encoder position can be used. 

Steppers: 

If ENCCNT0, commanded position is used. 

If ENCCNT1, encoder position is used. 

Sample Code 

for Setup 

In this example, the user wants to turn on output when the motor (servo) reaches encoder 

position 50,000. The output must remain on for 50 milliseconds. 

; Define axis 1 as servo, axis 2 as stepper 

; Select encoder feedback for axis 1 

OUTFNC1-H 

; Define onboard output #1 as an "output on 

; position" output 

; Define onboard output #2 as an "output on 

; position" output 

OUTP1,0,+50000,50 ; Turn on onboard output #1 for 50 ms when the 

; encoder position is > or = 

; absolute position +50,000 

Notes about Output On Position 

• On servos, this feature can be used only with encoder feedback and is not operational with 

ANI (analog input) feedback. 

On steppers, this feature can be based on commanded position or encoder position, 

depending on the ENCCNT setting (default is ENCCNT0, which uses the commanded 

position). 

• The output activates only during motion; thus, issuing a PSET command to set the 

absolute position counter to activate the output on position will not turn on the output until 

the next motion occurs. 


Variable Arrays (teaching variable data) 

More on variables: 

see page 18. 

Variable data arrays provide a method of storing (teaching) variable data and later using the 

stored data as a source for motion program parameters. The variable data can be any value that 

can be stored in a numeric (VAR or VARI) variable (e.g., position, acceleration, velocity, etc.). 

The variable data is stored into a data program, which is an array of data elements that have a 

specific address from which to write and read the variable data. Data programs do not contain 

Gem6K Series commands. 

The information below describes the principles of using the data program in a teach-type 

application. Following that is an application example in which the joystick is used to teach 

position data to be used in a motion program. 

Basics of Teach-Data Applications 

The basic process of using a data program for data teaching applications is as follows: 

1. Initialize a data program. 

2. Teach (store/write) variable data into the data program. 

3. Read the data elements from the data program into a motion program. 

1. Initialize a 

Data Program 

This is accomplished with the DATSIZ command. The DATSIZ command syntax is 

DATSIZi. The first integer (i) represents the number of the data program (1 - 50). You 

can create up to 50 separate data programs. The data program is automatically given a specific 

program name (DATPi). The second integer represents the total number of data elements (up 

to 6,500) you want in the data program. Upon issuing the DATSIZ command, the data program 

is created with all the data elements initialized with a value of zero. 

The data program has a tabular structure, where the data elements are stored 4 to a line. Each 

line of data elements is called a data statement. Each element is numbered in sequential order 

from left to right (1 - 4) and top to bottom (1 - 4, 5 - 8, 9 - 12, etc.). You can use the TPROG 

DATPi command (“i” represents the number of the data program) to display all the data 

elements of the data program. 

For example, if you issue the DATSIZ1,13 command, data program #1 (called DATP1) is 

created with 13 data elements initialized to zero. The response to the TPROG DATP1 

command is depicted below. Each line (data statement) begins with DATA=, and each data 

element is separated with a comma. 

*DATA=+Ø.Ø,+Ø.Ø,+Ø.Ø,+Ø.Ø 



*DATA=+Ø.Ø 

Each data statement, comprising four data elements, uses 43 bytes of memory. The memory 

for each data statement is subtracted from the memory allocated for user programs (see 

MEMORY command). 


2. Teach the Data 

to the Data 

Program 

The data that you wish to write to the data elements in the data program must first be placed 

into numeric variables (VAR). Once the data is stored into numeric variables, the data elements 

in the data program can be edited by using the Data Pointer (DATPTR) command to move the 

data pointer to that element, and then using the Data Teach (DATTCH) command to write the 

datum from the numeric variable into the element. 

When the DATSIZ command is issued, the internal data pointer is automatically positioned to 

data element #1. Using the default settings for the DATPTR command, the numberic variable 

data is written to the data elements in sequential order, incrementing one by one. When the 

last data element in the data program is written, the data pointer is automatically set to data 

element #1 and a warning message (*WARNING: POINTER HAS WRAPPED AROUND 

TO DATA POINT 1) is displayed. The warning message does not interrupt program 

execution. 

The DATPTR command syntax is DATPTRi,i,i. The first integer (i) represents the data 

program number (1 through 50). The second integer represents the number of the data element 

to point to (1 through 6500). The third integer represents the number of data elements by 

which the pointer will increment after writing each data element from the DATTCH command, 

or after recalling a data element with the DAT command. 

The DATTCH command syntax is DATTCHi. Each integer (i) represents the 

number of a numeric variable. The value of the numeric variable will be stored into the data 

element(s) of the currently active data program (i.e., the program last specified with the last 

DATSIZ or DATPTR command). As indicated by the number of integers in the syntax, the 

maximum number of variable values that can be stored in the data program per DATTCH 

command is 4. Each successive value from the DATTCH command is stored to the data 

program according to the pattern established by the third integer of the DATPTR command. 

As an example, suppose data program #1 is configured to hold 13 data elements 

(DATSIZ1,13), the data pointer is configured to start at data element #1 and increment 1 

data element after every value stored from the DATTCH command (DATPTR1,1,1), and the 

values of numeric variables #1 through #3 are already assigned (VAR1=2, VAR2=4, 

VAR3=8). If you then enter the DATTCH1,2,3 command, the values of VAR1 through VAR3 

will be assigned respectively to the first three data elements in the data program, leaving the 

pointer pointing to data element #4. The response to the TPROG DATP1 command would be 

as follows (the text is highlighted to illustrate the final location of the data pointer after the 

DATTCH1,2,3 command is executed): 

*DATA=+2.Ø,+4.Ø,+8.Ø,+Ø.Ø 



*DATA=+Ø.Ø 

If you had set the DATPTR command to increment 2 data elements after every value from the 

DATTCH command (DATPTR1,1,2), the data program would be filled differently and the 

data pointer would end up pointing to data element #7: 

*DATA=+2.Ø,+Ø.Ø,+4.Ø,+Ø.Ø 

*DATA=+8.Ø,+Ø.Ø,+Ø.Ø,+Ø.Ø 


*DATA=+Ø.Ø 

3. Recall the Data 

from the Data 

Program 

After storing (teaching) your variables to the data program, you can use the DATPTR command 

to point to the data elements and the DATi (“i” = data program number) data assignment 

command to read the stored variables to your motion program. You cannot recall more than 

one data element at a time; therefore, if you want to recall the data in a one-by-one sequence, 

the third integer of the DATPTR command must be a 1 (this is the default setting). 


Summary of Related Gem6K Series Commands 

DATSIZ ..... Establishes the number of data elements a specific data program is to contain. A 

new DATPi program name is automatically generated according to the number 

of the data program (i = 1 through 50). The memory required for the data 

program is subtracted from the memory allocated for user programs (see 

MEMORY command). 

DATPTR ..... Moves the data pointer to a specific data element in any data program. This 

command also establishes the number of data elements by which the pointer 

increments after writing each data element from the DATTCH command and 

after recalling each data element with the DAT command. 

DATTCH ..... Stores the variable data into the data program specified with the last DATSIZ or 

DATPTR command. After the data is stored, the data pointer is incremented the 

number of times entered in the third integer of the DATPTR command. The data 

must first be assigned to a numeric variable before it can be taught to the data 

program. 

TDPTR ....... Responds with a 3-integer status report (i,i,i): First integer is the number of 

the active data program (the program # specified with the last DATSIZ or 

DATPTR command); Second integer is the location number of the data element 

to which the data pointer is currently pointing; Third integer is the increment set 

with the last DATPTR command. 

[ DPTR ] ... From the currently active data program, uses the number of the data pointer's 

location in a numeric variable assignment operation or a conditional statement 

operation. 

[ DATPi ] . The name of the data program created after issuing the DATSIZ command. The 

integer (i) represents the number of the data program. Data programs can be 

deleted just like any other user program (e.g., DEL DATP1). 

[ DATi ] ... From the data program specified with i, assigns the numeric value of the data 

element (currently pointed to by the data pointer) to a specified variable 

parameter in a Gem6K series command (e.g., D(DAT3),(DAT3)). 

Teach-Data Application Example 

Step 1 

For the sake of brevity, this example is limited to teaching 10 position data points; however, 

in a typical application, many more points would be taught. Also, it is assumed that end-oftravel 

and home limits are wired and a homing move has been programmed. 

What follows is a suggested method of programming the controller to teach I/O data points. 

To accomplish the teach application, a program called MAIN is created, comprising three 

subroutines: SETUP (to set up for teaching data to the data program), TEACH (to teach the 

positions), and DOPATH (to implement a motion program based on the positions taught). 

The joystick operation in this example is based on using an analog inputs (ANI) SIM on an 

expansion I/O brick. The ANI SIM is in slot 2 of I/O brick 1 and inputs 1 and 2 are used to 

control axes 1 and 2, respectively. A digital input SIM is installed in slot 1 of I/O brick 1, and 

input 1 on that SIM is assigned the Joystick Release function to trigger the position teach 

operation. 

Initialize a Data Program. 

DEL DATP1 

DATSIZ1,1Ø 

; Delete data program #1 (DATP1) in preparation for 

; creating a new data program #1 

; Create data program #1 (named DATP1) with an 

; allocation of 10 data elements. Each element is 

; initialized to zero. 


Step 2 

Define the SETUP Subroutine. The SETUP subroutine need only run once. 

DEF SETUP 

1INFNC1-M 

JOYVH3 

JOYAXH1-9 

VAR1=Ø 

VAR2=Ø 

DRIVE1 

MA1 

END 

; Begin definition of the subroutine called SETUP 

; Assign digital input 1 on SIM 2 (I/O point #1) of 

; I/O brick 1 to function as a "Joystick Release" input. 

; Set the maximum velocity (3 units/sec) 

; achievable when the joystick is at full 

; deflection 

; Assign ANI input 1 on SIM 2 (I/O point #9) of I/O 

; brick 1 

; Initialize variable #1 equal to zero 

; Initialize variable #2 equal to zero 

; Enable the drive 

; Enable the absolute positioning mode 

; End definition of the subroutine called SETUP 

Step 3 

Define the TEACH Subroutine. 

DEF TEACH ; Begin definition of the subroutine called TEACH 

HOM1 

; Home the axis (absolute position counter is set to 

; zero after the homing move) 

DATPTR1,1,1 ; Select data program #1 (DATP1) as the current active 

; data program, and move the data pointer to the first 

; data element. After each DATTCH value is stored to 

; DATP1, increment the data pointer by 1 data element. 

REPEAT 

; Set up a repeat/until loop 

JOY1 

; Enable joystick mode. At this point, 

; you can start moving into position with the 

; joystick. WHILE USING THE JOYSTICK, COMMAND PROCESSING 

; IS STOPPED HERE UNTIL YOU ACTIVATE THE JOYSTICK 

; RELEASE INPUT. Activating the joystick release input 

; disables the joystick mode and allows the subsequent 

; commands to be executed (assign the current positions 

; to the variables and then store the positions in the 

; data program). 

VAR1=1PM ; Set variable #1 equal to the position of motor 1 

DATTCH1 ; Store variable #1. (The first time through the 

; repeat/until loop, variable #1 is stored into data ; 

;element #1. The data pointer is automatically 

; incremented once after each data element and ends up 

;pointing to the third data element in anticipation of 

;the next DATTCH command.) 

WAIT(1IN.1=b1) ; Wait for the joystick release input to be de-activated 

UNTIL(DPTR=1) ; Repeat the loop until the data pointer wraps around 

; to data element #1 (data program full) 

END 

; End definition of the subroutine called TEACH 


Step 4 

Define the DOPATH Subroutine. 

DEF DOPATH ; Begin definition of the subroutine called DOPATH 

HOM1 

; Move to the home position 

; (absolute counters set to zero) 

A5Ø 

; Set up the acceleration 

V3 

; Set up the velocity 

DATPTR1,1,1 ; Select data program #1 (DATP1) as the current active 

; data program, and set the data pointer to the first 

; data element. Increment the data pointer one element 

; after every data assignment with the DAT command. 

REPEAT 

; Set up a repeat/until loop 

D(DAT1) ; The position is recalled into 

; the distance command 

GO 

; Move to the position 

T.5 ; Wait for 0.5 seconds 

UNTIL(DPTR=1) ; Repeat the loop until the data pointer wraps around 

; to data element #1 (all data elements have been read) 

HOM1 

; Move back to the home position 

END 

; End definition of the subroutine called DOPATH 

Step 5 

Define the MAIN Program (Include SETUP, TEACH, and DOPATH). 

DEF MAIN ; Begin definition of the program called MAIN 

SETUP 

; Execute the subroutine called SETUP 

TEACH 

; Execute the subroutine called TEACH 

DOPATH 

; Execute the subroutine called DOPATH 

END 

; End definition of the program called MAIN 

Step 6 

Run the MAIN Program and Teach the Positions with the Joystick. 

1. Enter the MAIN command to execute the teach application program. 

2. 2. Use the joystick to move to the position to be taught. 

3. Once in position, activate the joystick release input to teach the positions. 

4. Repeat steps 2 and 3 for the remaining nine teach locations. After triggering the 

joystick release input the tenth time, the controller will home the motor, repeat the 

path that was taught, and then return to the home position. 


Product Control Options 

4 

CHAPTER FOUR 

Product Control 

Options 


This chapter explains various options for controlling your Gem6K product: 

• Safety features.................................................................................................... 116 

• Overview of product control options.................................................................. 116 

• Programmable I/O (switches, thumbwheels, PLCs, PLC Scan Mode, etc.) ................ 118 

• RP240 remote operator panel............................................................................. 123 

• Joystick and analog input interface (requires ANI SIM on expansion I/O brick)...... 130 

• Host computer interface ..................................................................................... 133

Safety Features 

WARNING 

The Gem6K Product is used to control your system's electrical and mechanical components. 

Therefore, you should test your system for safety under all potential conditions. Failure to do 

so can result in damage to equipment and/or serious injury to personnel. 

To help ensure a safe operating environment, you should take advantage of the safety features 

listed below. These features must not be construed as the only methods of ensuring safety. 

See Also refers you to where you can find more in-depth information about the feature (system 

connections and/or programming instructions) 

Feature Description See Also 

Enable Input 

End-of-travel 

Limit Inputs 

User Fault 

Input 

Maximum 

Allowable 

Position Error 

(servos only) 

The ENABLE input, found on the product’s drive I/O connector, is 

provided as an emergency stop input to the controller. 

If the ENABLE input is opened (disconnected from GND), output to 

the motors is inhibited. 

End-of-travel limits prevent the load from crashing through 

mechanical stops, an incident that can damage equipment and injure 

personnel. Use hardware or software limits, as your application 

requires. 

Using the INFNCi-F command or the LIMFNCi-F command, you 

can assign the user fault function to any of the programmable inputs. 

You can then wire the input to activate when an external event, 

considered a fault by the user, occurs. 

A position error (TPER) is defined as the difference between the 

commanded position (TPC) and the actual position as measured by 

the feedback device (TFB). The maximum allowable position error is 

set with the SMPER command. When the maximum allowable position 

error is exceeded (usually due to instability or loss of position 

feedback), the controller shuts down the drive and sets error status bit 

#12 (reported by the TER command). 

If SMPER is set to zero (SMPERØ), position error will not be monitored. 

Product’s 

hardware 

Installation Guide 

End-of-Travel 

Limits 

(page 74) 


(page 99) 

Servo Setup 

(page 85) 

☞ 

Programmed Error- 

Handling Responses 

When any of the safety features listed above are exercised (e.g., DFT input is activated, etc.), 

the controller considers it an error condition. With the exception of the shutdown output 

activation, you can enable the ERROR command to check for the error condition, and when it 

occurs to branch to an assigned ERRORP program. Refer to Error Handling (page 30) for 

further information. 

Options Overview 

Stand-Alone Interface Options 

After defining and storing controller programs, the controller can operate in a stand-alone 

fashion. A program stored in the controller may interactively prompt the user for input as part 

of the program (input via I/O switches, thumbwheels, RP240, joystick). A joystick can be use 

for situations requiring manual manipulation of the load. 

Option 

Application Example 


RP240 

(see page 123) 

Joystick 


ANI Analog Inputs 

(see page Error! Bookmark not 

defined.) 

Programmable inputs scanned 

in PLC Scan Mode 


Grinding: Program the RP240 function keys to select certain part types, 

and program one function key as a GO button. Select the part you want 

to grind, then put the part in the grinding machine and press the GO 

function key. The controller will then move the machine according to the 

predefined program assigned to the function key selected. 

X-Y scanning/calibration: Enter the joystick mode and use the 2-axis 

joystick to position an X-Y table under a microscope to arbitrarily scan 

different parts of the work piece (e.g., semi-conductor wafer). You can 

record certain locations to be used later in a motion process (e.g., for 

drilling, cutting, or photographing the work piece). Refer to page 112 an 

example using the joystick to teach positions. 

Injection Molding: Use for feedback from a pressure sensor to maintain 

constant, programmable force. (Note: ANI control requires that you install 

an analog input SIM on an expansion I/O brick.) 

The PLC Scan feature allows you to create a pre-compiled program that 

mimics PLC functionality by scanning through the I/O faster than in a 

normal program run. Because the functions of PLC programs are precompiled, 

delays associated with command processing are eliminated 

during profile execution, allowing more rapid sequencing of actions than 

would be possible with programs which are not compiled. Command 

processing is then free to monitor other activities. 

Programmable Logic Controller 

The controller's programmable I/O may be connected to most PLCs. After defining and 

storing controller programs, the PLC typically executes programs, loads data, and manipulates 

inputs to the controller. The PLC instructs the controller to perform the motion segment of a 

total machine process. 

EXAMPLE (X-Y point-to-point): A PLC controls several tools to stack and bore several 

steel plates at once. The controller is programmed to move an X-Y table in a pre-programmed 

sequence. The controller moves the load when the inputs are properly configured, signals the 

PLC when the load is in position, and waits for the signal to continue to the next position. 

Host Computer Interface 

A computer may be used to control a motion or machine process. A PC can monitor 

processes and orchestrate motion by sending motion commands to the controller or by 

executing motion programs already stored in the controller. This control might come from a 

BASIC or C program. A BASIC program example is provided on page 117.Custom 

Graphical User Interfaces (GUIs) 

Compumotor offers tools you can use to create your own custom graphical user interfaces 

(GUIs). More detailed descriptions are provided on page 144. 

• ActiveX Control: A Gem6K product communication control for custom 32-bit 

applications (e.g., developed with VisualBasic). Provided with Motion Planner. 

• PanelMaker: A VBScript-based operator interface tool. This is an add-on to Motion 

Planner, sold separately. 

Chapter 5. Custom Profiling 117

Programmable I/O Devices 

Programmable I/O Functions 

Programmable inputs and outputs are provided to allow the controller to detect and respond to 

the state of switches, thumbwheels, electronic sensors, and outputs of other equipment such as 

drives and PLCs. Listed below are the programmable functions that may be assigned to the 

programmable I/O. 

Programmable I/O offering differs by product. The total number of onboard inputs and 

outputs (trigger inputs, limit inputs, digital outputs) depends on the product. The total number 

of expansion inputs and outputs (analog inputs, digital inputs and digital outputs) depends on 

your configuration of expansion I/O bricks. To ascertain your product’s I/O bit patterns, refer 

to page 91. 

NOTE 

Refer to page 90 for instructions on establishing programmable input and output functions. 

Instructions for connecting to I/O devices are provided in your product’s Installation Guide. 


Virtual Inputs 

can be established 

to provide programmable 

input 

functionality for data 

or external events 

that are not 

ordinarily 

represented by 

inputs. See page 94 

for details. 

Input functions may be assigned to two basic groups of programmable inputs. LIMFNC assigns 

functions to the limit inputs found on the “LIMITS/HOME” connector. INFNC assigns functions to 

the trigger inputs (on the “TRIGGERS/OUTPUTS” connector) and to the digital inputs installed on 

expansion I/O bricks. The syntax, LIMFNCi-c or INFNCi-c, requires a letter designator (“c”) 

that corresponds to an input function; options for the input functions are listed in the table below. 

Letter Designator 

Function 

A....................General-purpose input (default function for triggers & inputs on I/O bricks) 

B....................BCD program select 

C....................Kill 

D....................Stop 

E....................Pause/Continue 

F....................User fault 

G.................... 

H....................Trigger Interrupt for position capture or registration (trigger inputs only). Special trigger 

functions can be assigned with the TRGFN command (see page 166). 

I....................Cause alarm event (requires Ethernet interface) in Communications Server 

J....................Jog in the positive-counting direction 

K....................Jog in the negative-counting direction 

L....................Jog velocity select 

M....................Joystick release 

N....................Joystick axis select 

O....................Joystick velocity select 

P....................One-to-one program select 

Q....................Program security 

R....................End-of-travel limit for positive-counting direction * 

S....................End-of-travel limit for negative-counting direction * 

T....................Home limit * 

* The limit inputs are factory-set to their respective end-of-travel or home limit function (see page 91). 

Output Functions Command Function 

OUTFNCi-A ............General-purpose output (default function) 

OUTFNCi-B ............Moving/not moving 

OUTFNCi-C ............Program in progress 

OUTFNCi-D ............Hardware or software end-of-travel limit encountered 

OUTFNCi-E ............Stall indicator — stepper axes only 

OUTFNCi-F ............Fault indicator (indicates drive fault input or user fault input is active) 

OUTFNCi-G ............Position error exceeds max. limit set with SMPER — servo axes only 

OUTFNCi-H ............Output on position 

* The “i” in the command syntax represents the number of the programmable input (e.g., OUTFNC3-H 

assigns onboard output #3 as an “output on position” function). 


Thumbwheels 

You can connect the controller's programmable I/O to a bank of thumbwheel switches to 

allow operator selection of motion or machine control parameters. 

The commands that allow for thumbwheel data entry are: 

INSTW.................. Establish thumbwheel data inputs 

OUTTW.................. Establish thumbwheel data outputs 

TW......................... Read thumbwheels or PLC inputs 

INPLC.................. Establish PLC data inputs 

OUTPLC................ Establish PLC data outputs 

Thumbwheel Setup 

The controller’s programming language allows direct input of BCD thumbwheel data via the 

programmable inputs. Use the steps below to set up and read the thumbwheel interface. Refer 

to the Gem6K Series Command Reference for descriptions of the commands used below. 

Step 1 

Wire your thumbwheels to the Gem6K. Refer to your product’s Installation Guide for I/O 

specifications. 

Step 2 

Set up the inputs and outputs for operation with thumbwheels. The data valid input will be an 

input which the operator holds active to let the controller read the thumbwheels. This input is 

not necessary; however, it is often used when interfacing with PLCs. 

OUTPLC1,1-4,0,12 ; Configure PLC output set 1: 

; onboard outputs 1-4 are strobe outputs, 

; no output enable bit, 

; 12 ms strobe time per digit read. 

INPLC1,1-8,9 ; Configure PLC input set 1: 

; onboard inputs 1-8 are data inputs, 

; onboard input 9 is a sign input, 

; no data valid input. 

INLVL000000000 ; Onboard inputs 1-9 configured active low 

Step 3 

The thumbwheels are read sequentially by outputs 1-4, which strobe two digits at a time. The 

sign bit is optional. Set the thumbwheels to +12345678 and type in the following commands: 

VAR1=TW5 

VAR1 

; Assign data from all 8 thumbwheel digits to VAR1 

; Displays the variable (*VAR1=+0.12345678). 

; If you do not receive this response, return to 

; step 1 and retry. 

PLCs 

The controller’s programmable I/O may be connected to most PLCs. After defining and 

storing controller programs, the PLC typically executes programs, loads data, and manipulates 

inputs to the controller. The PLC instructs the controller to perform the motion segment of a 

total machine process. 

Refer to your product’s Installation Guide for instructions on connecting to I/O devices. For 

higher current or voltages above 24VDC, use external signal conditioning such as OPTO-22 

compatible I/O signal conditioning racks. Contact your local distributor or automation 

technology center for information on these products. 


PLC Scan Mode 

Scan Time 

To check how much time 

(in 2 ms increments) the 

last scan took to complete, 

issue the TSCAN command 

or use the SCAN operand 

for variable assignments 

and IF conditions. 

For example, if the last 

PLC program took 3 

system updates (2 ms 

each) to scan, then TSCAN 

would report *TSCAN6, 

indicating that it took 6 ms 

to complete the scan. 

Each pass, if taking the 

same path through the 

conditional branches (IF 

statements), will always 

report the same TSCAN 

value. 

The PLC feature allows you to create a pre-compiled program that mimics PLC functionality by 

scanning through the I/O faster than in a normal program run. Because the functions of PLC 

programs are pre-compiled, delays associated with command processing are eliminated during 

profile execution, allowing more rapid sequencing of actions than would be possible with 

programs which are not compiled. Command processing is then free to monitor other activities. 

The PLC program is 

scanned/ executed at 

the beginning of the 

2-ms update period. 

The scan will stop after 

30 segments have been 

executed and resume at 

the next 2-ms update. 

PLCP programs, when 

compiled, comprise a 

linked list of PLC 

segments. During a 

scan, each segment is 

counted until the total 

number of segments 

executed exceeds 30. 

If the 30-segment limit 

occurs while executing 

a multi-segment 

To ascertain the scan time 

required to execute 30 

segments, use TSCAN 

or [SCAN]. 

Note: In Scan mode, when a 

scan is complete, the next scan 

will begin at the start of the 

next 2 ms System Update Period. 

Begin Scan Window 

30-segment limit 

• I/O Updated by System 

• Trajectories calculated 

• Programs/Tasks run 

• Etc. 

Begin New Scan 

(or resume scan 

at next segment) 

End Scan Window 

Time (msec) 

Scanning 

Scanning 

0 

2 millisecond 

System Update Period 

2 msec 

statement, then that statement will finish no matter how many segments it executes. For 

example, if 29 segments have executed, then the next segment will cause the scan to pause 

until the next 2-ms update. If that next statement is VARI1=1PE, which executes 2 segments, 

then VARI1=1PE will complete its operations before pausing the scan. 

To Implement a 

PLC Program … 

1. Define the PLC program (DEF PLCPi statement, followed by commands from the list 

below, followed by END). Up to 99 PLC programs may be defined, identified as PLCP1, 

PLCP2, PLCP3, and so on. Only these commands are allowed in a PLC program: 

• IF, ELSE, and NIF (conditional branching) —The PLC program uses the non-scaled 

integer (“raw”) operand values (e.g., PE value is not scaled by SCLD or ERES; PANI 

value is ADC counts, not volts). The only operands that are not allowed are: SIN, 

COS, TAN, ATAN, VCVT, SQRT, VAR, TW, READ, DREAD, DREADF, DAT, DPTR, and PI. 

• L and LN (loops) 

• HALT — 

- If the PLC program is executed with SCANP, HALT will terminate the current 

PLC program and kill the SCANP mode 

- If the PLC program is executed with PRUN, HALT will stop the PLC program 

(and the program that executed the PRUN statement) running in that task. 

• BREAK — 

- If the PLC program is executed with SCANP, BREAK will end only the current 

scan loop. At the next 2-millsecond update, the scan will restart at the first line 

of the PLC program. 

- If the PLC program is executed with PRUN, BREAK will stop the PLC program 

and execution will continue in the program from which the PRUN was executed 

(resuming at the command immediately following the PRUN command). 

• TIMST and TIMSTP (start and stop the timer) — 

• OUT (turn on a digital output) 


• ANO (set an analog output voltage – requires an extended I/O brick with on an 

analog output SIM) — 

• EXE (execute a program in a specific task — e.g., 2%EXE MOVE) 

• PEXE (execute a compiled program in a specific task — e.g., 3%PEXE PLCP4) 

• VARI (integer variables). A VARI assignment expression is limited to one math 

function — either addition (+) or subtraction (-). The operands can be any of the 

monitored integer assignment operators (e.g., PE, PC, etc.). 

NOTE: The PLC program uses the non-scaled (“raw”) operand values. 

• VARB (binary variables). Bitwise operations are limited to Boolean And (&), 

Boolean Inclusive Or (|), and Boolean Exclusive Or (^). The operands can be any 

of the monitored binary assignment operators (e.g., IN, LIM, AS, VARB, etc.). 

2. Compile the PLC program (PCOMP PLCPi). A compiled program runs much faster than a 

standard program. After the PLCP program is compiled, it is placed in the Gem6K 

controller’s “compiled” memory partition (see MEMORY command). To verify which PLC 

programs are compiled, type in the TDIR command; compiled PLC programs are identified 

as “COMPILED AS A PLC PROGRAM”. 

3. Execute the PLC program (SCANP PLCPi). When the PLC program is launched with the 

SCANP command, it is executed in the “PLC Scan Mode”. The advantage of the PLC Scan 

Mode is that the PLC program is executed within a dedicated 0.5 ms time slot during every 

2 ms system update period. This gives the PLCP program faster throughput for monitoring 

and manipulating I/O. 

An alternative execution method is to use the PRUN command (PRUN PLCPi). This method 

is similar to the SCANP PLCPi method, but will only run through the PLCP program once. 

Technical Notes 

About PLC 

Programs 

• Controller Status bit #3 is set when a PLCP program is being executed in Scan Mode. To 

check the controller status, use SC, TSC, or TSCF. 

• Launching programs external to the scan: Using the EXE command or the PEXE 

command, a scan program can launch another program in a specified task. EXE launches a 

standard, non-compiled program; PEXE launches a compiled program. 

• Stopping the scan: The scan program can be stopped in either of two ways: using the !K 

command, or clearing the scan program by issuing a SCANP CLR command. 

• Timing the PLC program outputs: It is not possible to control where the PLC program 

will pause if the scan takes more than the allowed time. This means that there can be a 

time lag of several update periods before the outputs, analog outputs, and/or variables 

affected by the PLC program are updated. The order in which the scan takes place should 

be considered when creating PLC programs to minimize the effects of such a lag. One 

way to avoid the lag is to create a binary variable as a temporary holding place for the 

desired output states. The last commands before the END statement of the PLC program 

can set the outputs according to the final status of the variable, such that all output states 

are written at the same time, just as the scan completes. This method is demonstrated in the 

example program below. 

• Memory Requirements: Most commands allowed in a PLC program consume one 

segment of compiled memory after the program is compiled with PCOMP; the exceptions 

are VARI and VARB (each consume 2 segments) and IF statements. Each IF conditional 

evaluation compounded with either an AND or an OR operator consumes an additional 

segment (e.g., IF(IN.1=b1 AND 1AS.1=b0) consumes three segments of compiled 

memory). The number of compounds is limited only by the memory available. 

• Order of Evaluation for Conditional Expressions: 

Because only one level of parenthesis is allowed, the order of evaluation of IF 


conditionals is from left to right. Refer to the flowchart below for the evaluation logic. 

Get Next Conditional 

FALSE 

Evaluate 

TRUE 

NO 

Compound = OR 

YES 

YES 

Compound = AND 

NO 

Statement 

Evaluates FALSE 

Statement 

Evaluates TRUE 

Programming 

Example 

DEF PLCP3 

; Binary states of outputs 1-6 represented by VARB1 bits 1-6. 

; Outputs 1-6 set at the end of program. 

VARB1=b000000 ; Initialize binary variable 1 

IF(IN.1=b1) 

; If onboard input 1 is ON, turn output 1 ON 

VARB1=VARB1 | b100000 ; Set binary bit for output 1 only to ON 

NIF 

IF(IN.2=b1) 



NIF 

IF(IN.3=b1) 



NIF 

IF(IN.4=b1) 



NIF 

IF(IN.5=b1) 



NIF 

IF(IN.6=b1) 



NIF 

OUT(VARB1) 

; Turn on appropriate onboard outputs 

END 

PCOMP PLCP3 

; Compile program PLCP3 

SCANP PLCP3 

; Run compiled program PLCP3 in Scan mode. See diagram. 

DEF PLCP3 

VARB1=b000000 

IF(IN.1=b1) 

VARB1=VARB1 | b100000 

NIF 

IF(IN.2=b1) 


NIF 

IF(IN.3=b1) 


NIF 

IF(IN.4=b1) 


NIF 

IF(IN.5=b1) 


NIF 

IF(IN.6=b1) 


NIF 

OUT(VARB1) 

END 

Pause Scan 

Scan 

Complete 

Begin New 

Scan 

Time (msec) 

Scanning 

Scanning 

Scanning 

0 

2 msec 

4 msec 

Scanning 

6 msec 

2 System Update Periods are needed to complete the scan 

for compiled program PLCP3, for a total of 4 msec. 

The response to a TSCAN command would be: *TSCAN4. 


RP240 Remote Operator Panel 

Gem6K Series products are directly compatible with the Compumotor RP240 Remote 

Operator Panel. This section describes how to use your Gem6K product with the RP240. 

Instructions for connecting the RP240 are provided in the Gem6K Hardware Installation 

Guide. Refer to the Model RP240 User Guide (p/n 88-012156-01) for information on RP240 

hardware specifications, mounting guidelines, environmental considerations, and 

troubleshooting. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Configuration 

NOTE 

As shipped from the factory, your Gem6K product is configured to operate an RP240 from the 

RS-232 connector (referred to as the “COM 2” port). This should be appropriate for the 

majority of applications requiring RP240 interface. 

For more information 

on controlling your 

product's multiple 

serial ports, refer to 

page 56. 

Every Gem6K Series product has two serial ports. The RS-232/485 connector is referenced as 

the “COM1” serial port, and the RS-232 connector is referenced as the “COM2” serial port. 

To configure the Gem6K product's serial ports for use with the RP240 and/or Gem6K language 

commands, use the DRPCHK command. Be sure to select the affected serial port (COM 1 or 

COM 2) with the PORT command before you execute the DRPCHK command. Once you issue 

the DRPCHK command, it is automatically saved in non-volatile memory. The configuration 

options are: 

DRPCHKØ ..........Use the serial port for Gem6K commands only (default for COM 1) 

DRPCHK1 ..........Check for RP240 on power up or reset. If detected, initialize RP240. 

If no RP240, use serial port for Gem6K commands. 

DRPCHK2 ..........Check for RP240 every 5-6 seconds. If detected, initialize RP240. Do not use 


port for Gem6K commands. 

DRPCHK3 ..........Check for RP240 on power up or reset. If detected, initialize RP240. 

If no RP240, use serial port for DWRITE command only. The DWRITE command 

can be used to transmit text strings to remote RS-232C devices. (default setting 

for COM 2) 

Example 

COM 2 is to be used for RS-232; COM 1 is to be used for RP240, but the RP240 will be plugged 

in on an as-needed basis. The set-up commands for such an application should be executed in 

the following order: 

PORT1 

DRPCHK2 

PORT2 

DRPCHKØ 

; Select COM1 serial port for setup 

; Configure COM1 for RP240, periodic check 

; Select COM2 serial port for setup 

; Configure COM2 for Gem6K commands only 

Operator Interface Features 

The RP240 may be used as your product’s operator interface, not a program entry terminal. 

As an operator interface, the RP240 offers the following features: 

• Displays text and variables 

• 8 LEDs can be used as programmable status lights 

• Operator data entry of variables: read data from RP240 into variables and command 

value substitutions (see Command Value Substitutions on page 7). 

Typically the user creates a program in the Gem6K controller to control the RP240 display 

and RP240 LEDs. The program can read data and make variable assignments via the RP240's 

keypad and function keys. 

The Gem6K Series software commands for the RP240 are listed below. Detailed descriptions 

are provided in the Gem6K Series Command Reference. The example below demonstrates the 

majority of these Gem6K Series commands for the RP240. 

DCLEAR............Clear The RP240 Display 

DJOG................Enter RP240 Jog Mode 

[DKEY]............Numeric value of RP240 Key 

DLED................Turn RP240 LEDs On/Off 

DPASS..............Change RP240 Password 

DPCUR..............Position The Cursor On The RP240 Display 

[DREAD] .........Read RP240 Data 

[DREADF] .......Read RP240 Function Key 

DREADI............RP240 Data Read Immediate Mode 

DRPCHK............Check for RP240 

DSTP................Enable/Disable the RP240 Stop Key 

DVAR................Display Variable On RP240 

DWRITE............Display Text On The RP240 Display 


Programming 

Example 

DEF panel1 

; Define program panel1 

REPEAT 

; Start of repeat loop 

DCLEAR0 

; Clear display 

DWRITE"SELECT A FUNCTION KEY" ; Display text "SELECT A FUNCTION KEY" 

DPCUR2,2 ; Move cursor to line 2 column 2 

DWRITE"DIST" 

; Display text "DIST" 


DWRITE"GO" 

; Display text "GO" 


DWRITE"EXIT" 

; Display text "EXIT" 

VAR1 = DREADF 

; Input a function key 

IF (VAR1=1) 

; If function key #1 hit 

GOSUB panel2 

; GOSUB program panel2 

ELSE 

; Else 

IF (VAR1=2) 

; If function key #2 hit 

DLED1 ; Turn on LED #1 

GO1 ; Start motion on axis #1 

DLED0 ; Turn off LED #1 

NIF 

; End of IF (VAR1=2) 

NIF 

; End of IF (VAR1=1) 

UNTIL (VAR1=6) ; Repeat until VAR1=6 (function key 6) 

DCLEAR0 


DWRITE"LAST FUNCTION KEY = F" ; Display text "LAST FUNCTION KEY = F" 

DVAR1,1,0,0 ; Display variable 1 

END 

; End of panel1 

DEF panel2 

DCLEAR0 

DWRITE"ENTER DISTANCE" 

D(DREAD) 

END 

; Define prog panel2 


; Display text "ENTER DISTANCE" 

; Enter distance number from RP240 

; End of panel2 

Using the Default Menus 

On power-up, the Gem6K product will automatically default to a mode in which it controls 

the RP240 with the menu-driven functions listed below. 

The flow chart below 

illustrates the RP240's 

menu structure in the 

default operating mode 

(when no Gem6K 

product user program 

is controlling the 

RP240). Press the 

Menu Recall key to 

back up to the previous 

screen. The menu 

functions are described 

in detail below. 

• Run a stored program (RUN, STOP, PAUSE and CONTINUE functions) 

• Jog the load 

• Display the status of: 

- System (TSS), for each task 

- Axis (TAS) 

- Extended Axis (TASX) 

- I/O (TIN and TOUT) 

- Limits (TLIM) and ENABLE input (TINO bit #6) 

- Position: Commanded (TPC), Encoder (TPE) 

- Firmware revision levels for the Gem6K product (TREV) and the RP240 

• Enable or disable the internal drive (DRIVE) 

• Access RP240 menu functions with a security password (set with DPASS) 

• Reset the Gem6K product (equivalent to the RESET command) 

NOTE: To disable these menus, the start-up program (the program assigned with the 

STARTP command) must contain the DCLEARØ command. 



Running a Stored 

Program 

 

 

 

 

 

 

or 

 

 

After accessing the RUN menu, press F1 to “find” the names of the programs stored in the 

Gem6K product’s memory; pressing F1 repeatedly displays subsequent programs in the order 

in which they were stored in BBRAM. To execute the program, press the ENTER key. 

To type in a program name at the location of the cursor, first select alpha or numeric 

characters with the F2 function key (characters will be alpha if an asterisk appears to the right 

of ALPHA, or numeric if no asterisk appears). If alpha, press the up (2) or down (8) keys to 

move through the alphabet, if numeric, press the desired number key. Press F3 to move the 

cursor to the left, or F4 to move the cursor to the right. 

Only user programs defined with DEF and END may be executed from this menu. Compiled 

profiles (GOBUF profiles) cannot be executed from this menu; they must be executed from the 

terminal emulator with the PRUN command, or you can place the PRUN (name of path) 

command in a user program and then execute that program from this menu. 

HINT: If you wish to 

display each command as 

it is executed, select STEP 

and TRACE and press the 

ENTER key to step 

through the program. 

When a program is RUN and TRACE is selected (TRACE*), the RP240 display will trace all 

program commands as they are executed. This is different from the TRACE command in that 

the trace output goes to the RP240 display, not to a terminal via the serial port. 

When a program is RUN and STEP is selected, step mode has been entered. This is similar to 

the STEP command, but when selected from the RUN menu the step mode allows single 

stepping by pressing the ENTER key. Both RP240 trace mode and step mode are exited when 

program execution is terminated. 

Jogging 

 

 

 

 

You can jog the axis by pressing the arrow keys on the RP240’s numeric keypad. The left and 

right arrow keys are for jogging the axis in the negative and positive direction, respectively. 

Pressing an arrow key starts motion and releasing the arrow key stops motion. 

The HI and LO values in the jog menu represent the velocity in units of revs/sec. If scaling is 

enabled, the value is multiplied by the programmed SCLV value. 

To edit the jog velocity* values: 

1. Press the F5 function key under EDIT (edit mode indicated with an asterisk). 

2. Press the F1 function key to select the HI and LO values (cursor appears under the 

first digit of the value selected). 

3. Using the numeric keyboard, enter the value desired. 

4. Repeat steps 2 and 3 for all values to be changed. 

5. Press ENTER when finished editing. 

6. To jog with the new velocity values, first press the F6 function key (under JOG) to 

enable the arrow keys again. 

Jog accel and decel values are specified by the JOGA and JOGAD commands, respectively. 


Status Reports: 

System & Axis 

 

 

 

 

 

 

 

 

 

 

After accessing the desired status menu, you can ascertain the function and status of each 

system (TSS, for each task) or axis (TAS and TASX) status bit by pressing the arrow keys on 

the numeric keypad. 

To view a more descriptive explanation of each status bit (includes a text description), press 

the left or right arrow keys on the numeric keypad. 

Status Reports: 

I/O, Limits, Position 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INPUTS Menu: This menu displays the TIN bit patterns for programmable inputs (onboard 

triggers and digital inputs on expansion I/O bricks). Remember that I/O bit patterns vary by 

product (see page 91 to find the bit patterns for your product). The initial menu show the 

trigger inputs status; use the up and down arrows to select the status of inputs on expansion 

I/O bricks. 

OUTPUTS Menu: This menu displays the TOUT bit patterns for programmable outputs 

(onboard outputs and digital outputs on expansion I/O bricks). Remember that I/O bit patterns 

vary by product (see page 91 to find the bit patterns for your product). The initial menu show 

the onboard outputs; use the up and down arrows to select the status of outputs on expansion 

I/O bricks. 


LIMITS Menu: 

• The POS, NEG and HOME status items represent the hardware states of the limit inputs 

on the “LIMITS/HOME” connector, regardless of their LIMFNC input function 

assignments; they do not represent INFNC limit functions assigned to onboard trigger 

inputs or digital inputs on expansion I/O bricks. 

• “POS” refers to the hardware end-of-travel limit imposed when counting in the positive 

direction. “NEG” refers to the limit imposed when counting in the negative direction. 

• A “1” indicates that the input is grounded, “0” indicates not grounded. 

The end-of-travel limits (POS and NEG) must be grounded to allow motion (this is 

reversed if the active level is reversed with the LIMLVL command). 

The Enable input (ENABLE input terminal) must also be grounded before motion is 

allowed. When not grounded, the output to the motor is cut off and the shutdown 

outputs are activated. 

POS Menu: 

• The position values (encoder, commanded, and position error) shown are continually 

updated. 

• The position error (“ERROR”) report is applicable only to servo axes. 

• Position values are subject to the SCLD scaling factor (if scaling is enabled—SCALE1), 

PSET offset value, encoder polarity (ENCPOL), and commanded direction polarity 

(CMDDIR). 

Enabling and 

Disabling the Drive(s) 

 

 

 

 

In the DRIVE menu, the current status of the drive(s) is displayed. To enable or disable the 

drive, press F1 or F2, respectively This menu offers the same functionality as the DRIVE 


WARNING 

Shutting down a rotary drive system allows the load to freewheel if there is no brake installed. 

Access Security 

 

 

 

 

 

 

 

 

 

 

 

 

 

If the RP240 password is modified with the DPASS command to be other than the default (see 

Changing the Password below) the ACCESS menu then becomes the new default menu after 

power-up or executing a RESET. After that, the new password must then be entered to access 

the original default menu (see “Access Approved” path in illustration). If the operator does not 

know the new password, all he or she can do is run programs stored in the Gem6K product 

(RUN). 


Changing the Password: The default password for Gem6K products is “6000”. A new 

password (numeric value of up to 4 characters) can be established with the DPASS command. 

For example, the DPASS2001 command sets the password to 2001. 

Revision Levels 

 

 

 

 

 

 

Resetting the Gem6K 

Product 

 

 

 

 

 

 

After accessing the RESET menu, press the F1 key to execute a reset (or press F2 to cancel 

and exit the menu). The reset is identical to issuing a RESET command or cycling power to 

the Gem6K product. If a start-up program has been assigned with the STARTP command, 

that program will be executed. 

CAUTION 

Executing a reset will restore most command values (exclusions: see page 65) to their 

factory default setting. 

Joystick Control, Analog Inputs 

☞ 

Refer to your 


connection 

procedures. 

Joystick Control 

The Gem6K allows you to add analog input (ANI) SIMs to the expansion I/O bricks (sold 

separately). Each ANI SIM provides 8 analog inputs. The default voltage range for these input 

is -10VDC to +10VDC, but other ranges are selectable with the ANIRNG command. ANI 

inputs may be used in a variety of ways: 

• Control an axis with a joystick (see Joystick Control) 

• Use the voltage value to control other events. The voltage value on the ANI inputs can 

be read using the ANI or TANI commands. 

The controller supports joystick operation with digital inputs and analog inputs. The digital 

inputs include the onboard limit inputs and trigger inputs, as well as digital input SIMs on an 

external I/O brick. The 12-bit analog inputs are available on board (single analog input) or if 

you install an analog input SIM on an external I/O brick (default voltage range is -10V to 

+10V, selectable with ANIRNG). 


To Set Up Joystick 

Operation 

(refer also to the 

example code below) 

1. Select the required digital inputs and analog inputs required for joystick operation. Connect 

the joystick as instructed in your controller’s Installation Guide. 

2. Assign the appropriate input functions to the digital inputs used for joystick's operation: 

• Release Input: INFNCi-M for triggers & I/O brick inputs, or LIMFNCi-M for limit 

inputs. 

• Velocity Select Input: INFNCi-O for triggers & external inputs, or LIMFNCi-O for 

limit inputs. 

3. (optional) Use the ANIRNG command to select the voltage range for the analog inputs you 

will use. The default range is -10VDC to +10VDC (other options are 0 to +5V, -5 to +5V, 

and 0 to +10V). 

4. Use the JOYAXH command to assign the analog input that will control the axis. 

5. Define the joystick motion parameters: 

• Max. Velocity when Velocity Select input switch is open/high (JOYVH command). If 

the Velocity Select input is not used, joystick motion always uses the JOYVH velocity. 

• Max. Velocity when Velocity Select input switch is closed/low (JOYVL command). 

• Accel (JOYA command). 

• Accel for s-curve profiling (JOYAA command). 

• Decel (JOYAD command). 

• Decel for s-curve profiling (JOYADA command). 

6. Define the usable voltage zone for your joystick: 

(make sure you have first assigned the analog inputs – see step 3 above) 

• End Deadband (JOYEDB): Defines the voltage offset (from the -10V & +10V 

endpoints) at which max. velocity occurs. Default is 0.1V, maxing voltage at -9.9V and 

+9.9V. 

• Center Voltage (JOYCTR or JOYZ): Defines the voltage when the joystick is at rest to be 

the zero-velocity center. Default JOYCTR setting is 0V. 

• Center Deadband (JOYCDB): Defines the zero-velocity range on either side of the 

Center Voltage. Default is 0.1V, setting the zero-velocity range at -0.1V to +0.1V. 

7. To jog the axis: 

a. In your program, enable Joystick Operation with the JOY command (Joystick Release 

input must be closed in order to enable joystick mode). When the JOY command 

enables joystick mode, program execution stops (assuming the Continuous Command 

Execution Mode is disabled with the COMEXCØ command). 

b. Move the load with the joystick. 

c. When you are finished, open the Joystick Release input to disable joystick mode. This 

allows program execution to resume with the next statement after the initial JOY 

command that started the joystick mode. 

Joystick 

Programming 

Example 

(refer also to the 

illustration below) 

Application Requirements: This example represents a typical two-axis joystick application in 

which a high-velocity range is required to move to a region, then a low-velocity range is 

required for a fine search. After the search is completed it is necessary to record the load 

positions, then move to the next region. A digital input can be used to indicate that the position 

should be read. The Joystick Release input is used to exit the joystick mode and continue with 

the motion program. 

Hardware Configuration: 

• An analog input SIM is installed in the 3rd slot of I/O brick 1. The eight analog inputs 

(1-8) are addressed as input numbers 17-24 on the I/O brick. Analog input 17 will 

control the motion. 

• A digital input SIM is installed in the 1st slot of I/O brick 1. The eight digital inputs (1- 

8) are addressed as input numbers 1-8 on the I/O brick. Digital input 6 will be used for 

the Joystick Release function, and input 7 will be used for the Joystick Velocity Select 

input. Input 8 will be used to indicate that the position should be read. 


Setup Code (the drawing below shows the usable voltage configuration): 

1INFNC7-M ; Assign Joystick Release f(n) to brick 1, input 7 

1INFNC8-O ; Assign Joystick Velocity Select f(n) to brick 1, input 8 

JOYAXH1-17 ; Assign analog input 17 to control the motion, 

JOYVH1 

; Max. velocity is 10 units/sec when the 

; Velocity Select input (1IN.7) is open (high) 

JOYVL10 

; Max. velocity is 1 unit/sec when the 

; Velocity Select input (1IN.7) is closed (low) 

JOYA100 

; Set joystick accel to 100 units/sec/sec 

JOYAD100 

; Set joystick decel to 100 units/sec/sec 

;**** COMMANDS TO SET UP USABLE VOLTAGE: ********** 

1JOYCTR.17=+1.0 ; Set center voltage for analog input 17 

; to+1.0V. The +1.0V value was 

; ascertained by checking the voltage of the both 

; inputs (with the 1TANI.17) 

; when the joystick was at rest. 

1JOYCDB.17=0.5 ; Set center deadband to compensate for the fact that 

; when the joystick is at rest, the voltage received on 

; the analog input may fluctuate +/- 0.5V on either 

; side of the +1.0V center. 

1JOYEDB.17=2.0 ; Set end deadband to compensate for the fact that the 

; joystick can produce only -8.0V to +8.0V. 

;************************************************** 

JOY1 

; Enable joystick mode 

Velocity 

(positive direction) 

JOYVH or JOYVL 

JOYCDB 

(zero-velocity range) 

JOYEDB 

-10V +10V 

Volts 

JOYEDB 

JOYCTR or JOYZ 

(voltage when joystick is at rest) 

JOYVH or JOYVL 

Velocity 

(negative direction) 

Analog Input Interface 

Refer to your product's 


ANI connection 

information. 

Using analog (ANI) inputs on expansion I/O bricks, your controller can use analog voltage as a 

means to control the program based on external conditions. 

Each ANI SIM on an expansion I/O brick provides eight analog inputs. The 12-bit analog 

inputs have a default voltage range of -10VDC to +10VDC. Other ranges are selectable with 

the ANIRNG command (0 to +5VDC, 0 to +10VDC, and -5 to +5VDC). The voltage value of 

the ANI inputs can be transferred to the terminal with the TANI command, or used in an 

assignment or comparison operation with the ANI operator (e.g., IF(1ANI

Host Computer Interface 

Another choice for product control is to use a host computer and execute a motion program using 

the serial interface (RS-232 or RS-485). A host computer may be used to run a motion program 

interactively from a BASIC or C program (high-level program controls the Gem6K product and acts 

as a user interface). A BASIC program example is provided below. 

10 ' Gem6K Series Serial Communication BASIC Routine 

12 ' Gem6K.BAS 

14 ' 

16 ' ************************************************************** 

18 ' 

20 ' This program will set the communications parameters for the 

22 ' serial port on a PC to communicate with a Gem6K series 

24 ' stand-alone product. 

26 ' 

28 ' ************************************************************** 

30 ' 

100 '*** open com port 1 at 9600 baud, no parity, 8 data bits, 1 stop bit 

110 '*** activate Request to Send (RS), suppress Clear to Send (CS), suppress 

120 '*** DATA set ready (DS), and suppress Carrier Detect (CD) *** 

130 OPEN "COM1:9600,N,8,1,RS,CS,DS,CD" FOR RANDOM AS #1 

140 ' 

150 '*** initialize variables *** 

160 MOVE$ = "" ' *** commands to be sent to the product *** 

170 RESPONSE$ = "" ' *** response from the product *** 

180 POSITION$ = "" ' *** feedback position reported *** 

190 SETUP$ = "" ' *** setup commands *** 

200 ' 

210 '*** format the screen and wait for the user to start the program *** 

220 CLS : LOCATE 12, 20 

230 PRINT "Press any key to start the program" 

240 ' 

250 '*** wait for the user to press a key *** 

260 PRESS$ = INKEY$ 

270 IF PRESS$ = "" THEN 260 

280 CLS 

290 ' 

300 '*** set a pre-defined move to make *** 

310 SETUP$ = "ECHO1:ERRLVL0:LH0:" 

320 MOVE$ = "A100:V2:D50000:GO1:TFB:" 

330 ' 

340 ' 

400 '*** send the commands to the product *** 

410 PRINT #1, SETUP$ 

420 PRINT #1, MOVE$ 

430 ' 

500 ' *** read the response from the TFB command *** 

510 ' *** the controller will send a leading "+" or "-" in response to the TFB command to 

520 ' *** indicate which direction travel has occurred. *** 

530 WHILE (RESPONSE$ "+" AND RESPONSE$ "-") ' *** this loop waits for the "+" 

540 RESPONSE$ = INPUT$(1, #1) ' *** or "-" characters to be returned 

550 WEND ' *** before reading the position *** 

560 ' 

570 WHILE (RESPONSE$ CHR$(13)) ' *** this loop reads one character at a time 

580 POSITION$ = POSITION$ + RESPONSE$ ' *** from the serial buffer until a carriage 

590 RESPONSE$ = INPUT$(1, #1) ' *** return is encountered *** 

600 WEND 

610 ' 

620 '*** print the response to the screen *** 

630 LOCATE 12, 20: PRINT "Position is " + POSITION$ 

640 ' 

650 'END 


Graphical User Interface (GUI) Development Tools 

TO ORDER 

To order Motion OCX Toolkit, DDE6000, or Motion Toolbox ® , contact your local 

Automation Technology Center (ATC) or distributor. 

ActiveX Control 

PanelMaker 

Provided with Motion Planner is the Gem6K ActiveX control, a 32-bit control which can be 

used as an interface tool between your custom Windows application and the Gem6K product. 

For example, you might use the ActiveX control with a third-part factory automation software 

and operator interface, such as Wonderware's In-Touch. 

Sold separately as an add-on utility to Motion Planner, PanelMaker is a custom GUI creation 

tool based on the VisualBasic Scripting language. Using PanelMaker, you can create custom 

interfaces for operator input and diagnostics. The PanelMaker custom controls include: 

• Communication between the application and the Gem6K product• 


Custom Profiling 

5C HAPTER FIVE 

Custom 

Profiling 


This chapter explains how to use these custom profiling features: 

• S-Curve Profiling ..............................................136 

• Compiled Motion Profiling...............................139 

• On-the-Fly Motion (pre-emptive GOs)..............155 

• Registration.......................................................159 

• Synchronizing Motion.......................................163 

For basic motion (accel/velocity/distance), see page ....71 

For homing profiles, see page ......................................79 

For Following profiles, see page ...................................168

S-Curve Profiling 

Controllers allow you to perform S-curve move profiles, in addition to the usual trapezoidal 

profiles. S-curve profiling provides smoother motion control by reducing the jerk (rate of 

change) in acceleration and deceleration portions of the move profile (see drawing below). 

Because S-curve profiling reduces jerk, it improves position tracking performance. 

Trapezoidal 

S-Curve 

Decel Accel Velocity 

Maximum Jerk 

Time 

Time 

Velocity 

Decel Accel 

Less Jerk 

Time 

Time 

S-Curve Programming Requirements 

To program an S-curve profile, you must use the average accel/decel commands provided in 

the Gem6K Series programming language. For every maximum accel/decel command (e.g., 

A, AD, HOMA, HOMAD, JOGA, JOGAD, etc.) there is an average command for S-curve 

profiling (see table below). 

Maximum Accel/Decel Commands: 

Command Function 

Average (“S-Curve”) Accel/Decel Commands: 

Command Function 

A Acceleration AA Average Acceleration 

AD Deceleration ADA Average Deceleration 

HOMA Home Acceleration HOMAA Average Home Acceleration 

HOMAD Home Deceleration HOMADA Average Home Deceleration 

JOGA Jog Acceleration JOGAA Average Jog Acceleration 

JOGAD Jog Deceleration JOGADA Average Jog Deceleration 

JOYA Joystick Acceleration JOYAA Average Joystick Acceleration 

JOYAD Joystick Deceleration JOYADA Average Joystick Deceleration 

LHAD Hard Limit Deceleration LHADA Average Hard Limit Deceleration 

LSAD Soft Limit Deceleration LSADA Average Soft Limit Deceleration 

PA Path Acceleration PAA Average Path Acceleration 

PAD Path Deceleration PADA Average Path Deceleration 

Determining the S-Curve Characteristics 

The command values for average accel/decel (AA, ADA, etc.) and maximum accel/decel (A, AD, 

etc.) determine the characteristics of the S-curve. To smooth the accel/decel ramps, you must 

enter average accel/decel command values that satisfy the equation ½ A ≤ AA < A, where 

A represents maximum accel/decel and AA represents average accel/decel. Given this 

requirement, the following conditions are possible: 


Acceleration Setting 

Profiling Condition 

AA > ½ A, but AA < A............. S-curve profile with a variable period of constant acceleration. Increasing 

the AA value above the pure S-curve level (AA > ½ A), the time required to 

reach the target velocity and the target distance is decreased. However, 

increasing AA also increases jerk. 

AA = ½ A ................................ Pure S-curve (no period of constant acceleration—smoothest motion). 

AA = A .................................... Trapezoidal profile (but can be changed to an S-curve by specifying a new 

AA value less than A). 

AA < ½ A; or AA > A............... When you issue the GO command, the move will not be executed and an 

error message, *INVALID CONDITIONS FOR S_CURVE ACCELERATION— 

FIELD n, will be displayed. 

AA = zero................................ S-curve profiling is disabled. Trapezoidal profiling is enabled. AA tracks A. 

(Track means the command's value will match the other command's value 

and will continue to match whatever the other command's value is set to.) 

However, if you enter an average decel command (e.g., ADA, HOMADA, etc.) 

equal to zero, you will receive the “INVALID DATA-FIELD n” error. 

AA ≠ zero and AA ≠ A ............ S-curve profiling is enabled only for standard moves (e.g., not for 

compiled motion, or on-the-fly motion changes). All subsequent standard 

moves for that axis must comply with this equation: 

½ A ≤ AA < A. 

AA > ½ A ................................ Average accel/decel is raised above the pure S-curve level; this decreases 

the time required to reach the target velocity and distance. However, 

increasing AA also increases jerk. After increasing AA, you can reduce jerk 

by increasing A, but be aware that increasing A requires a greater torque to 

achieve the commanded velocity at the mid-point of the acceleration profile. 

No AA value ever entered ...... Profile will default to trapezoidal. AA tracks A. 

If you never change the A or AA deceleration commands, AA deceleration will track AA 

acceleration. However, once you change A deceleration, AA deceleration will no longer track 

changes in AA acceleration. For example, if you never change the AD or ADA command values, 

ADA will track the AA command value. But once you change AD, the ADA command value will 

no longer track the changes in the AA command value. 

The calculation for determining S-curve average accel and decel move times is as follows 

(calculation method identical for S-curve and trapezoidal moves): 

Time = Velocity 

Aavg 

or Time = 

2 ∗ Distance 

Aavg 

Scaling affects the AA average acceleration (AA, ADA, etc.) the same as it does for the A 

maximum acceleration (A, AD, etc.). See page 67 for details on scaling. 

NOTE: Equations for calculating jerk are provided on page 138. 

Programming Example 

; In this example, axis 1 executes a pure S-curve and takes 1 second 

; to reach a velocity of 5 rps. 


DEF SCURV ; Begin definition of program SCURV 

MA0 ; Select incremental positioning mode 

 

D40000 ; Set distances to 40,000 positive- 

; direction steps 

A10 ; Set max. accel to 10 rev/sec/sec 

AA5 ; Set avg. accel to 5 rev/sec/sec on 

AD10 ; Set max. decel to 10 rev/sec/sec 

ADA5 ; Set avg. decel to 5 rev/sec/sec on 

Move profile 

V5 ; Set velocity to 5 rps 

GO1 ; Execute motion 

END ; End definition of program 

 

 

Chapter 6. Following 137

Calculating Jerk 

Zero Acceleration 

A 

(Programmed Accel) 

Rules of Motion: 

da 

Jerk = 

dt 

dv 

a = 

dt 

dx 

v = (x = distance) 

dt 

V 2 

V 

(Programmed Velocity) 

Assuming the accel profile starts 

when the load is at zero velocity and 

the ramp to the programmed velocity 

is not compromised: 

Zero Velocity 

Ø 

(zero) 

V 1 

t 1 t 2 t 3 

A B C 

Jerk = J A = 

A 2 * AA 

V (A-AA) 

A = programmed acceleration 

(A, AD, HOMAD, etc.) 

AA = average acceleration 

(AA, ADA, HOMAA, etc.) 

V = programmed velocity 

(V, HOMV, etc.) 

A 

A 

t 1 = 

t1 ≥ t ≥ Ø a (t) = J A * t 

a (t) = acceleration at time t 

v (t) = velocity at time t 

J A 

J A * t 2 d (t) = distance at time t 

v (t) = 

V A 

2 

t 2 = - 

AA J A 

J A * t 3 

d (t) = 

V 

6 

V 2 = V - 

A 2 

2 * J A 

C t3 ≥ t > t2 a (t) = A - (J A * (t - t 2 )) 

t 3 = 

AA 

NOTE: t 3 - t 2 = t 1 

B t2 ≥ t > t1 a (t) = A 

A 2 

v (t) = 

2J A 

+ A * (t - t 1 ) 

V 1 = 

2 

J A * t 1 A 2 

3 

J A * t 1 A * (t - t 1 ) 2 

= 

d (t) = + 

2 2 * J 

6 

2 

A 

+ V 1 * (t - t 1 ) 

J A * (t 3 - t) 2 

2 

v (t) = V - 

V 2 J A (t 3 - t) 3 

d (t) = 

2AA 

+ 

6 

- V * (t 3 - t) 

Starting at a Non-Zero Velocity: If starting the acceleration profile with a non-zero initial velocity, the move comprises 

two components: a constant velocity component, and an s-curve component. Typically, the change of velocity should be 

used in the S-curve calculations. Thus, in the calculations above, you would substitute “(V F - V O )” for “V” (V F = final 

velocity, V O = initial velocity). For example, the jerk equation would be: 

Jerk = J A = 

A 2 * AA 

(V F - V O ) (A-AA) 


Compiled Motion Profiling 

Gem6K Series products allow you to construct complex individual axis motion profiles which 

are compiled and saved. You can define separate and independent profiles for each individual 

axis. The profiles may contain: 

• Sequences of motion 

• Loops 

• Programmable output changes 

• Embedded dwells 

• Direction changes 

• Trigger functions 

Related Commands: 

Brief descriptions of related 

commands are found on page 139. 

For detailed descriptions, refer to the 

Gem6K Series Command Reference. 

☞ 

PLCP programs are 

stored in compiled 

memory 

(see page 11). 

Compiled motion profiles are defined like programs (using the DEF and END commands); the 

commands used to construct the motion profile segments are stored in a program (stored in 

Program memory). This program is then compiled (using the PCOMP command) and the 

compiled profile segments (GOBUF, PLOOP, GOWHEN, TRGFN, and POUTA statements) from 

the program are stored in Compiled memory. (TIP: The TDIR command reports which 

programs are compiled as a compiled profile.) You can then execute the compiled profile with 

the PRUN command. 

The amount of RAM allocated for storing compiled profile segments is determined by the 

MEMORY command setting. The list below identifies memory allocation defaults and limits for 

Gem6K Series products. Further details on re-allocating memory are provided on page 11. 

Total memory (bytes) .........................................300,000 

Default allocation (program,compiled)...............MEMORY150000,150000 

Maximum allocation for compiled profiles ........MEMORY1000,299000 

Maximum # of compiled profiles .......................300 

Maximum # of compiled profile segments .........2069 

CAUTIONS 

• Issuing a memory allocation command (e.g., MEMORY70000,230000) will erase all existing 

programs and compiled path segments. However, issuing the MEMORY command by itself (i.e., 

MEMORY—to request the status of how the memory is allocated) will not affect existing programs 

or segments. 

• After compiling (PCOMP) and running (PRUN) a compiled profile. The profile segments will be 

deleted from compiled memory if you cycle power or issue a RESET command. 

After compiling (PCOMP), you can execute the profiles with the PRUN command, and all of 

the motion and functions compiled into the profile are executed without any further 

commands during profile execution. 

Because the motion and functions are pre-compiled, delays associated with command 

processing are eliminated during profile execution, allowing more rapid sequencing of actions 

than would be possible with programs which are not compiled. Command processing is then 

free to monitor other activities, such as I/O and communications. 


NOTES 

• During compilation (PCOMP), most commands are executed the same as if no profile were being 

defined, even those which are not relevant to the construction of a profile. This is also true of 

non-compiled motion commands embedded in a compiled motion program during PCOMP. For 

this reason, it’s good to limit commands between DEF and END to those which actually assist in 

the construction of the profile. Even for those that do actually assist in the construction of the 

profile, such as A, V, and D, it is important to remember that the command is executed and data 

actually changes, and it is not restored after compilation is completed. 

• If your compiled motion program contains variables, the variables are evaluation only at compile 

time. 

Each motion segment in a compiled motion profile may have its own distance, velocity, 

acceleration, and deceleration, as shown in the program example below: 

Programming 

Example 

DEF simple ; Begin definition of program simple 

MC0 

; Preset positioning mode (disable continuous mode) 

D50000 ; Distance is 50000 



V5 ; Velocity is 5 

GOBUF1 ; Store the first motion segment for axis 1. 

; Profile attributes are: MC0, A10, AD10, V5, D50000 



GOBUF1 ; Store the second motion segment for axis 1 




GOBUF1 ; Store the third motion segment for axis 1 


; Because this is the last segment in a preset profile, 

; the velocity will automatically end at zero. 

END 


PCOMP simple 

PRUN simple 

; Compile simple 

; Run simple 

The resulting profile from the above program: 

v 

5 

D50000 

4 

3 

STATUS COMMANDS: 

Use these commands to 

check the status of 

compiled profiles. 

2 

1 

D30000 

D40000 

0 

t 

System Status (TSSF, TSS, & SS): 

• Bit #29 is set if compiled memory is 75% full. 

• Bit #30 is set if compiled memory is 100% full. 

• Bit #31 is set if a compile (PCOMP) failed; this bit is cleared on power-up, reset, or after 

a successful compile. Possible causes include: 

- Errors in profile design (e.g., change direction while at non-zero velocity, distance 

& velocity equate to

Axis Status (TASF, TAS, & AS): Bit #31 is set while compiled a GOBUF profile is executing. 

TSEG & SEG: Reports the number of available segments in compiled memory. 

TDIR: Identifies programs that are “compiled as a path” (compiled with the PCOMP 

command) and reports the percentage of remaining compiled memory. 

Rules for Using 

Velocity in Preset 

Compiled Motion 

When defining preset mode (MC0) compiled profiles there are several rules that govern the 

velocity. 

Rule #1: The last segment in the compiled profile will automatically end at zero velocity (only 

if not in a PLOOP/PLN loop). 

DEF PROF5 ; Begin definition of profile #5 

MC0 

; Select preset positioning 

V1 

; Set velocity to 1 rev/sec 

D4000 ; Set distance to 4000 

GOBUF1 ; First motion segment (V1, D4000) 

V2 

; Set velocity to 2 (second segment) 

GOBUF1 ; Second motion segment (V2, D4000) 

END ; End definition of profile #5 

PCOMP ; Compile profile #5 

; When you execute PRUN PROF5, the resulting profile is: 

V 

2 

1 

0 

4000 

8000 

D 

Rule #2: If you wish intermediate segments to end in zero velocity, use the VF0 command in 

the respective GOBUF segment. 


MC0 


V1 


VF0 

; End this segment at zero velocity 


GOBUF1 ; First motion segment (V1, D4000, VF0) 

V2 

; Set velocity to 2 (second segment) 

VF0 

; End this segment at zero velocity 

GOBUF1 ; Second motion segment (V2, D4000, VF0) 




V 

2 

1 

0 

4000 

8000 

D 

Rule #3: CAUTION: With compiled loops (PLOOP and PLN), the last segment within the loop 

must end at zero velocity or there must be a final segment placed outside the loop. Otherwise, 

when the profile is compiled with PCOMP you’ll receive the “ERROR: MOTION ENDS IN 

NON-ZERO VELOCITY–AXIS n” error message and system status bit #31 will be set. after the 

final segment is completed, the motor will continue moving at the last segment’s velocity. 


MC0 



PLOOP4 ; Loop (between PLOOP & PLN) 4 times 

V1 


GOBUF1 ; First motion segment 

PLN1 ; End loop 



PCOMP 

; Compile profile #7, but instead of compile, you receive 

; an error message 

To fix the profile, reduce the PLOOP count by one and add a GOBUF statement after the PLN 



MC0 




V1 


GOBUF1 ; Looped motion segment 


GOBUF1 ; Last motion segment (end at zero velocity) 




V 

2 

1 

0 

3000 

6000 9000 12000 

D 

Rule #4: With compiled loops (PLOOP and PLN), if you wish the velocity at the end of each 

loop to end at zero, use a VF0 command. 


MC0 




V1 


VF0 

; End each segment at zero velocity 

GOBUF1 ; Looped motion segment 





V 

2 

1 

0 

3000 

6000 9000 12000 

D 

Compiled Following Profiles 

More details on 

Following are 

found in Chapter 6 

(page 168). 

The new FOLRNF command designates that the motor will move the load the distance 

designated in a preset GOBUF segment, completing the move at the specified final ratio. The 

only allowable value for FOLRNF is zero (0). FOLRNF is allowed for a segment only if the 

starting ratio is also zero, i.e., it must be the first segment, or the previous segment must have 

ended in zero ratio. FOLRNF is only useful with compiled preset Following moves because the 

starting and final ratios are already zero for motion initiated with GO. 

Compiled motion profiles may be constructed with any combination of preset or continuous 

motion segments. A continuous (MC1) Following segment will start with the final ratio of the 

previous segment, and end with the ratio given by FOLRN and FOLRD. The motion segment 

will consist of one ramp from the starting ratio to the final ratio. Just as with continuous 

Following ramps outside of a compiled profile, the master travel over which the ramp takes 

place is specified with FOLMD. The slave travel over which the ramp takes place is simply the 


product of master travel and average ratio. Because the slave travel is not specified explicitly, 

it is possible for arithmetic round-off errors to cause actual slave travel during a ramp to differ 

from theoretical calculations. For applications in which slave distance is important, preset 

segments should be used. 

A preset (MCØ) Following segment will also start with the final ratio of the previous segment, 

but may end in one of two ways. FOLRNF specifies the final ratio of a preset Following 

segment. The only valid value for FOLRNF is zero (0). If FOLRNFØ is given before the 

GOBUF, the resulting motion segment will be constructed exactly as preset Following moves 

are outside of compiled profiles. In this case, the starting ratio must be zero, the final ratio 

will be zero, and the maximum intermediate ratio will be given by FOLRN and FOLRD. The 

relationships between ratio, master distance, and slave distance for this case are given on page 

192 under the heading Master and Follower Distance Calculations. The FOLRNF command 

affects only the immediately subsequent preset Following segment, and must be given 

explicitly for each preset segment which is to end in zero ratio. 

If FOLRNFØ is not given before the GOBUF, the segment will end with the ratio given by 

FOLRN and FOLRD, and need not start with zero ratio. This type of motion segment is 

constrained, however, to intermediate ratios which fall between the starting and final ratios. 

Compiled profiles are built from motion segments created with the GOBUF command. That 

is, the motion segments may be all Following or all non-Following, but not a mixture of 

Following and non-Following. 

The GOBUF command builds the appropriate type of motion segment based on the values of 

FOLMAS and FOLEN during compilation. These parameters may not be changed inside a 

compiled program after a GOBUF. The choice of zero or non-zero FOLMAS must be the same 

during PRUN as during PCOMP (if non-zero, the value can be changed, but still must be nonzero). 

If a non-zero FOLMAS is given, the value of FOLEN must be the same during PRUN as 

during PCOMP. 

Distance 

Calculations For 

Compiled 

Following Moves 

The graph below shows 6 possibilities of ratio change profiles for preset segments, with legal 

FOLMD and “D” values constrained by the requirement that the average ratio (given by 

“D”/FOLMD) is between R1 and R2. If the distance is outside these ranges, in the profile used 

to get from R1 to R2 over FOLMD (covering “D” slave distance), an error message will be 

generated during the PCOMP command. For the graphs shown, the constraints are expressed by: 

(R1 * FOLMD) = “D” >= (R2 * FOLMD) if R2 < R1 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The two graphs above show the cases of R1R2, but the distance calculations of the 

ramp and constant ratio portions are the same for the two cases. For each graph, the heavy 

lined profile (first case) of these mimics the shape of the corresponding preset velocity change 


(FOLENØ) segments in that the ramp takes place before the constant ratio portion. The second 

case occurs only if the distance specified exactly matches the start and end ratios and 

FOLMD1. In the third case, the ramp takes place after the constant ratio portion. In the first 

and third cases, only two segments are built, and the slave and master distances traveled in 

each segment are easily calculated with the simple formulas shown below. These formulas 

are based on positive ratios and master and slave distances. In the construction of Following 

profiles, ratios and master distances are always positive, with direction implied by the sign of 

the slave distance. For calculations with negative slave distances, simply use the magnitude 

of “D” in the formulas below, and invert the sign of the resulting slave distances. 

Case 1 (Ramp first) MD1 = [D-(R2*FOLMD)]/((R1-R2)/2) where MD1 = master distance during ramp 

MD2 = FOLMD - MD1 

where MD2 = master distance during flat 

D1 = .5*(R1+R2)*MD1 

where D1 = slave distance during ramp 

D2 = D - D1 

where D2 = slave distance during flat 

Case 2 (Ramp only) MD1 = FOLMD where MD1 = master distance during ramp 

D1 = D 


Case 3 (Ramp last) MD1 = [D-(R1*FOLMD)]/((R2-R1)/2) where MD1 = master distance during ramp 

MD2 = FOLMD - MD1 

where MD2 = master distance during flat 

D1 = .5*(R1+R2)*MD1 


D2 = D - D1 

where D2 = slave distance during flat 

Dwells and Direction Changes 

Compiled profiles may incorporate changes in direction only if the preceding motion segment 

has come to rest. This may be achieved for non-Following segments either by creating a 

continuous segment with a goal velocity of zero, or by preceding a preset segment with VFØ. 

It may be achieved for Following segments either by creating a continuous or preset segment 

with a goal ratio of zero, or by preceding a preset segment with FOLRNFØ. In all cases, 

motion within the profile comes to rest, although the profile is not yet complete. Even though 

the motor is not moving, the axis status bit 1 (AS.1) will remain set, indicating a profile is 

still underway. Only then can you change direction (using the D+ or D- command, D~ is not 

allowed) within a profile. An attempt to incorporate changes in direction if the preceding 

motion segment has not come to rest will result in a compilation error. 

In many applications, it may be useful to create a time delay between moves. For example, a 

machine cycle may require a move out, dwell for 2 seconds, and move back. To create this 

dwell, a compiled GOWHEN may be used between the two moves. The code within a compiled 

program may look like: 

MC0 

; Preset incremental positioning used 

D(VAR1) ; Target position is in VAR1 

VF0 

; Motion comes to rest at end of move (or use FOLRNFØ) 

GOBUF1 

; Create move out segment 

GOWHEN(T=2000) ; Profile delays for 2 seconds 

D- ; Return position is home (direction reversed) 

VF0 

; Motion comes to rest at end of move (or use FOLRNFØ) 

GOBUF1 

; Create move back home segment 

In Following applications, it may be more useful to create a master travel delay between 

moves. For example, a machine cycle replacing a cam may require a move out, dwell for 

2000 master counts, and move back. To create this dwell, a compiled GOBUF of zero slave 

distance may be used between the two moves. The code within a compiled program may look 


like: 

MC0 

; Preset incremental positioning used 

D(VAR1) ; Target position is in VAR1 

FOLMD4000 ; Move takes place over 4000 master counts 

FOLRNF0 ; Motion comes to rest at end of move 

GOBUF1 

; Create move out segment 

D0 

; No change in target position 

FOLMD2000 ; Dwell takes place over 2000 master counts 

FOLRNF0 ; Motion comes to rest at end of “move” (dwell) 

GOBUF1 

; Create dwell segment 

D(VAR1) ; Return position is home (direction change implied) 

D- ; Return position is home (direction reversed) 

FOLMD4000 ; Move takes place over 4000 master counts 

FOLRNF0 ; Motion comes to rest at end of move 

GOBUF1 

; Create move back home segment 

Compiled Motion Versus On-The-Fly Motion 

The two basic ways of creating a complex profile are with compiled motion or with on-the-fly 

pre-emptive GO commands. With compiled motion, portions of a profile are built piece by 

piece, and stored for later execution. Compiled motion is appropriate for profiles with motion 

segments of pre-determined velocity, acceleration and distance. Compiled motion profiles 

allow for shorter motion segments, which results in faster cycle times because there is no 

command processing and execution delay. The axes may perform their own motion control 

and coordination, freeing program flow for other tasks, such as I/O, machine control, and host 

requests. The disadvantages to pre-defined compiled motion profiles are the amount of 

memory use and limited run-time decision making and I/O processing. 

With pre-emptive GO moves, the motion profile underway is pre-empted with a new profile 

when a new GO command is issued. The new GO command constructs and launches the preempting 

profile. Pre-emptive GOs are appropriate when the desired motion parameters are not 

known until motion is already underway. 

The table below summarizes the differences between the use of compiled motion and on-thefly 

motion. 

Command/Issue Compiled Motion On-The-Fly Motion 

GOBUF 

Constructs motion segment and appends to N/A 

previously constructed segment 

PRUN Used to launch previously compiled motion N/A 

GO GO causes move during PCOMP GO Constructs & launches profile, 

even if moving 

Direction changes 

Insufficient room for 

AD (decel) value 

Only if previous motion segment comes to rest 

(MCØ & VFØ or MC1 & VØ), else compile error 

Same as on-the-fly 

Not allowed during motion, else 

AS.3Ø, ER.1Ø 

Decel is modified (steppers); 

Motion is killed, AS.3Ø (servos) 


Related Commands 

GOBUF 

Store a Motion Segment in Compiled Memory: 

The GOBUF command creates a motion segment as part of a profile and places it in a segment 

of compiled memory, to be executed after all previous GOBUF motion segments have been 

executed. An individual axis profile is constructed by sequentially appending motion segments 

using GOBUF commands. Each motion segment may have its own distance to travel, velocity, 

acceleration, and deceleration. 

The end of a GOBUF motion segment in preset mode is determined by the distance or position 

specified. The end of a GOBUF motion segment in continuous mode is determined by the goal 

velocity specified. In both cases, the final velocity and position achieved by a segment will be 

the starting velocity and position for the next segment. If either type of segment is followed by 

a GOWHEN command, the segment’s final velocity will be maintained until the GOWHEN 

condition becomes true. 

PLOOP & PLN 

Loop Start & Loop End (Compiled Motion only): 

The PLOOP and PLN commands specify the beginning and end of an axis-specific profile loop, 

respectively. All segments defined between the PLOOP and PLN commands are included 

within that loop. 

VF & FOLRNF 

GOWHEN 

Final Velocity & Numerator of Slave-to-Master Final Ratio: 

The VF and FOLRNF commands are used to designate that the motor will move the load the 

distance designated in a preset GOBUF motion segment, completing the move at a final speed 

of zero. The VF command is used when the Following mode is disabled (FOLENØ). The 

FOLRNF command is used when the Following mode is enabled (FOLEN1). 

Conditional GO: 

When GOWHEN is compiled in a profile, the GOWHEN condition is stored as part of that profile 

instead of being executed immediately. When progress through the profile reaches the 

compiled GOWHEN, AS.26 is set, and the next segment’s execution will be suspended until the 

GOWHEN condition becomes true. This allows subsequent GOWHEN and GOBUF combinations 

to be issued and stored, instead of overriding each other. 

TRGFN 

Trigger Functions: 

When TRGFN is compiled in a profile, the TRGFN condition is stored as part of that profile 

instead of being executed immediately. When progress through the profile reaches the 

compiled TRGFN, the embedded trigger functions are assigned to that trigger. AS.26 is set if 

the GOWHEN function has been assigned to the trigger, and the next segment’s execution will 

be suspended until the specified trigger input goes active. This allows subsequent TRGFN, 

GOWHEN, and GOBUF combinations to be issued and stored, instead of overriding each other. 

PCOMP, PRUN 

& PUCOMP 

Compile a Program, Run a Compiled Program, & Un-Compile a Compiled Program: 

The PCOMP, PRUN, and PUCOMP commands allow you to incorporate individual axis profiles 

within compiled motion profiles. Compiled motion for the Gem6K series allows you to 

construct complex motion programs using individual profiles (a series of GOBUF commands). 

PEXE 

Execute Compiled GOBUF Profile from PLC Program: 

You can place a PEXE command inside a compiled PLCP program. When the PLCP program 

is scanned in the PLC Scan Mode (SCANP), the PEXE command launches the specified 

compiled profile in another task. For details on the PLC Scan Mode, see page 120. 


POUTA 

Output During Compiled Motion Profile: 

The POUTA command turns the programmable output bits on and off. 

TSEG & SEG 

Transfer/Display (TSEG) or Assign (SEG) the Number of Free Segment Buffers: 

The TSEG command returns the number of free segment buffers in compiled memory. The 

SEG command is used to assign the number of free segment buffers in compiled memory to a 

variable or to make a comparison against another value. 

Compiled Motion — Sample Application 1 

Profile 

A manufacturer has an application where wire is being wrapped onto a spindle. There is a 

motor controlling the rotational speed of the spindle. Every application of the spindle requires 

that the motor runs at a fast speed with a slow acceleration for the first few revolutions, a 

medium speed for the next couple of revolutions, and a slower speed as the spindle gets fuller 

to maintain somewhat of a constant velocity off the feed wire. The technician would like to 

use an RP240 to enter the velocity and number of revolutions for each stage of winding. 

Programmable outputs 1, 2 and 3 are wired to status LEDs, and should go on for the 

respective stages of winding (output 1 for stage 1, etc.). 

 

 

 

 

 

 

 

Program DEF PROFIL ; Define motion profile program 

VAR10 = 4000 * VAR4 ; Get distance of first stage 

; (assuming 4000 steps/revolution) 

D(VAR10) 


V(VAR1) 

; Set velocity of first stage 

POUTA.1-1 

; Turn output 1 on 

GOBUF1 

; Build motion 

VAR10 = 4000 * VAR5 ; Get distance of second stage 

D(VAR10) 


V(VAR2) 

; Set velocity of second stage 

POUTA01 

; Turn output 1 off and output 2 on 

GOBUF1 


VAR10 = 4000 * VAR6 ; Get distance of third stage 

D(VAR10) 


V(VAR3) 

; Set velocity of third stage 

POUTAx01 

; Turn output 2 off and output 3 on 

GOBUF1 


POUTA.3-0 ; Turn off output 3 

END 

; End motion profile program 

 

DEF EXMPL1 ; Define program example 1 

L 

; Continual loop of program execution 

DCLEAR0 

; Clear all lines on RP240 display 

DPCUR1,1 ; Position cursor at line 1, column 1 

DWRITE"ENTER VELOCITY STAGE 1" ; Prompt user 

VAR1 = DREAD 

; Get 1st velocity from RP240 entry 

DCLEAR1 

; Clear line 1 on RP240 display 



VAR2 = DREAD 

; Get 2nd velocity from RP240 entry 

DCLEAR1 




VAR3 = DREAD 

; Get 3rd velocity from RP240 entry 

DCLEAR1 



DWRITE"ENTER REVOLUTIONS STAGE 1" ; Prompt user 


VAR4 = DREAD 

; Get # of windings 1st stage from RP240 entry 

DCLEAR1 



DWRITE"ENTER REVOLUTIONS STAGE 2" ; Prompt user 

VAR5 = DREAD 

; Get # of windings 2nd stage from RP240 entry 

DCLEAR1 



DWRITE”ENTER REVOLUTIONS STAGE 3" ; Prompt user 

VAR6 = DREAD 

; Get # of windings 3rd stage from RP240 entry 

PCOMP PROFIL 

; Re-compile profile with new vel/dist info 

$AGAIN 

; Label for repeating same profile 

PRUN PROFIL 

; Execute profile 

DCLEAR1 



DWRITE"SAME DATA (1=YES,2=NO)" 

; Prompt user if perform again with old data 

VAR7 = DREAD 

; Get response 

IF(VAR7=1) 

; If user wants to perform same profile 

GOTO AGAIN 

; perform again 

NIF 

; End conditional 

LN 

; End command execution loop 

END ; End definition program example 1 

; ****************************************** 

; * To begin, execute the EXMPL1 program * 

; ****************************************** 


Here’s an example of replacing a mechanical cam using a compiled Following profile. There 

is evenly spaced product coming in on a feeder belt. The feeder belt may vary in speed. The 

cam that you are replacing controls a push arm that will push the product into a box for 

shipping. You would also like the arm to retract at a faster rate than it extends. In other 

words, you would like to have a smooth push to load and a fast retract to set up for the next 

product. Since this is a cam, this profile must repeat continuously for each product or master 

cycle but won’t start until the first product is detected. 

 

 

 

 

 

The feeder belt is the master and the master cycle length (space from the front of one product 

to the front of the next) is 12000 master (encoder) counts on the feeder belt. The push of the 

product will start 2000 counts into the master cycle. The push will take place over Gem6K 

master counts, and the retract over 2000 master counts. The distance the push arm (slave) 

must travel is 4000 counts. Assume the detector is wired to trigger 1A (onboard trigger input 

1). Below is a graph of this Following profile. 


Profile 

 

 

 

Program 

 

 

; Setup code 

FOLMAS1 

FOLEN1 

INFNC1-H 

 

 

 

 

 

; Master is coming in on the master encoder input 

; Enable Following 

; Assign onboard input 1 (TRG-1A) as trigger interrupt 

; Motion program 

DEL EXPL2 

; Delete program (in case it already exists in memory) 

DEF EXPL2 ; Begin definition of program example 2 

1TRGFNA1 

; Launch axis 1 profile upon receiving TRG-1A 

; (1st product detected) 

PLOOP0 

; Loop continuously to mimic a mechanical cam 

; Program first move - dwell 

FOLRN1 

; Set up ratios - numerator 

FOLRD1 

; and denominator 

FOLMD2000 

; Over a distance of 2000 master steps 

D0 

; slave will not move 

FOLRNF0 

; and end at zero ratio 

GOBUF1 


; Program second move - positive slave move 

FOLMD6000 


D4000 

; slave will move 4000 steps 

FOLRNF0 


GOBUF1 


; Program third move - negative slave move 

FOLRN3 

; New ratio to accommodate larger distance of slave travel 

FOLMD2000 


D-4000 ; slave will move -4000 steps 

FOLRNF0 


GOBUF1 


; Program last move - dwell 

FOLMD2000 


D0 


FOLRNF0 


GOBUF1 


PLN1 

; Close cam loop 

END ; End program example 2 

PCOMP EXPL2 ; Compile program EXPL2 

; ** To execute the program, enter the PRUN EXPL2 command ** 


Program 

Modification 

Let’s now modify the constraints of the system. Let’s say that the product will be spaced roughly 12000 

master counts apart. It may or may not be exactly 12000, but it will never be less than 10000 (just to 

make sure the retraction finishes before the next product is detected). We can then modify the program to 

wait for the product to be detected each cycle. We can also take the extra “dwell” or zero distance move 

out of the end of the profile. See program below: 

; Setup code 

FOLMAS1 

; Master is coming in on the master encoder 

FOLEN1 

; Enable Following mode 

INFNC1-H 

; Assign onboard input 1 (TRG-1A) as trigger interrupt 

; Motion program 

DEL EXPL2B 

DEF EXPL2B 

PLOOP0 

1TRGFNA1 

; Delete program (in case it already exists in memory) 

; Begin definition of program example 2b 

; Loop continuously to mimic a mechanical cam 

; Pause axis 1 profile until TRG-1A is activated 

; (detect next product) 

; Program first move - dwell 

FOLRN1 

; Set up ratios - numerator 

FOLRD1 

; and denominator 

FOLMD2000 


D0 


FOLRNF0 


GOBUF1 


; Program second move - positive slave move 

FOLMD6000 


D4000 

; slave will move 4000 steps 

FOLRNF0 


GOBUF1 


; Program third move - negative slave move 

FOLRN3 

; New ratio to accommodate larger distance of slave travel 

FOLMD2000 


D-4000 ; slave will move -4000 steps 

FOLRNF0 


GOBUF1 


PLN1 

; Close cam loop 

END 

; End program example 2b 

PCOMP EXPL2B 

; Compile program EXPL2B 

; ********************************************************** 

; * To execute the program, enter the PRUN EXPL2B command * 

; ********************************************************** 



In this application, there is a wheel that stamps a logo onto the product. The product is 

assumed to be entering at a constant and fixed spacing, each product is 4 inches in length with 

2 inches separating each unit. The stamp wheel has a circumference of 9 inches, and must be 

traveling at a 1 to 1 ratio with the product at the time of stamping. The stamp wheel must then 

travel five inches in just 2 inches of master travel. There is a sensor wired to trigger A of the 

Gem6K controller to detect the first product and start the cycling. At the time of the trigger 

the product is 1 inch away from contact with the stamp wheel. Assume that the home position 

of the slave is 0.5 inches away from a stamp. The mechanics of the system give 3000 steps of 

master travel per inch and 1500 steps of slave travel per inch. 

Profile 

 

 

 

 

 

 

 

 

 

 

 

 

As you can see above, we have a multi-tiered Following profile. By multi-tiered we mean 

that ratio is changing from a non-zero value to another non-zero value. To program this 

profile effectively, we will break the profile into pieces as shown with the dotted lines in the 

above illustration: 

Program FOLMAS1 ; Define the master as the master encoder input 

FOLEN1 


INFNC1-H ; Assign onboard input 1 (TRG-1A) as trigger interrupt 

SCLMAS3000 ; Set scaling of master steps per inch 

SCLD1500 ; Set scaling of slave steps per inch 

SCALE1 


DEF EXMPL3 ; Start definition of example program 3 

1TRGFNA1 ; Launch axis 1 profile when TRG-1A is activated 

; Program first ramp from ratio 0 to ratio 1 

FOLRD1 

; Set Following ratio - denominator 

FOLRN1 ; Set the Following ratio at 1 to 1 

FOLMD1 ; Over a master distance of 1" 

D0.5 ; Slave will travel 0.5" 

GOBUF1 


PLOOP0 

; Start the continuous loop 

; Program constant ratio 

FOLRN1 

; At a 1 to 1 ratio 


D4 ; Slave will travel 4" 

GOBUF1 


; Program ramp to new ratio 

FOLRN3 

; Go to a 3 to 1 ratio 

FOLMD0.5 ; Over a master distance of 0.5" 


GOBUF1 



; Program second constant ratio 

FOLRN3 

; At a 3 to 1 ratio 



GOBUF1 


; Program ramp to lower ratio 

FOLRN1 

; Go to a 1 to 1 ratio 

FOLMD0.5 ; Over a master distance of 0.5" 


GOBUF1 


PLN1 

; Close motion loop 

; Define the exit motion 

FOLRN0 

; Stop slave at zero ratio (and zero velocity) 


D0.5 ; And a slave distance of 0.5" 

GOBUF1 


END ; End definition of example program 3 

PCOMP EXMPL3 ; Compile example program 3 

; ********************************************************** 

; * To execute the program, enter the PRUN EXMPL3 command * 

; ********************************************************** 

NOTE: The GOBUF command has been added to the “Define the exit motion” portion 

of the program despite the fact that an infinite loop has been programmed earlier in the 

program. This is to avoid an error message when the program is compiled. 


A manufacturer of stamped molds needs to make a machine which will stamp molds into a 

continuous flow of extruded plastic material. The stamp must be lowered 0.5 inches into the 

plastic to leave the correct impression. Because the flow is continuous, the stamp must also 

move in synchronization with plastic in the direction of flow as it is lowered and raised. The 

initial design approach to the machine required two axes of motion. One was needed to lower 

and raise the stamp, the other to allow the stamp to follow the plastic. With the availability of 

complex Following cam profiles the job can done with a single axis. 

In the drawing below, the stamp is attached to a rotating arm in such a way that the stamp 

remains level as the arm rotates. The length of the arm at the stamp fixture, or radius of 

rotation, is exactly one inch. The arm is mounted above the plastic so that at the bottom of its 

rotation (270 degrees), the stamp will be 0.5 inches into the plastic. Using trigonometry, the 

horizontal and vertical positions and speeds may be calculated at other arm angles. Because 

the stamp must follow the flow of the plastic, we must adjust the ratio of rotational speed to 

plastic speed so that the horizontal velocity component of the arm stays at 1:1 with the plastic 

while the stamp is in the plastic. 

 

 

 

 

 


The table below shows these relationships. The arm is directly driven with a servo motor 

having 4096 steps per revolution. The table shows increments of 30 degrees, which is about 

341 servo motor steps, or about 0.524 slave inches measured around the circumference 

described by rotation of the arm. The plastic flow is measured with an encoder giving 1000 

steps per inch of flow. To maintain ratios in terms of inches, FOLRD will always be 1000. The 

required FOLRN value is simply the inverse of the arm’s horizontal velocity component 

multiplied by the number of slave steps per inch. The corresponding ratio in terms of surface 

speeds is given in parentheses. The required FOLMD is the number of master steps 

corresponding to the horizontal component of slave rotation. 

Arm angle, 

degrees 

Horizontal 

component 

(in.) = cos(deg) 

FOLMD = 

1000 * delta cos(deg) 

Horizontal vel 

component = -sin(deg) 

Required FOLRN = 

-651.9/sin(deg) 

210 -0.866 n/a 0.500 1304 (2:1) 

240 -0.500 366 0.866 753 (1.155:1) 

270 0.000 500 1.000 652 (1:1) 

300 0.500 500 0.866 753 (1.155:1) 

330 0.866 366 0.500 1304 (2:1) 

The profile that we construct from these number is meant to approximate the inverse sine 

function in the last column, but of course, will actually be a series of ramps and constant ratio 

segments. Let’s review the Compiled Following Move Distance Calculations to determines 

the exact shape and error in the first motion segment( from 210 to 240 degrees). First, we need 

to determine if the ramp or constant ratio is first for that segment. Using ratios and distances 

in inches, we have: 

R1 = 2......................................... Starting ratio 

R2 = 1.155.................................. Final ratio 

D = (2*pi)/12 = 0.524 .................. Distance at stamp hinge 

FOLMD=.366.............................. Travel along plastic 

We find (R1+R2) * FOLMD/2 = 0.577, which is greater than D, so the “Ramp First” 

equations apply to this segment. Let’s examine the error at the junction between the ramp and 

constant ratio portion of this segment. 

MD1 = [D - (R2 * FOLMD)] / ( (R1 - R2) / 2) = 0.239 master inches 

D1 = 0.5 * (R1 + R2) * MD1 = 0.377 slave inches at circumference = 21.6 degrees 

cos(210+21.6) - cos(210) = -0.621 - (-0.866) = 0.245 inches slave horizontal travel 

error = horizontal slave travel - master travel = 0.245 - 0.239 = 0.006 inches 

A similar calculation may be done for the “elbow” of the next of the next segment, and 

symmetry indicates these errors will be the same between 270 and 330 degrees. The error 

along intermediate points may be found with linear interpolation of ratio and master distance. 

In this case, the errors fall within manufacturing tolerance. If the errors were too large, the 

travel could be broken into more segments, each with exactly correct positions and ratios at 

their boundaries. 

So far, we have only discussed the portion of the profile which lowers and raises the stamp. 

During the remainder of the profile, the arm must continue its rotation to bring the stamp to its 

starting position in time for the next mold. The mold is 3 inches long, and .4 inches are needed 

between molds for strength at the edges. This makes the total master cycle 3.4 inches long. 

The total slave cycle must be 4096 steps, so the segments required to bring the arm around 

must complete the portions of master and slave cycles not already accounted for. We will 

create two segments, which divide the remaining master and slave travels in two, and are 

mirror images of each other. The average ratio of these two segments must simply be slave 

travel divided by master travel, i.e., (D / FOLMD). As previously determined, the FOLRN 

value for the boundaries of the stamping portion of the profile is 638. From this value and the 

average ratio, we can calculate the peak FOLRN value. 

D = 0.5 * remaining slave = 0.5 * (4096 - 4 * 341) = 1366 

FOLMD = 0.5 * remaining master = 0.5 * [1000 * (3.4 - 2 * 0.866)] = 834 

peak ratio = FOLRN/1000 

0.5 * (FOLRN/1000 + 1304/1000) = average ratio = D / FOLMD = 1366 / 834 = 1.638 

FOLRN = 1972 (solved from above) 


Finally, we need to design a segment used to create a smooth entry into the repetitive portion 

of the profile. We’ll assume that the home position of the arm is at 180 degrees, so it needs to 

achieve the FOLRN ratio of 1304 in 30 degrees (341 slave steps). Using the same averaging 

arithmetic as above, the required master distance for the entry segment is 523 steps. A sensor 

is positioned with this entry segment in mind, and wired to TRG-1A. A function to start motion 

when the sensor is triggered will be imbedded inside the profile. The motion segments for the 

stamping portion and recovery portions of the profile must be enclosed in a loop, and may be 

programmed by picking the numbers from the table and equations above. Because the ratio 

denominators are the same for all segments, and the slave distances are the same for the entry 

and each of the stamping segments, these are commanded only when the values change. 

Repetitive Portion of 

Profile 

 

 

 

 

 

 

 

 

 

 

 

Program FOLMAS1 ; Follow master encoder 

FOLEN1 


INFNC1-H ; Enable trigger 1 (TRG-1A) for interrupt function 

SCALE0 

; Parameters are in steps 

DEF STAMP ; Start program definition 

TRGFNA1 

; Motion profile starts upon trigger 1 (TRG-1A) 

FOLRD1000 ; Ratio denominator, 1ØØØ steps per inch 

;define the entry segment 

D341 

; Distance of 341 steps is about 3Ø degrees 

FOLRN13Ø4 ; Goal ratio for start segment 

FOLMD523 ; Master distance during ramp 

GOBUF1 

; Build start segment 

PLOOP0 

; Start the continuous loop 

;this profile section starts 2-to-1 ratio, or a starting FOLRN13Ø4 

FOLRN753 ; Goal ratio for segment 

FOLMD366 ; Master travel in steps for segment 

GOBUF1 

; Build motion segment 

;the 2nd section of profile starts with the final ratio of the 1st section 

FOLRN652 ; Goal ratio for segment 

FOLMD500 ; Master travel in steps for segment 

GOBUF1 


;the next two sections are mirror images of the first two 

FOLRN753 ; Goal ratio for third segment 

FOLMD500 ; Master travel in steps for 3rd segment 

GOBUF1 


FOLRN1304 ; Goal ratio for 4th segment 

FOLMD366 ; Master travel in steps for 4th segment 

GOBUF1 


;the next two sections complete the loop and are mirror images of each other 

D1366 

; Slave travel in recovery segments 

FOLMD834 ; Master travel in steps for recovery segments 

FOLRN1972 ; Goal ratio for ramp up segment 

GOBUF1 

; Build ramp up motion segment 

FOLRN523 ; Goal ratio for ramp down segment 

GOBUF1 

; Build ramp down motion segment 

PLN1 

; End of loop cycle 

;finally, a segment to end motion 

D341 

; Distance of 341 steps is about 3Ø degrees 

FOLRN0 

; Goal ratio for end segment 

FOLMD1000 ; Master distance during ramp 

GOBUF1 

; Build end segment 

END 

; End of STAMP program definition 

PCOMP STAMP ; Compile the program 

; ********************************************************** 

; * To execute the program, enter the PRUN STAMP command * 

; ********************************************************** 


On-the-Fly Motion (pre-emptive GOs) 

While motion is in progress, you can change these motion parameters to affect a new profile: 

• Acceleration (A) — s-curve acceleration is not allowed 

• Deceleration (AD) — s-curve deceleration is not allowed 

• Velocity (V) 

• Distance (D) 

• Preset or Continuous Positioning Mode Selection (MC) 

• Incremental or Absolute Positioning Mode Selection (MA) 

• Following Ratio Numerator and Denominator (FOLRN and FOLRD, respectively) 

The motion parameters can be changed by sending the respective command (e.g., A, V, D, MC) 

followed by the GO command. If the continuous command execution mode is enabled 

(COMEXC1), you can execute buffered commands; otherwise (COMEXCØ), you must prefix each 

command with an immediate command identifier (e.g., !A, !V, !D, !MC, followed by !GO). 

The new GO command pre-empts the motion profile in progress with a new profile based on 

the new motion parameter(s). On-the-fly motion changes are applicable only for motion 

started with the GO command, and not for motion started with other commands such as HOM, 

JOG, JOY, or PRUN. 

On-the-fly motion changes are most likely to be used to change the velocity and/or goal 

position of a preset move already underway. In the event that the goal position is completely 

unknown before motion starts, a move may be started in continuous mode (MC1), with a switch 

to preset mode (MCØ), a distance command (D), and a GO given later. In absolute positioning 

mode (MA1) the new goal position given with a pre-emptive GO is explicit in the D command. 

In incremental positioning (MAØ) the distance given with a new pre-emptive GO is always 

measured from the at-rest position before the original GO. If a move is stopped (with the S 

command), and then resumed (with the C command), this resumed motion is considered to be 

part of the original GO. A subsequent distance given with a new pre-emptive GO is measured 

from the at rest position before the original GO, not the intermediate stopped position. 

Programming Example: 

This program creates a 2-tiered profile (single-axis) that changes velocity 

and deceleration at specific motor positions. 

SCALE0 

; Disable scaling 

DEL OTF 

; Delete program (in case program is already in memory) 

DEF OTF 

; Begin definition of program 

PSET0 

; Set position to zero 

COMEXC1 

; Enable continuous command processing mode 

MC0 


MA0 

; Select incremental positioning 

A20 

; Set accel to 20 revs/sec/sec 

AD20 

; Set decel to 20 revs/sec/sec 

V9 

; Set velocity to 9 revs/sec 

D500000 

; Set distance to 20 revs 

GO1 


WAIT(PC>100000) ; Wait until commanded position > 100000 steps (4 revs) 

V4 

; Slow down for machine operation 

GO1 

; Initiate new profile with new velocity 

WAIT(PC>450000) ; Wait until the motor position > 450000 steps (18 revs) 

AD5 

; Set decel for gentle stop 

V1 

; Slow down for gentle stop 

GO1 

; Initiate new profile with new velocity 

END 



The table below summarizes the restrictions on pre-emptive GOs. 

Condition 

Execute GO during MC1 & FOLENØ 

Execute GO during MC1 & FOLEN1 

Execute GO during MCØ & FOLENØ 

Execute GO during MCØ & FOLEN1 

Change MC setting during motion 

Change ENC setting during motion 

Change FOLENØ to FOLEN1 during motion 

Change FOLEN1 to FOLENØ during motion 

Possible 

Yes 

Yes 

Yes 

No 

Yes (but cannot change MC1 to MCØ during FOLEN1) 

No 

No 

Only while MC1, constant ratio, and not shifting 

OTF Error Conditions 

The ability to change the goal position on the fly raises the possibility of several error 

conditions: 

Further instructions 

about handling error 

conditions are provided 

on page 30. 

Error Conditions 

The new position goal of an on-the-fly 

GO cannot be reached with the 

current direction, velocity, and decel. 

Set axis status 

bit #30 

Gem6K Response 

Set error 

status bit #10 

Kill motion (decelerate 

at the LHAD value) 

YES YES NO 

The direction of the new goal position 

is opposite that of current travel YES YES YES 

There has not yet been an overshoot, 

but it is not possible to decelerate to YES YES YES 

the new distance from the current 

velocity using the specified AD value. 

RELATED STATUS COMMANDS 

Axis Status — Bit #30: (this status bit is cleared with the next GO command) 

AS.30 ....Assignment & comparison operator — use in a conditional expression (see pg. 25). 

TASF ......Full text description of each status bit. (see “Preset Move Overshot” line item) 

TAS ........Binary report of each status bit (bits 1-32 from left to right). See bit #30. 

Error Status — Bit #10: The error status is monitored and reported only if you enable errorchecking 

bit #10 with the ERROR command (e.g., ERROR.1Ø-1). NOTE: When the error occurs, the 

controller with branch to the error program (assigned with the ERRORP command). (this status bit is 

cleared with the next GO command) 

ER.10 ....Assignment & comparison operator — use in a conditional expression (see pg. 25). 

TERF ......Full text description of each status bit. (see “Preset Move Overshot” line item) 

TER ........Binary report of each status bit (bits 1-32 from left to right). See bit #10. 

Scenarios 

Scenario #1: OTF change of velocity and 

distance, where new commanded distance (D 2 ) is 

greater than the original distance (D 1 ) that was 

pre-empted [D 2 >D 1 ]. The distances are the areas 

under the profiles, starting at t 0 for both. If the 

original move had continued, D 1 would have been 

reached at time t 1 . D 2 is reached at time t 2 . 

 

 

 

 

 

 


Scenario #2: OTF change of distance, where 

new commanded distance (D 2 ) is less than the 

original distance (D 1 ) that was pre-empted [D 2 < 

D 1 ]. In this example, the position where the OTF 

change was entered is already beyond D 2 (or D 2 

can not be reached with the commanded 

deceleration). The result is an error and motion is 

killed (decel at the LHAD value) and TAS bit #30 

and TER bit #10 are set. 

 

 

 

 

 

 

Scenario #3: OTF change of velocity. Note that 

motion must continue for a longer time at the 

reduced velocity to reach the original 

commanded distance than if it had continued at 

the original velocity (t 2 > t 1 ). 

 

 

 

 

 

 

On-The-Fly Motion — Sample Application 

A manufacturer of three products wishes to produce a “sampler-pak” package which will 

contain a few of each of his products. The products all have the same width and length, but 

are 3, 4, and 5 inches high respectively. The 3 products are fed from individual lines into a 

common conveyor, and arrive at a stacking and wrapping station. At this station, a tray 

accepts a product and must have moved down by that product’s height by the time the next 

product arrives. This means that each time a new product arrives, the velocity of the tray must 

be changed to match the height of that product. Although product spacing will be regular, the 

ordering of product type on the common conveyor will be random, due to variations in the 

input lines. Also, a finished sampler-pak should contain 5 products or be at least 18 inches 

high, whichever occurs first. This means that the total move distance of the tray will be 

unknown until the last product arrives. When the last product is stacked, an output is asserted 

which will pause the conveyor and start the wrapping process. When wrapping is complete, 

the sampler-pak is removed from the tray, and the tray returns to the starting position. 

The basic problems in this application are that the move distance is not known until near the 

end, and the velocity must change on the fly. As the products approach the tray, they are 

detected with a near vertical arrangement of three sensors. Products of heights 3, 4, and 5 

inches are detected by 1, 2, or all 3 sensors respectively. Input 1 always detects a product, and 

switches last, so that the others will be stable. When each product is identified, the motion 

profile is modified accordingly. 


Program 

(portion only) 

VAR1=0 

; Initialize product count 

VAR2=0 

; Initialize move distance variable 

VAR3=0 

; Initialize velocity 

A10 

; Moderate acceleration 

MC0 

; Start with preset move 

WHILE(VAR1

Registration 

A “registration input” is 

a trigger input assigned 

the “trigger interrupt” 

function with the 

INFNCi-H command. 

When a registration input is activated, the motion profile currently being executed is replaced 

by the registration profile with its own distance (REG), acceleration (A & AA), deceleration (AD 

& ADA), and velocity (V) values. The registration move may interrupt any preset, continuous, 

or registration move in progress. 

The registration move does not alter the rest of the program being executed when registration 

occurs, nor does it affect commands being executed in the background if the controller is 

operating in the continuous command execution mode (COMEXC1). 

Registration moves will not be executed while the motor is not performing a move, while in 

the joystick mode (JOY1), or while decelerating due to a stop, kill, soft limit, or hard limit. 

How to Set up a Registration Move 

☞ 

ENCCNT: Encoder 

capture options for 

stepper axes are 

discussed on page 85. 

Before you can initiate a registration move, you must program these elements (refer also to the 

programming examples below): 

1. Configure one of the trigger inputs (TRG-nA [#1] or TRG-nB [#2]) to function as a 

trigger interrupt input; this is done with the INFNCi-H command, where “i” is the 

input bit number representing the targeted trigger input. Note that the “Master Trigger” 

input may not be used for registration. 

2. Specify the distance of the registration move with the REG command. For servo axes, 

the distance refers to the encoder position. For stepper axes, the distance refers to 

commanded position if ENCCNT0 (default setting) or encoder position if ENCCNT1. 

3. Enable the registration function with the RE command. Registration is performed only 

when the registration function is enabled, and with a non-zero distance specified in the 

respective axis-designation field of the REG command. 

NOTE: The registration move is executed using the A, AA, AD, ADA, and V values that 

were in effect when the REG command was entered. 

Registration Move Accuracy (see also Registration Move Status below) 

The accuracy of the registration move distance specified with the REG command is ±1 count 

(servo axes: encoder count; stepper axes: commanded count if ENCCNT0 or encoder count if 

ENCCNT1). 

RULE OF THUMB: To prevent position overshoot, make sure the REG distance is greater 

than 4 ms multiplied by the incoming velocity. 

The lapse between activating the registration input and commencing the registration move 

(this does not affect the move accuracy) is less than one position sample period (2 ms). 

The REG distance will be scaled by the distance scale factor (SCLD value) if scaling is 

enabled (SCALE1). See page 67 for details on scaling. 


Preventing Unwanted Registration Moves (methods) 

• Registration Input Debounce: Registration Input Debounce: By default, the registration 

inputs are debounced for 2 ms before another input on the same trigger is recognized. 

(The debounce time is the time required between a trigger's initial active transition and 

its secondary active transition.) Therefore, the maximum rate that a registration input 

can initiate registration moves is 500 times per second. If your application requires a 

shorter debounce time, you can change it with the TRGLOT command. 

• Registration Single-Shot: The REGSS command allows you to program the Gem6K 

controller to ignore any registration commands after the first registration move has 

been initiated. Refer to the REGSS command description for further details and an 

application example. 

• Registration Lockout Distance: The REGLOD command specifies what distance an axis 

must travel before any trigger assigned as a registration input will be recognized. Refer 

to the Sample Application 3 below. 

Registration Move Status & Error Handling 

Axis Status — Bit #28: This status bit is set when a registration move has been initiated by 

any registration input (trigger). This status bit is cleared with the next GO command. 

AS.28 .......Assignment & comparison operator — use in a conditional expression (see pg. 26). 

TASF..........Full text description of each status bit. (see “Reg Move Commanded” line item) 

TAS............Binary report of each status bit (bits 1-32 from left to right). See bit #28. 

Axis Status — Bit #30: If, when the registration input is activated, the registration move 

profile cannot be performed with the specified motion parameters, the Gem6K controller will 

kill the move in progress and set axis status bit #30. This status bit is cleared with the next GO 


AS.3Ø .......Assignment & comparison operator — use in a conditional expression (see pg. 26). 

TASF..........Full text description of each status bit. (see “Preset Move Overshot” line item) 




conditions are provided 

on page 30. 

Error Status — Bit #10: This status bit may be set if axis status bit #30 is set. The error 

status is monitored and reported only if you enable error-checking bit #10 with the ERROR 

command (e.g., ERROR.1Ø-1). NOTE: When the error occurs, the controller will branch to 

the error program (assigned with the ERRORP command). This status bit is cleared with the 

next GO command. 

ER.1Ø .......Assignment & comparison operator — use in a conditional expression (see pg. 26). 

TERF..........Full text description of each status bit. (see “Preset Move Overshot” line item) 

TER............Binary report of each status bit (bits 1-32 from left to right). See bit #10. 

Trigger Status — Bits #1-17: Trigger status bits are set when a registration move has been 

initiated by trigger inputs A or B, or with the TRIG-M (master trigger) input. This also 

indicates that the position has been captured. As soon as the captured information is 

transferred or assigned/compared (see page 99), the respective trigger status bit is cleared (set 

to Ø). 

TRIG..........Assignment & comparison operator — use in a conditional expression.(see pg. 26). 

TTRIG .......Binary report of each status bit (bits 1-17 from left to right). From left to right the bits 

represent trigger A and B, the 17 th bit is master trigger M (the “MASTER TRIG” input 

terminal) — see page 91. 


Registration — Sample Application 1 

In this example, two-tiered registration is achieved (see illustration below). While the motor 

is executing it’s 50,000-unit move, trigger input 1 (TRG-1A) is activated and executes 

registration move A to slow the load’s movement. An open container of volatile liquid is then 

placed on the conveyor belts. After picking up the liquid and while registration move A is 

still in progress, trigger input 2 (TRG-1B) is activated and executes registration move B to 

slow the load to gentle stop. 

DEL REGI1 ; Delete program (in case program already resides in memory) 

DEF REGI1 ; Begin program definition 

INFNC1-H ; Define trigger input 1 (TRG-1A) as trigger interrupt input 

INFNC2-H ; Define trigger input 2 (TRG-1B) as trigger interrupt input 

A20 

; Set acceleration on axis 1 to 20 units/sec2 

AD40 ; Set deceleration on axis 1 to 40 units/sec2 

V1 

; Set velocity on axis 1 to 1 unit/sec 

1REGA4000 ; Set TRG-1A's registration distance on axis 1 to 4000 units 

; (registration A move will use the A, AD, & V values above) 

A5 

; Set acceleration on axis 1 to 5 units/sec/sec 

AD2 

; Set deceleration on axis 1 to 2 units/sec/sec 

V.5 ; Set velocity on axis 1 to 0.5 units/sec 

1REGB13000 ; Set TRG-1B's registration distance on axis 1 to 13,000 units 

; (registration B move will use the A, AD, & V values above) 

RE10 ; Enable registration on axis 1 only 

A50 ; Set acceleration to 50 units/sec/sec on axis 1 

AD50 ; Set deceleration to 50 units/sec/sec on axis 1 

V10 ; Set velocity to 10 unit/sec on axis 1 

D50000 ; Set distance to 50000 units on axis 1 

GO10 ; Initiate motion on axis 1 

END 


v 

10 

8 

1st Registration mark 

(TRG-1A) occurs 

2nd Registration mark 

(TRG-1B) occurs 

6 

4 

Pick up 

container 

here 

2 

0 

0 

10,000 

20,000 

D 



A user has a line of material with randomly spaced registration marks. It is known that the 

first mark must initiate a registration move, and that each registration move cannot be 

interrupted or the end product will be destroyed. Since the distance between marks is random, 

it is impossible to predict if a second registration mark will occur before the first registration 

move has finished. 

DEL REGI2 

DEF REGI2 

INFNC1-H 

RE1 

V2 

REGA20000 

MC1 

V1 

GO1 

END 

; Delete program (in case program already resides in memory) 

; Begin program definition 

; Trigger capture mode for trigger 1 (TRG-A) 

; Enable registration 

; Set registration move to a velocity of 2 rps 

; and a distance of 20000 steps 

; Start a mode continuous 

; move at a velocity of 1 rps 



v 

2 

1st Registration 

mark occurs 

2nd Registration 

mark occurs 

The first registration move 

is pre-empted by a second 

registration input. 

1 

0 

t 

In order to stop the second registration from occurring, REGSS can be used: 

DEL REGI2b 

DEF REGI2b 

INFNC1-H 

RE1 

V2 

REGA20000 

REGSS1 

MC1 

V1 

GO1 

END 







; Enable registration single shot mode 





v 

2 

1 

1st Registration 

mark occurs 


mark occurs 

Because of REGSS, the 

first registration move is 

NOT pre-empted by the 

second registration input. 

The registration “single 

shot” will be reset when 

you issue a new motion 

command (GO, PRUN, etc.). 

0 

t 



A print wheel uses registration to initiate each print cycle. From the beginning of motion, the 

controller should ignore all registration marks before traveling 2000 steps. This is to ensure 

that the unit is up to speed and that the registration mark is a valid one. 

DEL REGI3 

DEF REGI3 

INFNC1-H 

RE1 

V2 

REGA2500 

REGLOD2000 

MC1 

V1 

GO1 

END 







; Set registration lockout distance to 2000 steps 





v 

2 

1st Registration mark occurs 

after 1500 steps, but the 

registration 

move does not 

occur because 

the lockout 

distance is set 

to 2000 steps. 


mark occurs after 

3000 steps. 

1 

0 

t 

Synchronizing Motion (GOWHEN and TRGFN operations) 

Conditional “GO”s (GOWHEN) 

GOWHEN and TRGFN allow you to synchronize the execution of motion and other events: 

• GOWHEN — synchronize execution of the subsequent start-motion command (GO, GOL, 

FGADV, FSHFC, or FSHFD) to: 

- Position (commanded, feedback device, motor, master, slave, Following shift) 

- Master cycle number 

- Input status 

- Time delay (dwell) 

• TRGFN: 

- Suspend execution of the next start-motion command (GO, GOL, FGADV, FSHFC, 

or FSHFD) until the specified trigger input goes active. 

- Suspend beginning a new Following master cycle until the specified trigger 

input goes active. 

The GOWHEN command is used to synchronize a motion profile with a specified position 

count, input status, dwell (time delay), or master cycle number. Command processing does not 

wait for the GOWHEN conditions (relational expressions) to become true during the GOWHEN 

command. Rather, the motion from the subsequent start-motion command (GO, GOL, FGADV, 

FSHFC, and FSHFD) will be suspended until the condition becomes true. 

Start-motion type commands that cannot be synchronized using the GOWHEN command are: 

HOM, JOG, JOY, and PRUN. A preset GO command that is already in motion can start a new 

profile using the GOWHEN and GO sequence of commands. Continuous moves (MC1) already 

in progress can change to a new velocity based upon the GOWHEN and GO sequence. Both 

preset and continuous moves can be started from rest with the GOWHEN and GO sequence. 


GOWHEN 

Syntax 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Using the numeric variable operand: VAR will be sampled only once, at the moment the 

GOWHEN command is executed. To use other right-hand side data sources, precede the 

GOWHEN command with a command that loads a variable with the data source desired and 

then use that variable in the GOWHEN expression. 

SCALING 

If scaling is enabled (SCALE1), the right-hand operand is multiplied by SCLD if the left-hand 

operand is FB, PC, PE, PSLV, or PSHF. The right-hand operand is multiplied by the SCLMAS 

value if the left-hand operand is PMAS. (The SCLD or SCLMAS values used correlate to the 

axis specified with the variable–e.g., a GOWHEN expression with PE scales the encoder 

position by the SCLD value.) 

GOWHEN 

Status 

Axis Status — Bit #26: Bit #26 is set when motion has been commanded by a GO, GOL, 

FGADV, FSHFC, or FSHFD command, but is suspended due to a pending GOWHEN condition. This 

status bit is cleared when the GOWHEN condition is true or when a stop (!S) or kill (!K or ^K) 

command is executed. The GOWHEN command can be cleared using S or K command 

(e.g., !S11XØ or !KØXX1). 

AS.26 .......Assignment & comparison operator — use in a conditional expression (see page 26). 

TASF..........Full text description of each status bit. (see “Gowhen is Pending” line item) 


Axis Status — Bit #29: Bit #29 is set when the input state of position relationship specificed 

in the GOWHEN expression was already true when the subsequent GO, GOL, FGADV, FSHFC or 

FSHFD command was executed. 

AS.29 .......Assignment & comparison operator — use in a conditional expression (see page 26). 

TASF..........Full text description of each status bit. (see “Gowhen Error” line item) 




conditions are 

provided on page 30. 

Error Status — Bit #14: Bit #14 is set if the input state or position relationship specified in 

the GOWHEN expression was already true when the subsequent GO, GOL, FGADV, FSHFC, or 

FSHFD command is issued. The error status is monitored and reported only if you enable errorchecking 

bit #14 with the ERROR command (e.g., ERROR.14-1). NOTE: When the error 

occurs, the controller with branch to the error program (assigned with the ERRORP command). 


ER.14 .......Assignment & comparison operator — use in a conditional expression (see page 26). 

TERF..........Full text description of each status bit. (see “GOWHEN condition true” line item) 

TER ............Binary report of each status bit (bits 1-32 from left to right). See bit #14. 

GOWHEN ... 

On A Trigger Input 

GOWHEN 

VS 

WAIT 

Factors Affecting 

GOWHEN Execution 

☞ 

GOWHEN in Compiled 

Motion (Compiled 

Motion is discussed on 

page 139) 

Sample 

Gem6K Code 

If you wish motion to be triggered with a trigger input, use the TRGFNc1 command. The 

TRGFNc1 command executes in the same manner as the GOWHEN command, except that 

motion is executed when the specified trigger input “c” is activated.. For more information, 

refer to Trigger Functions below. 

A WAIT will cause the controller program to halt program flow (except for execution of 

immediate commands) until the condition specified is satisfied. Common uses for this function 

include delaying subsequent I/O activation until the master has achieved a required position or 

an object has been sensed. 

By contrast, a GOWHEN will suspend the motion profile until the specified condition is met. It 

does not affect program flow. If you wish motion to be triggered with a trigger input, use the 

TRGFNc1 command. The TRGFNc1 command executes in the same manner as the GOWHEN 

command, except that motion is executed when the specified trigger input (c) is activated (see 

Trigger Functions below for details). In addition, GOWHEN expressions are limited to the 

operands listed above; WAIT can use additional operands such as FS (Following status) and 

VMAS (velocity of master). 

If a second GOWHEN command is executed before a start-motion command (GO, GOL, FSHFC, 

or FSHFD), then the first GOWHEN is over-written by the second GOWHEN command. (GOWHEN 

commands are not nested.) An error is not generated when a GOWHEN command is over-written 

by another GOWHEN. 

While waiting for a GOWHEN condition to be met and a start-motion command has been 

issued, if a second GOWHEN command is encountered, then the first sequence is disabled and 

another start-motion command is needed to re-arm the second GOWHEN sequence. 

A new GOWHEN command must be issued for each start-motion command (GO, GOL, FGADV, 

FSHFC, or FSHFD). That is, once a GOWHEN condition is met and the motion command is 

executed, subsequent motion commands will not be affected by the same GOWHEN command. 

If the GOWHEN and start-motion commands are issued, the motion profile is delayed until the 

GOWHEN condition is met. If a second start-motion command is encountered, the second startmotion 

command will override the GOWHEN command and start motion. If this override 

situation is not desired, it can be avoided by using a WAIT condition between the first startmotion 

command and the second start-motion command. 

It is probable that the GOWHEN command, the GO command, and the GOWHEN condition 

becoming true may be separated in time, and by other commands. Situations may arise, or 

commands may be given which make the GOWHEN invalid or inappropriate. In these cases, the 

GOWHEN condition is cleared, and any motion pending the GOWHEN condition becoming true 

is canceled. These situations include execution of the JOG, JOY, HOM, PRUN, and DRIVEØ 

commands, as well motion being stopped due to hard or soft limits, a drive fault, an 

immediate stop (!S), or an immediate kill (!K or ^K). 

When used in a compiled program, a GOWHEN will pause the profile in progress (motion 

continues at constant velocity) until the GOWHEN condition evaluates true. When executing a 

compiled Following profile, the GOWHEN is ignored on the reverse Following path (i.e., when 

the master is moving in the opposite direction of that which is specified in the FOLMAS 

command). A compiled GOWHEN may require up to 4 segments of compiled memory storage. 

In the example below, the motor must start motion when input #2 signals a safe condition. 

While waiting, the program must be monitoring inputs and serving other system requirements, 

so a WAIT statement cannot be used; instead, a GOWHEN and GO sequence will delay the move 

profile of axis 2. 


Trigger Functions (TRGFN) 

MC0 

; Set to preset move mode 

D20 

; Set distance end-point 

COMEXC1 

; Enable continuous command execution mode 

V1 


A100 


GOWHEN(IN.2=b1) ; Delay profile. When expression is true (input #2 is 

; low) start motion. 

GO 

; Command to move. Motor will not start until 

; conditions in the GOWHEN statement are true. 

; Command processing does not wait, so other system 

; functions may be performed. 

The Trigger Functions command (TRGFN) allows you to assign additional functions to trigger 

inputs that have been defined as “trigger interrupt” inputs (INFNCi-H): 

TRGFNc bb 

Start New Master Cycle (FMCNEW) function 

Conditional GO (GOWHEN) function 

Trigger letter. Two triggers are available (A or B). 

The “Master Trigger” (letter M) may also be used. 

• “Conditional GO” Function (TRGFNc1x): Suspend execution of the next start-motion 

command until specified trigger input “c” goes active. Start-motion commands are listed 

below. Refer to page 163 or to the GOWHEN command description for additional details. 

- GO (standard command to begin motion) 

- FGADV (begin geared advance – for Following motion) 

- FSHFC (begin continuous shift – for Following motion) 

- FSHFD (begin preset shift – for Following motion) 

Axis status bit #26 (reported with TASF, TAS, or AS) is set to one (1) when there is a 

pending “Conditional GO” condition initiated by a TRGFN command; this bit is cleared 

when the trigger is activated or when a stop command (S) or a kill command (K) is issued. 

If you need execution to be triggered by other factors (e.g., input state, master position, 

encoder position, etc.) use the GOWHEN command. 

• “New Master Cycle” Function (TRGFNcx1): This is equivalent to executing the FMCNEW 

command. When specified trigger input “c” goes active, the controller begins a new 

Following master cycle. For more information on master cycles, refer to page 182 or to 

the FMCNEW command description. 

These trigger functions are cleared once the function is complete (trigger input is activated). To 

use the trigger to perform a GOWHEN function again, the TRGFN command must be given again. 

Sample 

Gem6K Code 

INFNC1-H 

INFNC2-H 

TRGFNBx1 

TRGFNB1x 

GO1 

; Define input #1 (TRG-A) as a trigger interrupt input 

; Define input #2 (TRG-B) as a trigger interrupt input 

; When TRG-1B goes active, motor will begin a new 

; master cycle 

; When TRG-2B goes active, motor will execute the move 

; commanded with the GO command. 

; The move is commanded, but will not execute 

; until trigger 2B goes active. 


Following 

6C HAPTER SIX 

Following 


This chapter will help you understand Ratio Following: 

• Introduction to Ratio Following ......................................................................168 

• Implementing Ratio Following .......................................................................170 

• Master Cycle Concept .....................................................................................182 

• Technical Considerations for Following .........................................................186 

• Troubleshooting for Following .......................................................................196 

• Following Commands (list).............................................................................198

Ratio Following – Introduction 

As part of its standard features, the Gem6K Series Drive/Controller family allows you to solve 

applications requiring Ratio Following. 

Compiled Profiles 

You can pre-compile 

Following profiles 

(saves processing 

time). See page 142 

for details. 

Ratio Following is, essentially, controlled motion based on the measurement of external 

motion. This includes concepts such as an electronic gearbox, trackball, follower axis feed-tolength, 

as well as complex changes of ratio as a function of master position. Ratio Following 

can include continuous, preset, and registration-like moves in which the velocity is replaced 

with a ratio. 

The follower axis may follow in either direction and change ratio while moving, with phase 

shifts allowed during motion at otherwise constant ratio. Ratio changes or new moves may be 

dependent on master position or based on receipt of a trigger input. Also, a follower axis may 

perform Following moves or normal time-based moves in the same application because 

Following can be enabled and disabled at will. Product cycles (operations which repeat with 

periodic master travel) can be easily specified with the master cycle concept (see page 182). 

In Ratio Following, acceleration ramps between ratios will take place over a user-specified 

master distance. Product cycles can be easily specified with the master cycle concept. 

This chapter highlights the capabilities of the Gem6K Following features and provides 

application examples. If you need more details on the operation or syntax of a particular 

command, please refer to the Gem6K Series Command Reference. 

Before delving into the specifics of Ratio Following, read on to gain a basic understanding of 

how the Gem6K follows. 

What can be a master 

The Gem6K can be made to “follow” any of the master input (“master”) sources listed in the 

table below. 

• Incremental encoder. The encoder can be the axis-related “ENCODER” port on a stepper, 

or it can be the “MASTER ENCODER” port. 

• Analog input (servo axes only). This requires an ANI SIM be installed on an expansion 

I/O brick (see your product’s Installation Guide for instructions). ANI SIMs and 

expansion I/O bricks are sold separately. 

• Internal count source (a “virtual master” option) 

• Internal sine wave source (a “virtual master” option) 

• Integer variable (VARI) 

A servo axis may not follow its own feedback device input (encoder or analog input). 

A stepper axis may follow its own encoder input, as long as that axis does not use the Encoder 

Stall Detect feature (ESTALL1 mode). 

For instructions on assigning a master for a particular follower axis, refer to Define the 

Master and Follower (page 170), or refer to the FOLMAS command description in the Gem6K 

Series Command Reference. 


Following Status (TFSF, TFS & FS Commands) 

Many of the Following features described in this document have associated status bits that can be displayed 

(with the TFSF and TFS commands) or used in assignment or comparison operations (with the FS operator). 

The portions of this document which describe those features also summarize the related status bits. 

FS Bit Function (YES = 1; NO = Ø) 

1....... Follower in Ratio Move..... A Following move is in progress. 

2....... Ratio is Negative .............. The current ratio is negative (i.e., follower counts counting in the opposite direction from master). 

3....... Follower Ratio Changing .. The follower is ramping from one ratio to another (including a ramp to or from zero ratio). 

4....... Follower At Ratio .............. The follower is at constant non-zero ratio. 

Bits 1-4 indicate the status of the follower axis in Following motion. 

* 5....... FOLMAS Active.................. A master is specified with the FOLMAS command. 

* 6....... FOLEN Active.................... Following has been enabled with the FOLEN command. 

* 7....... Master is Moving .............. The specified master is currently in motion. 

8....... Master Dir Neg ................. The current master direction is negative. (Bit must be cleared to allow Following move in preset 

mode—MCØ). 

Bits 5-8 indicate the status required for Following motion (i.e., a master must be assigned, Following must be enabled, 

the master must be moving, and for many features, the master direction must be positive). 

Unless the master is a commanded position of another axis, minor vibration of the master will likely cause bits 7-8 to 

toggle on and off, even if the master is nominally “at rest”. These bits are meant primarily as a quick diagnosis for the 

absence of master motion, or master motion in the wrong direction. Many features require positive master counting to 

work properly. 

9....... OK to Shift ........................ Conditions are valid to issue shift commands (FSHFD or FSHFC). 

10....... Shifting now ...................... A shift move is in progress. 

11....... Shift is Continuous............ An FSHFC-based shift move is in progress. 

12....... Shift Dir is Neg.................. The direction of the shift move in progress is negative. 

Bits 9-12 indicate the shift status of the follower. Shifting is super-imposed motion, but if viewed alone, can have its 

own status. In other words, bits 10-12 describe only the shifting portion of motion. 

13....... Master Cyc Trig Pend....... A master cycle restart is pending the occurrence of the specified trigger. 

14....... Mas Cyc Len Given .......... A non-zero master cycle length has been specified with the FMCLEN command. 

15....... Master Cyc Pos Neg......... The current master cycle position (PMAS) is negative. This could be by caused by a negative initial 

master cycle position (FMCP), or if the master is moving in the negative direction. 

16....... Master Cyc Num > 0......... The master position (PMAS) has exceeded the master cycle length (FMCLEN) at least once, causing 

the master cycle number (NMCY) to increment. 

Bits 13-16 indicate the status of master cycle counting. If a Following application is taking advantage of master cycle 

counting, these bits provide a quick summary of some important master cycle information. 

17....... Mas Pos Prediction On..... Master position prediction has been enabled (FPPEN). 

18....... Mas Filtering On ............... A non-zero value for master position filtering (FFILT) is in effect. 

19....... 

20....... 

Bit 17 and 18 indicate the status of master position measurement features. 

21....... 

22....... 

23....... OK to do FGADV move...... OK to do Geared Advance move (master assigned with FOLMAS, Following enabled with FOLEN, and 

follower axis is either not moving, or moving at constant ratio in continuous mode). 

24....... FGADV move underway .... Geared Advance move profile is in progress. 

Bits 23 and 24 indicate the status of a Geared Advance move. 

25....... 

26....... FMAXA/FMAXV limited........ The present Following move profile is being limited by FMAXA or FMAXV. 

27....... 

28....... 

Bits 23 and 24 indicate the status of a Geared Advance move. 

* All these conditions must be true before Following motion will occur. 

Chapter 7. Multi-Tasking 169

Implementing Ratio Following 

This section covers the basic elements of implementing Ratio Following: 

• Applying Following setup parameters 

• Move profiles 

• Performing phase shifts (FSHFC and FSHFD) 

• Geared advanced (FGADV) 

• Application scenarios: 

- Electronic gearbox 

- Trackball 

Ratio Following Setup Parameters 

Prior to executing a Following move, there are several setup parameters that must be 

specified. These parameters may be established: 

Programming 

examples — see 

application examples 

later in this chapter. 

• Define the master and follower (FOLMAS) 

• Define master & follower scaling factors (SCLMAS, SCLA, SCLD, and SCLV) – if required 

• Define the follower-to-master Following ratio (FOLRN and FOLRD) 

• Define the master distance (FOLMD) – define scaling first 

• Enable the Following Mode (FOLEN) 

Following Status 

(see TFSF, TFS and FS 

commands) 

Following Status bits 5-8 (see table below) are meant to indicate the status required for 

Following motion (i.e., a master must be assigned, Following must be enabled, the master must 

be moving, and for many features, the master direction must be positive). 

Bits 7-8 represent master motion and master direction respectively. Unless the master is a 

commanded position of another axis, it is likely that minor vibration of the master will cause 

these bits to toggle on and off, even if the master is nominally “at rest”. These bits are meant 

primarily as a quick diagnosis for the absence of master motion, or master motion in the wrong 

direction. Many features require positive master counting to work properly. 

Bit # Function (yes = 1; no = Ø) 

5 FOLMAS Active ................A master is specified with the FOLMAS command. 

6 FOLEN Active ..................Following has been enabled with the FOLEN command. 

7 Master is Moving.............The specified master is currently in motion. 

8 Master Dir Neg................The current master direction is negative. (bit must be cleared to 

allow Following move in preset mode–MCØ). 

Define the Master 

and Follower; 

(FOLMAS) 

The FOLMAS command defines the masters and the followers. The command syntax is: 

Follower 

Axis 

FOLMAS 

Format for master assignment to follower: 

 

Sign Bit 

Master source axis # (optional) 

Master source selection 


• Sign bit (±): Specifies the count direction of the master source which will result in 

positive master travel counts. The sign bit is not meant to be used simply to change the 

direction of follower motion. That function can be done with the sign of the D command. 

Rather, the sign bit is used to allow forward motion of the physical master (e.g., conveyor 

belt, rotating wheel, or the continuous feed of material or product) to result in positive 

counts. Several features described later in this document require increasing master counts 

for proper operation. These include Following motion in preset positioning mode (MCØ) , 

master cycle counting, and executing GOWHEN based on master cycle position. 

• Master source axis number (1 st i): Selects the axis number of the master source. This 

number is not required when selecting the Master Encoder as the master source. . If the 

master source is “8” (VARI), this represents the integer variable (VARI) number. 

• Master source selection (2 nd i): Selects the master source (according to the master source 

axis number). The options, selected by their respective number, are: 

1.... Incremental encoder connected to one of the axis-related “ENCODER” ports, or the 

“MASTER ENCODER” port. If the master encoder is selected, the master source 

input number must be omitted from the syntax. 

2.... Analog input (servo axes only). This requires an ANI SIM be installed on an 

expansion I/O brick (see your product’s Installation Guide for instructions), and 

the ANI input must be designated as a master input source with the ANIMAS 

command. ANI SIMs and expansion I/O bricks are sold separately. 

5.... Internal count source (see Following a Virtual Master below for details) 

6.... Internal sine wave source (see Following a Virtual Master below for details) 

8.... VARI variable (see Following an Integer Variable below for details) 

NOTES 

• Servo controllers: The follower axis cannot use its own commanded position or its 

currently selected feedback device (encoder or ANI) as the master input. 

• Stepper controllers: A follower axis that is using the Stall Detect mode (ESTALL1) cannot 

use its own encoder as the master input. 

• If scaling is enabled (SCALE1), the measurement of the master is scaled by the SCLMAS 

value. 

As an example, suppose the Master Encoder input is to be the master input for follower axis 1, 

and forward travel of the physical master (e.g., conveyor belt) results in negative counts on 

the Master Encoder. Given these operating constraints, you would use the FOLMAS-1 


The default axis follower setting is disabled. If you do not want the axis to be a follower, 

simply leave it not configured (e.g., FOLMAS+11 command configures axis #1 as a follower 

to encoder #1;). If an axis is currently configured as a follower, you can disable its follower 

status by putting a zero (Ø) in the parameter field (e.g., the FOLMASØ command disables axis 

1 from being a follower axis). 

As soon as the master/follower configuration is specified with the FOLMAS command, a 

continuously updated relationship is maintained between the follower’s position and the 

master’s position. The update period is 2 ms. 

FOLMAS Setting Not Saved in Non-Volatile Memory 

The FOLMAS configuration is not saved in non-volatile memory. Therefore, you may wish to 

include it in the power-up program (STARTP). 


Following a Virtual 

Master 

The Gem6K allows two “Virtual Master” options for applications that require the 

synchronization features of Following, but have no external master to measure. 

• Internal count source. 

• Internal sine wave. 

Internal Count Source 

The internal count source is intended to mimic the counts which might be received on an 

external encoder port. Just as may be encountered with an external encoder, this count 

source may speed up, slow down, stop, or count backwards. There is one count source 

with a user definable and variable count frequency. The count frequency, specified in 

counts per second with FVMFRQ, is a signed value, allowing the master to move forward 

or backwards. The rate at which the count frequency may change is specified in counts 

per second per second with the FVMACC command. This allows smooth changes in 

master velocity and direction. Neither of these commands are scaled or have associated 

report backs. The accumulated raw count and count rate have no report back, but may be 

accessed via TPMAS and TVMAS respectively if the internal count source is specified as 

master. 

The associated commands are: 

FVMFRQi ........................................ Where “i” is the count frequency in counts/sec 

(range is 0-1,000000) 

FVMACCi ........................................ Where “i” is the count accel in counts/sec 2 

(range is 0-9,999,999) 

The count source is always enabled, counting at the signed rate specified with the 

FVMFRQ command. There are no start or stop commands, no modes, distances, or limit 

inputs. To stop and start the count source, specify zero or non-zero values respectively 

for the FVMFRQ command. To add or subtract a “preset” number of counts (i.e., move 

the master forward or backward a “preset distance”), you must calculate the time required 

for that distance, (using the frequency and acceleration values), and command the 

appropriate value of FVMFRQ for that duration. 

Internal Sine Wave 

The internal sine wave is generated using the internal count source as a frequency input. 

By designating the internal sine wave as a master (e.g., FOLMAS+16), you may produce 

a sinusoidally oscillating motion, with control of the phase (angle), amplitude, and center 

of oscillation. There is one sine wave using the variable count frequency (FVMFRQ) to 

increase or decrease the angle from which the sine is calculated. Each count of the count 

frequency changes the angle by one tenth (0.1) of a degree. For example, a FVMFRQ 

value of 3600 would create an angular frequency of 3600 tenths degrees per second, or 1 

cycle per second. When used as a source for the sine wave, the maximum value for 

FVMFRQ is 144000. This results in a maximum of 40 Hz angular frequency. Higher 

frequencies are not allowed because they may be subject to aliasing. 

The associated commands are: 

SINANGi ........................................ Where “i” is the new angle (range is 0.0-360.0 degrees) 

SINAMPi ........................................ Where “i” is the amplitude (range is 0-9,999,999 — 

maximum peak-to-peak is 16384)) 

SINGOb .......................................... Where “b” is the binary start/stop for the master axis: 

1 = restart from zero degrees 

0 = stop the sine wave 

The SINAMP command is included in the specification in order to allow a change in slave 

amplitude without changing the center of oscillation. Changing the ratio (with FOLRN) 

will also change the slave amplitude, but unless the command is given at exactly the 

master zero crossing, it will also change the center of slave oscillation. The center of 

oscillation may be changed by a controlled amount by using the FSHFD command. The 

SINAMP command affects the sine wave immediately, without any built in ramp in 

amplitude. If a gentle change is desired, a user program should be written which 


epeatedly issues the command with small changes in value, until the desired value is 

reached. 

Using SINGO with a “0” parameter abruptly stops the sine wave, without changing its 

current magnitude. Using SINGO with a “1” parameter abruptly starts the sine wave, also 

without changing its current magnitude. To gently pause the slave output, use an 

FVMFRQ value of zero, with a moderate FVMACC value; to resume, restore the FVMFRQ 

value. 

The SINGO with a “1” parameter always starts at the previous angle, which may not be 

the desired start of oscillation. The SINANG command will instantly change the angle 

and corresponding sine of the angle. This represents an abrupt change in master position. 

If the slave is still following when this occurs, there will be an abrupt change in 

commanded slave position. To start the slave properly, move the slave to the desired 

start position first (using MC0, D, GO), then issue SINANG, then MC1, GO1, and finally 

SINGO. If SINANG is issued without any parameters, the current angle is reported, not 

the most recent user SINANG command value. 

Sinewave Example: 

In the example below, the follower will oscillate at 1 Hz centered around zero, with a peak-topeak 

amplitude of 2048. Assume both the master axis and the follower axis use the same units. 

Based on this assumption, we can use a following ratio of 1 to 1 and control the amplitude with 

the SINAMP command. In order to provide a gentle start the oscillation is started at the bottom 

of the cycle, where the velocity is zero. 

D-1024 ; Establish desired bottom of oscillation 

MC0 

; Put into preset move mode 

GO1 

; Move to desired bottom location 

FOLMAS16 

; Set follower to follow internal sine wave 

FOLRN1 ; Set following ratio to 1 to 1 

FOLRD1 

FOLEN1 

; Enable following mode 

MC1 

; Enable continuous motion 

SINAMP1024 ; Establish center to peak amplitude 

FVMFRQ3600 ; Establish 1 Hz frequency 

FVMACC999999 ; Reach frequency rapidly 

SINANG270 

; Start angle at bottom of cycle 

GO1 

; Lock follower to master (not started yet) 

SINGO1 

; Start sine wave (and hence follower motion) 

Following an Integer 

Variable 

Syntax is FOLMASn8. This option allows an axis to follow the integer variable (VARI) 

specified with “n”; that is, VARIn. The range for “n” is 1-8 (VARI1 – VARI8). For example, 

FOLMAS48 assigns axis #1 to follow VARI4. 

This option is particularly useful in conjunction with the INVARI (Map Inputs to a VARI 

Variable) feature. INVARI continuously updates a specified VARI variable with the value of a 

specified group of digital inputs, allowing an axis to follow a binary input pattern. Another 

useful way to update the value of the VARI variable is to calculate its value in a PLCP program 

(launched with the SCANP command). 

The INVARI and SCANP options for updating VARI are good choices, because both are 

performed every system update, thus facilitating smooth Following motion. It is also possible 

to use an extra task (multi-tasking) to calculate VARI values, but the resulting updates will not 

be as fast (not perfectly periodic); consequently, Follow motion will be less smooth. 



and Follower 

Scaling Factors; 

(SCLMAS); 

. . . . if required; 

If you will be scaling your motion parameters (distance, velocity, acceleration/deceleration), be 

aware that the only variance from non-Following scaling is that the master source (distance) is 

scaled by the SCLMAS value. Virtual master sources are not scaled. 

Typically, the master and follower scale factors are programmed so that master and follower units are 

the same, but this is not required. Consider the scenario below as an example. 

The master is a 1000-line encoder (4000 counts/rev post-quadrature) mounted to a 50 teeth/rev pulley 

attached to a 10 teeth/inch conveyor belt, resulting in 80 counts/tooth (4000 counts/50 teeth = 80 

counts/tooth). To program in inches, you would set up the master scaling factor with the SCLMAS800 

command (80 counts/tooth * 10 teeth/inch = 800 counts/inch). 

The follower axis is a servo motor with position feedback from a 1000-line encoder (4000 counts/rev). 

The motor is mounted to a 4-pitch (4 revs/inch) leadscrew. Thus, to program in inches, you would set 

up the follower scaling factor with the SCLD16000 command (4000 counts/rev * 4 revs/inch = 1Gem6K 

counts/inch). 

Define the Followerto-Master 

Following 

Ratio (FOLRN & 

FOLRD) 

FOLRNF may be used to 

define a final ratio for 

compiled Following 

profiles (see page 142). 

NOTE: Additional details on scaling and non-scaled units of measure are presented on page 67. 

The FOLRN and FOLRD commands establish the goal ratio between the follower and master 

travel, just as the V command establishes the goal velocity for a typical non-Following move. 

The FOLRN command specifies the ratio's numerator (follower travel), and the FOLRD 

command specifies the ratio’s denominator (master travel). If the denominator (FOLRD) is not 

specified, it is assumed to be 1. 

FOLRN and FOLRD are specified with two positive numbers, but the resulting ratio applies to 

moves in both directions; the actual follower direction will depend on the direction commanded 

with the D command and master direction. Numeric variables (VAR) can be used with these 

commands for follower and/or master parameters (e.g., FOLRN(VAR1) : FOLRD3). The 

maximum value of the resulting quotient is 127 to 1. 

For a preset Following move (MCØ mode), the FOLRN/FOLRD ratio represents the maximum 

allowed ratio. For a continuous move (MC1 mode), it represents the final ratio r eached by the 

follower axis. 

Example As an example, assume the follower-to-master ratio is set to 5-to-3 for an axis (FOLRN5 : 

FOLRD3). The first parameter (5) is scaled by the SCLD value to give follower steps. The 

second parameter (3) is scaled by the SCLMAS value to give master steps. If the SCLD setting 

is 25000 and the SCLMAS setting is 4000, the follower-to-master step ratio would be 5 ∗ 25000 

to 3 ∗ 4000, or 125 follower steps for every 12 master steps. 


Distance; (FOLMD); 

The “master distance” for moves in the Following mode (FOLEN1) is analogous to the move 

time for normal time-based moves with Following disabled (FOLENØ). For time-based moves, 

the time required to ramp to a new velocity (MC1 mode) or move to a new position (MCØ 

mode) is determined indirectly by the acceleration (A), deceleration (AD), and velocity (V) 

command values. For Following mode moves, a ramp to a new ratio (MC1 mode) or a move to 

a new position (MCØ mode) takes place over a specific master distance, not over a specific 

time. This distance is defined directly by the user with the FOLMD command. 

In other words, the FOLMD command defines the master distance over which a preset follower 

move will take place, or the master distance over which a continuous follower move will 

change from its current ratio (including zero) to the commanded ratio (ratio established by 

FOLRN and FOLRD). 

By carefully specifying a master distance (FOLMD), a precise position relationship between 

master and follower during all phases of the profile is ensured. 

☞ HINT: If the follower axis is in continuous mode (MC1) and the master is starting from 

rest, setting FOLMD to Ø will ensure precise tracking of the master's acceleration ramp. 

If scaling is enabled (SCALE1), the FOLMD value is scaled by the SCLMAS parameter. 

Examples and more information on this topic can be found below in the section titled 

Follower vs. Master Move Profiles. 


Enable the 

Following Mode; 

(FOLEN1) 

When an axis is configured as a follower with the FOLMAS command, it will continuously 

monitor the position and motion of its master, even if the follower is at rest. This allows 

subsequent motion to be related to the motion of the master via ratios (FOLRN/FOLRD) and 

ramping over master distances (FOLMD). Such moves are done with Following enabled 

(FOLEN1). 

It is also possible, and sometimes desirable, to have the follower axis motion independent of 

master axis motion, yet still “aware” of master position. For example, a move may need to 

start at a specified master position, yet finish in a fixed time, independent of the master speed. 

This move would be performed with Following disabled (FOLENØ). 

Following may be enabled or disabled between moves, as needed, without affecting the 

monitoring of the master. 

If a move is performed with Following disabled, its motion profile is determined by the 

acceleration, deceleration, and velocity specified with the A, AD, and V commands. Its motion 

is the same as if the axis were not configured as a follower, but the axis does monitor the 

master. 

If a move is performed with Following enabled, its profile is determined by the specified 

master distance (FOLMD) and Following ratio (FOLRN/FOLRD). The next section describes 

such profiles. 

Follower vs. Master Move Profiles 

Before an axis begins moving in the Following Mode (FOLEN1), the program should define 

how the follower will reach the commanded ratio. This is accomplished with the FOLRN and 

FOLRD commands. The acceleration and deceleration of the follower can be defined in two 

ways: a time-based acceleration ramp with the A and AD commands, or acceleration over a 

certain master distance with the FOLMD command. Specifying an acceleration (A) for the 

follower means that the acceleration ramp is time-based and there is no position relationship 

between master and follower until the commanded Following ratio (defined with FOLRN and 

FOLRD) is reached. Specifying a master distance for the follower's move profile (FOLMD) 

ensures a precise position relationship between master and follower during all phases of the 

profile. Thus, whenever the position relationship between master and follower is important, the 

FOLMD method should be used. Following Status (TFSF, TFS, and FS) bits 1-4 indicate the 

status of follower in motion. They mimic the meaning and organization of Axis Status (TASF 

and AS) bits 1-4, except that each bit indicates the current state of the ratio, rather than the 

current state of the velocity: 

Bit # Function (YES = 1; NO = Ø) 

1 Follower in Ratio Move ..... A Following move is in progress 

2 Ratio is Negative............... The current ratio is negative (i.e., the follower counts are counting in 

the opposite direction from the master counts). 

3 Follower Ratio Changing .. The follower is ramping from one ratio to another (including a ramp 

to or from zero ratio). 

4 Follower At Ratio .............. The follower is at constant non-zero ratio. 


Continuous 

Positioning Mode 

Moves 

For Following moves in the continuous positioning mode (MC1), FOLMD specifies the exact 

master travel distance over which the follower ratio changes. This will be required for any 

application that uses multiple ratios and continuous moves for the construction of precisely 

defined multi-segment moves. 

☞ HINT: If the follower is in continuous mode (MC1) and the master is starting from rest, 

setting FOLMD to Ø will ensure precise tracking of the master’s acceleration ramp. 

In the profile below, the first two moves each change ratio over one master inch, and the final 

ramp to zero takes place over two master inches. 

3 

Ratio 

2 

1 

1 2 3 4 5 6 7 

Master Travel (inches) 

Example 

In the sample Gem6K code below, assume the follower has a 1000-line encoder connected to a 

2-pitch leadscrew. This gives 8000 follower axis steps per inch. The master is a toothed belt 

with a pulley connected to the master encoder, such that there are 800 master steps per inch. 

SCALE1 


SCLD8000 

; Set scaling so that follower commands are in inches 

SCLMAS800 

; Set scaling so that master commands are in inches 

COMEXC1 

; Allow commands during motion 

FOLMAS1 

; Define master to be master encoder input 

FOLEN1 

; Enable Following (will follow master encoder) 

FOLMD1 

; Follower to change ratio over 1 inch of the master travel 

FOLRD1 

; Set Following ratio denominator to 1 for subsequent ratios 

D+ ; Set direction positive 

MC1 

; Mode set to continuous clockwise moves 

FOLRN1 ; Set Following ratio numerator to 1 (ratio set to 1:1) 

FMCNEW1 

; Restart master cycle counting 

GO1 

; Start from rest to reach velocity of master encoder 

WAIT(1FS.4=B1) ; (for steppers) Wait until follower is at ratio 

FOLRN3 ; Set Following ratio numerator to 3 (ratio set to 3:1) 

GOWHEN (1PMAS>=2) ; Enable motion pre-processing so that the next ramp 

; begins at master position 2 

GO1 ; Follower starts ratio change to 3 to 1 at master position 2 

FOLRN0 ; Set Following ratio numerator to zero (ratio is 0 to 1) 

FOLMD2 

; Follower changes ratio over 2 inches of master travel 

WAIT(1AS.26=b0) ; Wait until the previous ramp is started 

; (GOWHEN bit in axis status register is cleared) 

WAIT(1FS.3=b0) ; Wait until the previous ramp is finished 

GOWHEN(1PMAS>=5) ; Enable motion pre-processing so that follower motion 

; begins at master position 5 

GO1 

; Wait for master to reach 5 revolutions before 

; follower starts ratio change to 0 (zero) 


Preset Positioning 

Mode Moves 

For preset positioning mode (MCØ) moves, the FOLMD parameter is the master distance over 

which the entire follower move is to take place. 

As an example, a follower is to move 20 inches over a master distance of 25 inches with a 

maximum ratio of 1:1 (ratio set with the FOLRN1 and FOLRD1 commands). The program and 

a diagram of the move profiles are provided below. 

FOLMAS1 

; Define master to be master encoder 

FOLMD25 

; Define follower to perform the move over 25 inches 

; of the master 

MC0 

; Set positioning mode to preset 

MA0 

; Set preset positioning mode to incremental 

D20 

; Set follower distance to 20 inches 

FOLRN1 ; Set Following ratio numerator to 1 

FOLRD1 ; Set Following ratio denominator to 1 (ratio is 1:1) 

GO1 

; Perform the follower move 

Ratio 

1 

Master Profile 

Slave Profile 

5 10 15 20 25 


If the master distance specified is too large for the follower distance and ratio (FOLRN and 

FOLRD) commanded, the follower will never actually reach the commanded ratio, and the 

move profile will look similar to that below. Here, the FOLMD is 25 inches and the follower is 

commanded to move 10 inches: 

Ratio 

1 

Master Profile 

Slave Profile 

5 10 15 20 25 


If the master distance is too small for the follower distance and ratio commanded, the Gem6K 

will not perform the move at all. For example, if the FOLMD is 25, the ratio is 1:1, and the 

follower is commanded to move 30 inches, the move will not even be attempted. The error 

message “INVALID DATA” will be displayed (depending on the ERRLVL setting) and 

program execution will continue. 


Performing Phase Shifts 

Following Status (TFSF, TFS and FS) bits 9-12 indicate the shift status of the follower. 

Shifting is super-imposed motion, but if viewed alone, can have its own status. In other words, 

bits 10-12 describe only the shifting portion of motion. 


9 OK to Shift.......................Conditions are valid to issue shift commands (FSHFD or FSHFC). 

10 Shifting now ....................A shift move is in progress. 

11 Shift is Continuous..........An FSHFC-based shift move is in progress. 

12 Shift Dir is Neg................The direction of the shift move in progress is negative. 

When a follower is following a master continuously, it may be necessary to adjust, or shift, the 

Following phase (follower’s position with respect to the master) independent of motion due to 

ratio moves. The FSHFC and FSHFD commands allow time-based follower moves to be 

superimposed upon ratio Following moves. Because phase shifts are time-based, they are 

independent of master motion; in fact, the master may be at rest and a shift may still be 

performed. 

Use the FSHFD command to perform a preset shift move with a specific change in follower 

phase. The FSHFD distance value will be scaled by SCLD if scaling is enabled (SCALE1). 

Use the FSHFC command to superimpose a continuous shift move in the positive (FSHFC1) 

or negative (FSHFC2) direction. The FSHFC parameters stop (Ø) and kill (3) can be used to 

halt a continuous FSHFC move or a preset FSHFD move without affect the ratio motion. 

The most recently defined velocity and acceleration (i.e., the V and A values) for the follower 

will determine the basis for the superimposed shift move profile for both FSHFC and FSHFD 

moves. The commanded velocity of the FSHFC or FSHFD move will be added to the current 

velocity at which the follower is performing the Following move . For example, assume a 

follower is traveling at 1 rps in the positive direction as a result of following a master. If a 

FSHFC move is commanded in the positive direction at 2 rps, the follower's actual velocity 

(after acceleration) will be 3 rps. 

For servos, shifting may be performed whenever Following is enabled (FOLEN1). For steppers, 

this may only be done while Following is enabled and the follower is either not in a move, or is 

in continuous positioning mode (MC1) and moving at constant ratio. For both products, TFS/FS 

bit 9 indicates when a shift is allowed. 

The current follower position (TPSLV value) and the net follower shift accumulated since the 

most recent FOLEN1 command (TPSHF value) may be read into numeric variables (VAR) 

using the PSLV and PSHF commands, respectively (e.g., VAR6=1PSLV). They may also be 

used for subsequent decision making (e.g., IF(1PSHFVAR2), etc.). 

The TPSHF and PSHF values are set to zero each time the Following mode is enabled 

(FOLEN1), even if the follower is already in Following mode. This provides a way of 

clearing these values for programming convenience. 

Note that the distance traveled during the time-based deceleration due to stop, kill, or limits is 

included in the PSHF value. By comparing “before and after” values of PSHF, a Gem6K 

program may calculate how much shift was required to perform visual- or sensor-based 

alignment of a master/follower phase relationship. 


Phase Shift 

Examples 

FSHFC Example 

An FSHFC or FSHFD move may be needed to adjust the follower position on the fly because of 

a load condition which changes during the continuous Following move. Below are 

programming examples to demonstrate both shift methods. 

An operator is visually inspecting the follower’s continuous Following motion with respect to 

the master. If he notices that the master and follower are out of synchronization, it may be 

desirable to have an interrupt programmed (e.g., activated by pressing a push-button switch) 

that will allow the operator to move the follower at a superimposed correction speed until the 

operator chooses to have the follower start tracking the master again (by releasing the pushbutton). 

The programming example below illustrates this. 

Assume all scale factors and set-up parameters have been entered for the master and follower. 

In this example, the follower is continually following the master at a 1:1 ratio. If the operator 

notices some mis-alignment between master and follower, he can press 1 of 2 pushbuttons 

(connected to onboard trigger inputs #1 and #2) to shift the follower in the positive or 

negative direction until the button is released. After the adjustment, the program continues on 

as before. 

DEL SHIFT ; Delete program before defining 

DEF SHIFT ; Begin definition of program called SHIFT 

COMEXS1 

; Continue command execution after stop 

COMEXC1 

; Continue command execution during motion 

FOLMAS1 

; Master encoder is the master 

FOLRN1 ; Set follower-to-master Following ratio numerator to 1 

FOLRD1 ; Set follower-to-master Following ratio denominator to 1 

; (ratio set to 1:1) 

FOLEN1 


A25 


AD18 

; Set deceleration 

V5 


D+ ; Set direction to positive 

MC1 

; Select continuous positioning mode 

GO1 

; Start following master continuously 

VARB1=b10 ; Define onboard input pattern #1 and assign to VARB 

VARB2=b01 ; Define onboard input pattern #2 and assign to VARB 

$TESTIN 

; Define label called TESTIN 

IF(IN=VARB1) ; IF statement (if input #1 is activated, do the jump) 

JUMP SHIFTP ; Jump to shift follower in the positive direction 

; when pattern 1 active 

NIF 


IF(IN=VARB2) ; IF statement (if input #2 is activated, do the jump) 

JUMP SHIFTN ; Jump to shift follower in the negative direction 

; when pattern 2 active 

NIF 


JUMP TESTIN ; Return to main program loop 

$SHIFTP 

; Define label called SHIFTP (subroutine to shift in 

; the positive direction) 

FSHFC1 

; Start continuous follower shift in positive direction 

WAIT(IN.1=B0) ; Continue shift until input bit #1 is deactivated 

FSHFC0 

; Stop shift move 

WAIT(1FS.10=B0) ; (steppers only) Wait until the shift is completed 


$SHIFTN 

; Define label called SHIFTN (subroutine to shift 

; in the negative direction) 

FSHFC2 

; Start continuous follower shift move in the 

; negative direction 

WAIT(IN.2=B0) ; Continue shift until bit #2 is deactivated 

FSHFC0 

; Stop shift move 

WAIT(1FS.10=B0) ; (steppers only) Wait until the shift is completed 


END 

; End definition of program called SHIFT 


FSHFD Example 

In this example, the follower follows a master that moves in a continuous cycle. Once each 

cycle, the master and follower both pick parts. The master’s part is detected by a sensor 

connected to trigger 1B, and the follower’s part is detected by a sensor connected to trigger 1A. 

After both parts are detected, they must be aligned. The sensors are mounted 2 inches apart 

from each other, so that proper alignment would result in 2 inches of follower travel between 

detection of the master's part and detection of the follower’s part. 

The follower position is sampled when each of the sensors activates. The difference between 

the follower positions is compared to the required 2 inches. If the measured difference is 

greater than or less than 2 inches, then a shift move to correct the alignment is made. At that 

point, the follower will then start tracking the master again. The follower is continually 

following the master at a 1:1 ratio. 

DEL ALIGN 

; Delete program before defining 

DEF ALIGN 

; Begin definition of program called ALIGN 

COMEXC1 

; Allow continuous command execution during motion 

FOLMAS1 

; The master encoder input is the master 

FOLRN1 ; Set follower-to-master ratio numerator to 1 

FOLRD1 ; Set follower-to-master ratio denominator to 1 

; (ratio set to 1:1) 

FOLEN1 


MC1 

; Enable continuous positioning mode 


GO1 

; Start Following master continually 

INFNC1-H 

; Enable trigger input 1A to latch position of follower 

; when the follower's part is detected 

INFNC2-H 

; Enable trigger input 1B to latch position of follower 

; when the master's part is detected 

$SYNCLP 

; Main loop where synchronizing moves occur 

WAIT(TRIG.1=b1 AND TRIG.2=b1) 

; Wait for both follower and master inputs to occur 

VAR10=1PCCA ; Load VAR10 with the follower commanded position due 

; to follower input activation 

VAR11=1PCCB ; Load VAR11 with the follower commanded position due 

; to master input activation 

VAR12=VAR10-VAR11 ; Load VAR12 with the offset distance 

VAR13=VAR12-2 ; Calculate the required shift 

FSHFD(VAR13) ; Perform synchronization move of distance in VAR13 

JUMP SYNCLP ; Return (jump) to main program loop 

END 

; End of program 

Geared Advance Following 

The FGADV command provides the ability to super-impose an advance or retard on Following 

motion. This is the same ability provided by the FSHFD command (see Performing Phase 

Shifts above), except that the super-imposed motion is also geared to master motion. The 

FGADV command has the positive or negative “advance” distance as a parameter, but it 

initiates motion instead of simply setting up the distance. The shape of the super-imposed 

profile is determined by the FOLMD, FOLRN, and FOLRD commands (just as a normal preset 

Following move). 

The FGADV command profile may be delayed with the GOWHEN command. 

A FGADV move may be performed only while the conditions below exist (Following status bit 

#23, reported with the FS, TFS, and TFSF commands, indicates that it is “OK to do FGADV 

move”): 

• Master is specified with a FOLMAS command 

• Following is enabled with the FOLEN command 

• The follower is either not moving, or moving at constant ratio in continuous mode 

(MC1) 


A FGADV move may not be performed: 

• During a preset (MC0) move 

• In a compiled profile or program 

Following Status (FS, TFS, and TFSF) bit #24 reports if a “FGADV move is underway”. 

Example COMEXC1 ; All command processing during motion 

FOLRN25 ; Set numerator of follower-to-master Following ratio 

FOLRD10 ; Set denominator of follower-to-master Following ratio 

FOLMD1000 ; Set master distance to 1000 units 

MC1 

; Enable continuous positioning mode 


FOLEN1 


GO 

; Ramp up to a 2.5:1 ratio over 1000 master distance units 

FOLMD500 ; Set master distance to 500 units 

FOLRN13 ; Superimposed ratio will be 1.3 (added to 2.5 = 3.8 total) 

WAIT(FS.23=B1) ; Wait for OK to do geared advance 

; (in this case, ramp is complete) 

FGAVD400 ; Advance the follower 400 counts over a distance 

; of 500 master counts 

WAIT (FS.23=B1) ; Wait for OK to do geared advance (in this case, 

; FGADV400 super-imposed profile is complete) 

FGADV-400 ; Retard the follower 400 counts over a distance of 

; 500 master counts (2.5 - 1.3 = 1.2 net ratio) 

Summary of Ratio Following Commands 

ANIMAS............................ Assigns an analog input to be used as a master in a FOLMAS assignment 

(requires a ANI SIM located on an expansion I/O brick) 

FGADV .............................. Defines the geared advance distance 

FOLEN .............................. Enables or disables Following mode 

FOLMAS............................ Defines masters 

FOLMD .............................. Defines the master distance over which follower acceleration or moves are 

to take place 

FOLRN and FOLRD............. Establishes the maximum follower-to-master ratio for a preset move or the 

final ratio for a continuous move (FOLRN for the numerator and FOLRD for 

the denominator) 

FSHFD .............................. Initiates preset advance or retard (shift) of follower position during 

continuous Following moves 

FSHFC .............................. Initiates continuous advance or retard (shift) of follower position (or kills or 

stops the shift portion of motion) during continuous Following moves 

FVMACC............................ Establishes the rate at which the virtual master count frequency (FVMFRQ) 

may change. 

FVMFRQ............................ Defines the frequency of the virtual master count. 

SCLD ................................ Sets the follower distance scale factor 

SCLMAS............................ Sets the master distance scale factor 

SINAMP............................ Defines the amplitude of the internal sine wave 

SINANG............................ Defines the phase angle of the internal sine wave 

SINGO .............................. Initiates the internal sine wave 

TPSHF or [ PSHF ]........... Transfers or assigns the net position shift since constant ratio 

TPSLV or [ PSLV ]........... Transfers or assigns the current follower position 

TVMAS or [ VMAS ]........... Transfers or assigns the velocity of the master 


Master Cycle Concept 

Ratio Following can also address applications that require precise programming 

synchronization between moves and I/O control based on master positions or external 

conditions. The concept of the master cycle greatly simplifies the required synchronization. 

A master cycle is simply an amount of master travel over which one or more related follower 

axis events take place. The distance traveled by the master in a master cycle is called the 

master cycle length. A master cycle position is the master position relative to the start of the 

current master cycle. The value of master cycle position increases as positive-direction 

master cycle counts are received, until it reaches the value specified for master cycle length. 

At that point, the master cycle position becomes zero, and the master cycle number is 

incremented by one—this condition is called rollover. 

The master cycle concept is analogous to minutes and hours on a clock. If the master cycle is 

considered an hour, then the master cycle length is 60 minutes. The number of minutes past 

the hour is the master cycle position, and current hour is the master cycle number. In this 

analogy, the master cycle position decrements from 59 to zero as the hour increases by one. 

By specifying a master cycle length, periodic actions may be programmed in a loop or with 

subroutines which refer to cycle positions, even though the master may be running 

continuously. To accommodate applications where the feed of the product is random, the start 

of the master cycle may be defined with trigger inputs. Two types of waits are also 

programmable to allow suspension of program operation or follower moves based on master 

positions or external conditions. 

Master Cycle Commands 

Following Status (TFSF, TFS and FS) bits 13-16 indicate the status of master cycle counting. 

If a following application is taking advantage of master cycle counting, these bits provide a 

quick summary of some important master cycle information: 


13 Master Cyc Trig Pend .....A master cycle restart pending the occurrence of the specified trigger. 

14 Mas Cyc Len Given.........A non-zero master cycle length has been specified with FMCLEN. 

15 Master Cyc Pos Neg.......The current master cycle position (PMAS) is negative. This could be 

by caused by a negative initial master cycle position (FMCP), or if the 

master is moving in the negative direction. 

16 Master Cyc Num > 0 .......The master position (PMAS) has exceeded the master cycle length 

(FMCLEN) at least once, causing the master cycle number (NMCY) to 

increment. 

Master Cycle Length 

(FMCLEN); 

The FMCLEN command is used to define the length of the master cycle. The value entered 

with this command is scaled by the SCLMAS parameter to allow specification of the master 

cycle length in user units. This parameter must be defined before those commands which wait 

for periodically repeating master positions are executed. 

The default value of FMCLEN is zero, which means the master cycle length is practically 

infinite (i.e., 4,294,967,246 steps, after scaling). If a value of zero is chosen, the master cycle 

position will keep increasing until this very high value is exceeded or a new cycle is defined 

with the FMCNEW command (or triggered after a TRGFNcx1 command) described below. If a 

non-zero value for FMCLEN is chosen, the internally maintained master cycle position will 

keep increasing until it reaches the value of FMCLEN. At this point, it immediately rolls over 

to zero and continues to count. 

The master cycle length may be changed with the FMCLEN command even after a master cycle 

has been started. The new master cycle length takes affect as soon as it is issued. If the new 

master cycle length is greater than the current master cycle position, the cycle position will not 

change, but will rollover when the new master cycle length is reached. If the new master 


Example 

Code 

cycle length is less than the current master cycle position, the new master cycle position 

becomes equal to the old cycle position minus one or more multiples of the new cycle length. 

FMCLEN23 

; Set master cycle length: 

; (axis 1: 23 units 

Restart Master Cycle 

Counting (FMCNEW or 

TRGFNcx1xxxxxx); 

Once the length of the master cycle has been specified with the FMCLEN command, master 

cycle counting may be restarted immediately with the FMCNEW command, or based on 

activating a trigger input as specified with the TRGFNcx1 command. The new master cycle 

count is started at an initial position specified with the FMCP command (see below). 

When the TRGFNcx1 command is used, the restart of master cycle counting is pending 

activation of the specified trigger. If an FMCNEW command is issued while waiting for the 

specified trigger to activate, counting is restarted immediately with the FMCNEW command, 

and the TRGFNcx1 command is canceled. 

When using TRGFNcx1 

• Before the TRGFN command can be used, you must first assign the trigger interrupt function 

to the specified trigger input with the INFNCi-H command, where “i” is the input number of 

the trigger input desired for the function (input bit assignments vary by product). 

• Because the Gem6K program will not wait for the trigger to occur before continuing on with 

normal program execution, a WAIT or GOWHEN condition based on PMAS will not evaluate 

true if the restart of master cycle counting is pending the activation of a trigger. To halt 

program operation, the WAIT command can be used. 

A new master cycle will restart automatically when the total master cycle length (FMCLEN value) 

is reached. This is useful in continuous feed applications. 

Example 

Code 

FMCNEW1 

INFNC2-H 

1TRGFNBx1 

; Restart new master cycle counting 

; Assign input #2 (TRG-1B) the trigger interrupt 

; function (prerequisite to using the TRGFN features) 

; When trigger input 2 (TRG-1B) goes active, 

Initial Master Cycle 

Position (FMCP); 

The FMCP command allows you to assign for the first cycle only, an initial master cycle 

position to be a value other than zero. When master cycle counting is restarted with the 

FMCNEW command or with the trigger specified in the TRGFNcx1 command, the master cycle 

position takes the initial value previously specified with the FMCP command. The value for 

FMCP is scaled by SCLMAS if scaling is enabled (SCALE1) 

FMCP was designed to accommodate situations in which the trigger that restarts master cycle 

counting occurs either before the desired cycle start, or somewhere in the middle of what is to 

be the first cycle. In the former case, the FMCP value must be negative. The master cycle 

position is initialized with that value, and will increase right through zero until it reaches the 

master cycle length (FMCLEN). At that point, it will roll over to zero as usual. 

The continuous cut-to-length example below illustrates the use of a negative FMCP (a trigger 

that senses the motion of the master is physically offset from the master position at which 

some action must take place). If it is desired that the first cycle is defined as already partially 

complete when master cycle counting is restarted, the FMCP value must be greater than zero, 

but less than the master cycle length. 

To give a value for FMCP which is greater than master cycle length is meaningless since 

master cycle positions are always less than the master cycle length. The Gem6K responds to 

this case as soon as a new master cycle counting begins by using zero instead of the initial 

value specified with FMCP. 


Transfer and 

Assignment/ 

Comparison of Master 

Cycle Position and 

Number; 

The current master cycle position and the current master cycle number may be displayed with 

the TPMAS and TNMCY commands, respectively. These values may also be read into numeric 

variables (VAR) at any time using the PMAS and NMCY commands (e.g., VAR6=NMCY). If 

position capture is used, the master cycle position and be captured, and the value is available 

with the TPCMS and PCMS commands. 

Very often, the master cycle number will be directly related to the quantity of product produced 

in a manufacturing run, and the master cycle position can be used to determine what portion of 

a current cycle is complete. 

The master cycle number is sampled once per position sampling period (see note, left). If the 

master cycle length (FMCLEN) divided by the master's velocity (VMAS) is less than the 

position sampling period (2 ms), then the sample (TNMCY or NMCY value) may not be 

accurate. 

Details on using PMAS in conditional expressions is provided below in Using Conditional 

Statements with PMAS. 

Using Conditional 

Statements with 

Master Cycle Position 

(PMAS); 

The current master cycle position (PMAS) value may be used in comparison expressions, just 

like other position variables such as PC, PE, and FB. PMAS is a special case, however, because 

its value rolls over to zero when the master cycle length (FMCLEN) is met or exceeded. This 

means that PMAS values greater than or equal to the master cycle length will never be reported 

with the TPMAS command, or with expressions such as (VAR1=1PMAS). 

The other fact that makes PMAS special is that master cycle counting may be restarted after 

the command containing the PMAS expression has been executed. Either the FMCNEW 

command or the TRGFNcx1 command may be used to restart counting, each with a different 

effect on the evaluation of PMAS. 

The treatment of PMAS in comparison expressions depends on the command using the 

expression, as described below. WAIT and GOWHEN are treated as special cases. 

IF, UNTIL, and 

WHILE 

WAIT and GOWHEN 

These commands evaluate the current value of PMAS in the same way that TPMAS does (i.e., 

PMAS values will never be greater than or equal to the master cycle length). With these 

commands, avoid comparing PMAS to be greater than or equal to variables or constants which 

are nearly equal to the master cycle length, because rollover may occur before a PMAS sample 

is read which makes the comparison true. If such a comparison is necessary, it should be 

combined (using OR) with a comparison for master cycle number (NMCY) being greater than 

the current master cycle number. 

Also, master cycle counting restart may be pending activation of a trigger, but this will not 

affect the evaluation of PMAS for IF, WAIT, and WHILE. It is simply evaluated based on 

counting currently underway. 

These commands evaluate the current value of PMAS differently than TPMAS does, in such a 

way that it is possible to compare PMAS to variables or constants which are greater than or 

equal to the master cycle length and still have the comparison be reliably detected. 

Effectively, PMAS is evaluated as if the master cycle length were suddenly set to its maximum 

value (2 32 ) at the time the WAIT or GOWHEN command is encountered. It eliminates the need to 

OR the PMAS comparison with a comparison for master cycle number (NMCY) being greater than 

the current master cycle number. Such multiple expressions are not allowed in the GOWHEN 

command, so this alternative evaluation of PMAS offers the required flexibility. 

This method of evaluation of PMAS allows commands which sequence follower axis events 

through a master cycle to be placed in a loop. The WAIT or GOWHEN command at the top of 

the loop can execute, even though the actual master travel has not finished the previous cycle. 

If it is desired to WAIT or GOWHEN for a master cycle position of the next master cycle, the 

variable or constant specified in the command should be calculated by adding one master 

cycle length to the desired master cycle position. 


Finally, master cycle counting restart may be pending activation of a trigger (TRGFNcx1), 

and this will suspend the evaluation of PMAS for these commands. PMAS is not sampled, and 

the comparison evaluates as false. During this time, if the pending status of master cycle 

counting restart is aborted with FMCNEWØ, the GOWHEN condition is also cleared, and any 

motion profile of any axis waiting on that PMAS comparison will be canceled. Otherwise, 

when master cycle counting is restarted by a trigger, evaluation takes place as described 

above. This allows GOWHEN to include waiting on a trigger without explicitly including it in 

the GOWHEN expression. 

Synchronizing 

Following Moves with 

Master Positions 

A final special case allows perfect synchronization between the start of a Following motion 

profile of a follower axis and a specified position of its master. If a GOWHEN(1PMAS >= x) 

expression is used to synchronize a follower with its own master, with the operator specifically 

“>=”, a special synchronization occurs. Although it may be impossible for the Gem6K product 

to sample the exact master position specified, the Following motion profile is calculated from 

master travel based on that position. This allows for the construction of profiles in which the 

synchronization of master and follower positions is well defined and precisely maintained. 

This feature requires positive travel of the master, which can be achieved with the appropriate 

sign for the FOLMAS specification. 

Summary of Master Cycle and Wait Commands 

FMCLEN................................ Defines the length of the master cycle 

FMCNEW................................ Immediately restart master cycle counting 

FMCP .................................... Defines the initial position of a new master cycle 

GOWHEN................................ GOWHEN suspends execution of the next move on the specified axis until 

the specified conditional statement (based on T, IN, LIM, FB, NMCY, PC, 

PE, PMAS, PSLV, or PSHF) is true 

TNMCY or [ NMCY ].............. Transfers or assigns the current master cycle number 

TPCMS or [ PCMS ]............... Transfers or assigns the captured master cycle position 

TPMAS or [ PMAS ].............. Transfers or assigns the current master cycle position 

TRGFN.................................. aTRGFNc1x initiates a GOWHEN, suspending execution of the next 

follower move on axis (a) until the specified trigger input (c) goes active. 

aTRGFNcx1 causes master cycle counting to restart when the specified 

trigger input (c) goes active. 

WAIT .................................... WAIT suspends program execution until the specified conditional 

statement (based on PMAS, FS, NMCY, PCMS, PSHF, PSLV, or VMAS) is 

true; 

WAIT(SS.i=b1) suspends program execution until a trigger input is 

activated. The “i” is the programmable input bit number corresponding 

to the trigger input. (Input bit assignments vary by product; refer to the 

Programmable I/O Bit Patterns table on page 91 to determine the 

correct bit pattern for your product.) 

AS and TAS bit #26............... AS and TAS (and TASF) bit #26 is set when there is a profile suspended 

pending GOWHEN condition, initiated either by a GOWHEN command or a 

TRGFNc1 command; this bit is cleared when the GOWHEN condition is 

true or when a stop or kill command is issued. 

ER and TER bit #14............... ER, TER, and TERF bit #14 is set if the GOWHEN condition is already true 

when the GO, GOL, FGADV, FSHFC, or FSHFD command is given (ERROR 

bit #14 must first be enabled to check for this condition) 

NOTE 

The continuous cut-to-length application example below illustrates the use of the master 

cycle concept and the commands above. 


Technical Considerations for Following 

Keep in mind that 

in all cases, the 

follower position is 

calculated from a 

sampled master 

position. 

In the introduction to Following (see page 168), the algorithm for Gem6K Following was 

briefly discussed. Here we will address some of the more technical aspects of Following: 

• Performance 

• Master Position Prediction 

• Master Position Filtering 

• Following error 

• Maximum acceleration and velocity (stepper axes only) 

• Factors affecting Following accuracy 

• Preset vs. Continuous Following moves 

• Master and follower axis distance calculations 

• Using other features with Following 

Performance Considerations 

When a follower axis is following a master, the Gem6K does not simply measure the master 

velocity to derive follower axis velocity. Instead, the Gem6K samples the master position 

(position sampling period = 2 ms) and calculates the corresponding follower axis position 

command. This is true even if the follower axis is in the process of changing ratios. A follower 

axis is not simply following velocity, but rather position. With this algorithm, the master and 

follower position or phase relationship is maintained indefinitely, without any drift over time due 

to velocity measurement errors. 

The Gem6K also measures master velocity by measuring the change in master position over a 

number of sample periods. The present master velocity and position may be used to calculate 

the next commanded follower position, so the follower has no velocity-dependent phase 

delay. This concept is known as Master Position Prediction and may be enabled or disabled 

as needed with the FPPEN command. 

The Gem6K's default Following algorithm should work well for most applications; however, 

you can change the Following algorithm to meet application-specific needs. For instance, 

suppose that the speed of the master is very slow, or has some vibration. For a case like this, 

the Gem6K allows you to filter the master position signal to generate a smooth follower 

position command. This is known as Master Position Filtering and is programmed with the 

FFILT command. 


Master Position Prediction 

Master Position Prediction is a technique used to compensate for the fact a follower's position 

command cannot be calculated and implemented infinitely fast. 

The master position prediction mode is enabled by default (FPPEN1) in the Following 

algorithm, but can be turned off as desired with the FPPENØ command. 

The Gem6K measures master position once per position sampling period (2 ms), and 

calculates a corresponding follower position command. This calculation and achieving the 

subsequent follower commanded position requires 2 sample periods (4 ms). 

If master position prediction mode is disabled (FPPENØ), waiting 2 sample periods results in 

a follower position lag. That is, by the time the follower reaches the position that corresponds 

to the sampled master position, 2 sample periods have gone by, and the master may be at a 

new position. Measured in time, the lag is 2 sample periods. Measured in position, the lag is 

2 sample periods ∗ current follower velocity. 

For example, suppose the follower is traveling at a speed of 25000 counts per second. If 

master position prediction mode is disabled (FPPENØ), the follower will lag the master by 

100 counts (25000 counts/sec ∗ 4 ms = 100 counts). 

By measuring the change in master position over sequential sample periods, the master's 

present velocity is calculated. The present master velocity and position are used to predict 

future master position. If master position prediction mode is enabled (FPPEN1, the predicted 

future master position is used to determine the follower's position command. In this case the 

follower has no velocity-dependent phase delay. The follower's velocity for a given sample 

will always be the velocity required to move from its current position to the next calculated 

position command. 

If the master motion is fairly smooth and velocity is not very slow, the measurement of its recent 

velocity will be very accurate, and a good way of predicting future position. But the master 

motion may be rough, or the measurements may be inaccurate if there is no filtering (see Master 

Position Filtering below). In this case, the predicted master position and the corresponding 

follower position command will have some error, which may vary in sign and magnitude from 

one sample to the next. This random variation in follower position command error results in 

rough motion. The problem is particularly pronounced if there is vibration on the master. 

It may be desirable to disable the master position prediction mode (FPPENØ) when maximum 

follower smoothness is important and minor phase delays can be accommodated. 

If master filtering is enabled (FFILT_Ø), then the prediction algorithm would be used on the 

filtered master position, resulting in a smoother follower position command. However, due to 

the delay introduced by the filtering, the prediction algorithm would not compensate for the 

total delay in the follower's tracking command. (See also Master Position Filtering below.) 

Following Status (TFSF, TFS, and FS) bit 17 indicates the status of where or not the master 

position prediction mode is enabled. 

Master Position Filtering 

The follower axis' position command is calculated at each position sample period (2 ms). This 

calculation is a function of the master position and the master velocity estimated from the 

change in master position over 2 position sample periods. 

The Master Position Filter feature allows you to apply a low-pass filter to the measurement of 

master position. Master position filtering is used in these situations: 

• Measurement of master position is contaminated by either electrical noise (when analog 

input is the master) or mechanical vibration. 

• Measurement noise is minimal, but the motion that occurs on the master input is 

oscillatory. In this case, using the filter can prevent the oscillatory signal from 

propagating into the follower axis (i.e., ensuring smoother motion on the follower axis). 


The bandwidth of the low-pass filter is controlled with the FFILT command: 

FFILT Setting 

Low pass Filter Bandwidth 

Ø infinite (no filtering) – default setting 

1 120 Hz 

2 80 Hz 

3 50 Hz 

4 20 Hz 

When considering whether or how much master position filtering to use, consider the 

application requirement itself. The application requirements related to filtering can be 

categorized into these three types: 

Type I: 

Type II: 

Type III: 

If an application requires smooth motion but also high follower tracking accuracy, 

then a heavy filtering should not be used. It should not be used because it may 

introduce too much velocity phase lag, although the motion may be smooth. In 

other words, the master axis in the first place should produce very smooth motion 

and low sensor measurement noise such that a higher level of master filtering is 

not needed. 

If follower axis velocity tracking error is not critical but smooth follower axis 

motion is desired, then you can use a higher level of master filtering to deal with 

sensor noise or master vibration problems. 

If it is determined that under certain dynamic conditions the master position's 

oscillatory measurement is purely caused by its vibration motion (noise is 

insignificant), and it is necessary for the follower to follow such motion, then the 

filter command should not be used or only use the highest bandwidth (FFILT1). 

Following Status (TFSF, TFS, and FS) bit 18 indicates the status of master position filtering. 

Following Error 

As soon as an axis becomes configured as a follower, the follower's position command is 

continuously updated and maintained. At each update, the position command is calculated 

from the current master position and velocity, and the current ratio or velocity of the follower. 

Whenever the commanded position is not equal to the actual follower position, a Following 

error exists. This error, if any, may be positive or negative, depending on both the reason for 

the error and the direction of follower travel. Following error is defined as the difference 

between the commanded position and the actual position. 

Following Error = Commanded position - Actual position 

If the follower is traveling in the positive direction and the actual position lags the 

commanded position, the error will be positive. If the follower is traveling in the negative 

direction and the actual position lags the commanded position, the error will be negative. This 

error is always monitored, and may be read into a numeric variable (VAR) at any time using 

the PER command. The error value in follower steps is scaled by SCLD for the axis. This 

value may be used for subsequent decision making, or simply storing the error corresponding 

to some other event. 


Maximum Velocity and Acceleration 

(Stepper Axes Only) 

The follower's attempt to faithfully follow the master may command velocities and 

accelerations that the follower axis is physically not able to complete. Therefore, the FMAXV 

and FMAXA commands are provided to set the maximum velocity and acceleration at which 

the follower will be allowed to move. 

If the follower is commanded to move at rates beyond the defined maximums, the follower 

will begin falling behind it's commanded position. If this happens, a correction velocity will 

be applied to correct the position error as soon as the commanded velocity and acceleration 

fall within the limitation of FMAXV and FMAXA. 

The FMAXA and FMAXV commands should be used only to protect against worst case 

conditions, and should be avoided altogether if they are not needed. If an axis is not able to 

follow its profile because of limitations imposed by these commands, some correction motion 

will occur. If the maximum acceleration (FMAXA value) is set very low, some oscillation 

about the commanded position may occur because the follower is not allowed to decelerate 

fast enough to prevent overshoot. 

Factors Affecting Following Accuracy 

There are additional accuracy requirements of Following applications beyond those of 

standard positioning. The follower axis must maintain positioning accuracy while in motion, 

not just at the end of moves, because it is trying to stay synchronized with the master. 

Assuming parameters such as master and follower scaling and ratios have been specified 

correctly, the overall positioning accuracy for an application depends on several factors: 

• Resolution of the master 

• Resolution of the follower axis 

• Position sampling accuracy 

• Accuracy of the follower axis motor and drive 

• Accuracy of load mechanics 

• Master position prediction 

• Master velocity relative to master position prediction & master position filtering 

• Tuning (servo axes only) 

• Repeatability of the trigger inputs and sensors 

Just as with a mechanical arrangement, the accuracy errors can build up with every link from 

the beginning to the end. The overall worst case accuracy error will be the sum of all the 

sources of error listed below. The errors fall into two broad categories, namely, master 

measurement errors and follower errors. These both ultimately affect follower accuracy, 

because the commanded follower position is based on the measured master position. 

It is important to understand how master measurement errors result in follower position errors. 

In many applications, master and follower units will be the same (e.g., inches, millimeters, 

degrees). These applications will require linear speeds or surface speeds to be matched (i.e., a 

1:1 ratio). For example, suppose that in a rotary knife application, there were 500 master 

steps per inch of material, so an error in master measurement of one encoder step would result 

in 0.002 inches of follower position error. 

If the master and follower units are not the same, or the ratio is not 1:1, the master error times 

the ratio of the application gives the follower error. An example would be a rotary master and 

a linear follower. For instance, suppose one revolution of a wheel gives 4000 master counts, 

and results in 10 inches of travel on the follower. The ratio is then 10 inches/revolution. The 

follower error which results from one step of master measurement error is (1/4000) ∗ 10 

inches/revolution = 0.0025 inches. 


Resolution of the 

Master; 

Resolution of the 

Follower; 

Position Sampling 

Accuracy; 

Accuracy of the 

Follower Motor and 

Drive; 

Accuracy of the 

Load Mechanics 

Master Position 

Prediction; 

The best case master measurement precision is the inverse of the number of master steps per 

user's master unit. For example, if there are 100 master steps/inch, then the master 

measurement precision is 0.01 inches. Even if all other sources of error are eliminated, 

follower accuracy will only be that which corresponds to 1 step of the master (e.g., 0.01 inches 

in the previous example). 

The best case follower axis precision is the inverse of the number of follower steps per user's 

position unit. For example, if there are 1000 follower steps/inch, then the follower resolution is 

0.001 inches. Even if all other sources of error are eliminated, follower positioning accuracy 

will only be that which corresponds to 1 step of the follower. This must be at least as great as 

the precision required by the application. 

The position sampling rate for the Gem6K depends on whether it is a servo or a stepper. The 

sample period for is 2 ms. 

The repeatability of the sampling rate, from one sample to the next, may vary by as much as 

100 µs. This affect may be eliminated by using non-zero master position filter (FFILT) 

command values. Otherwise, measurement of master position may be off by as much as (20 to 

100 microseconds ∗ master speed). This may appear to be a significant value at high master 

speeds, but it should be noted that this error changes in value (and usually sign) every sample 

period. It is effectively like a noise of 200-600 Hz; if the mechanical frequency response of the 

motor and load is much less than this frequency, the load cannot respond to this error. 

The precision also depends on how accurately the drive follows its commanded position while 

moving. Even if master measurement were perfect, if the drive accuracy is poor, the precision 

will be poor. 

In the case of stepper drives, this amounts to the specified motor/drive accuracy. 

In the case of servo drives, the better the drive is tuned for smoothness and zero Following 

error, the better the precision of the positioning. Often, this really only matters for a specific 

portion of the profile, so the drive should be tuned for zero Following error at that portion. 

The accuracy (not repeatability) of the load mechanics must be added to the overall build up of 

accuracy error. This includes backlash for applications which involve motion in both 

directions. 

The master position prediction mode may be enabled or disabled with the FPPEN command, 

but each state contributes a different error. 

Disabled (FPPENØ): The follower position command is based on a master position that is 2 

sample periods (4 ms) old. This means that master measurement error due to 

disabling the position prediction mode will be (2 sample periods ∗ master speed). 

Enabled (FPPEN1): If the position prediction mode is enabled (default setting), its accuracy is 

also affected by position sampling accuracy, master speed, and master position 

filtering. The error due to enabling the position prediction mode is about twice that 

due to sampling accuracy (i.e., 40 to 200 microseconds ∗ master speed). As with the 

error due to position sampling accuracy, the error due to the position prediction mode 

being enabled is like a noise on the order of 200-600 Hz, which is not noticed by 

large loads. 


Master Velocity 

Relative to Master 

Position Prediction; 

Variation in Master Velocity: Although increasing master position filtering (increasing the 

FFILT command value) eliminates the error due to sampling accuracy, it increases the error 

due to variations in master speed when the master position prediction mode is enabled 

(FPPEN1). 

Most applications maintain a constant master speed, or change very slowly, so this effect is 

minimal. But if the master is changing rapidly, there may be a significant master speed 

measurement error. Because predicted master positions are in part based on master speed 

measurement, the can result in an error in master position prediction mode (FPPEN1). This 

effect will always be smaller than that due to the master position prediction mode being 

disabled (FPPENØ). 

Tuning; 

(Servo Axes Only) 

A servo system’s tuning has a direct impact on how well the follower axis can track the master 

input. Overshoot, lag, oscillation, etc., can be devastating to Following performance. The best 

tool to use for tuning the Gem6K series controller is Motion Planner’s Gemini Servo Tuner 

utility. 

Repeatability of the 

Trigger Inputs and 

Sensors; 

Some applications may use the trigger inputs for functions like registration moves, GOWHENs, 

or new cycles. For these applications, the repeatability of the trigger inputs and sensors add to 

the overall position error. 

Refer to page 99 for accuracy specifications on the trigger input position capture function. 

Refer to your sensor manufacturer’s documentation for the sensor repeatability. In the Gem6K 

controller, the position capture from the trigger inputs have approximately 100 µs 

repeatability, and the sensor repeatability (SR) should be determined, too. Velocity ∗ time = 

distance, so the error due to repeatability is (SR + 0.0001 seconds) ∗ speed = error. If the 

sensor repeatability is given in terms of distance, that value can be added directly. 

Preset vs. Continuous Following Moves 

When a follower performs a preset (MCØ) move in Following mode (FOLEN1), the 

commanded position is either incremental or absolute in nature, but it does have a commanded 

endpoint. The direction traveled by the follower will be determined by the commanded 

endpoint position, and the direction the master is counting. 

Let’s illustrate this with an example. Assume all necessary set-up commands have been 

previously issued for our follower (axis #1) and master so that distances specified are in 

revolutions: 

FOLRN3 ; Set Following follower-to-master ratio numerator to 3 

FOLRD4 ; Set Following follower-to-master ratio denominator to 4 

; (ratio is 3 revs on the follower to 4 revs on the master) 

FOLEN1 ; Enable Following on axis #1 

FOLMD10 ; Set preset move to take place over 10 master revolutions 

MC0 

; Set follower to preset positioning mode 

MA1 

; Set follower to absolute positioning mode 

PSET0 ; Set current absolute position reference to zero 

D5 

; Set move distance to absolute position 5 revolutions 

GO1 ; Initiate move to absolute position 5 

If the master is stationary when the GO1 command is executed, the follower will remain 

stationary also. If the master begins to move and master pulses are positive in direction, the 

follower will begin the preset move in the positive direction. If the master pulses stop arriving 

before 10 master revolutions have been traveled, the follower will also stop moving, but that 

GO1 command will not be completed. If the master then starts to count in the negative 

direction, the follower will follow in the negative direction, but only as far as it's starting 

position. If the master continues to count negative, the follower will remain stationary. The 


GO1 command will not actually be completed until the master has traveled at least 10 

revolutions in the positive direction from where it was at the time the GO1 command was 

executed. If the master oscillates back and forth between it's position at the start of the GO1 

command to just under 10 revolutions, the follower will oscillate back and forth as well. 

The master must be counting in the positive direction for any preset (MCØ) GO1s commanded 

on the follower to be completed. If mechanics of the system dictate that the count on the 

source of the master pulses is negative, a minus (-) sign should be entered in the FOLMAS 

command so that Gem6K sees the master counts as positive. 

Continuous follower moves (MC1) react much differently to master pulse direction. Whereas a 

preset move will only start the profile if the master counts are counting in the positive 

direction, a continuous move will begin the ramp to its new ratio following the master in either 

direction. As long as the master is counting in the positive direction, the direction towards 

which the follower starts in a continuous move is determined by the argument (sign) of the D 

command. The follower direction is positive for D+ and negative for D-. 

If the master is counting in the negative direction when follower begins a continuous move, 

the direction towards which the follower moves is opposite to that commanded with the D 

command. The follower direction is positive for D- and negative for D+. 

If the master changes direction during a continuous follower move, the follower will also 

reverse direction. As with standard continuous moves, the GO1 will continue until terminated 

by S, K, end-of-travel limits, stall condition, or command to go to zero velocity. As with 

preset moves, the sign on the FOLMAS command determines the direction of master counting 

with respect to the direction of actual counting on the master input. 

Master and Follower Distance Calculations 

The formulas below show the relationship between master move distances and the 

corresponding follower move distances. These relationships may be used to assist in the 

design of Following mode moves in which both the position and duration of constant ratio are 

important. 

In such calculations, it is helpful to use SCLMAS and SCLD values which allow the master and 

follower distances to be expressed in the same units (e.g., inches or millimeters). In this case, 

many applications will be designed to reach a final ratio of 1:1, and the distances in these 

figures can be easily calculated. 

☞ HINT: For a trapezoidal preset follower axis move with a maximum ratio of 1:1, the 

master and follower distances during the constant ratio portion will be the same. The 

follower travel during acceleration will be exactly half of the corresponding master travel, 

and it will also occur during deceleration. 

Master Distance (FOLMD) 

The FOLMD command determines the master distance over which the acceleration (mode 

continuous moves – MC1) or the entire move (preset moves – MCØ) takes place. If the 

follower axis is in continuous positioning mode (MC1), FOLMD is the master distance over 

which the follower axis is to accel or decel from the current ratio to the new ratio. If the 

follower axis is in preset positioning mode (MCØ), FOLMD is the master distance over which 

the follower's entire move will take place. 

When the Follower is in Continuous Positioning Mode (MC1) 

D = FOLMD * (R 2 + R 1 ) 

2 

where: 

FOLMD = Master distance 

R 2 = New ratio (FOLRN ÷ FOLRD) 

R 1 = Current ratio (FOLRN ÷ FOLRD) 

D = Follower distance traveled during ramp 


When the Follower is in Preset Positioning Mode (MCØ) 

Trapezoidal 

Follower Moves 

D max = (FOLMD * R max ) 

D 1 = (D max - D) 

2 

MD 1 = 2 * D 1 

R max 

D 2 = D - (2 * D 1 ) 

MD 2 = D 2 

R max 

FOLMD = (2 * MD 1 ) + MD 2 

where: 


MD 1 = Master distance during accel & decel ramps 

MD 2 = Master distance during constant ratio 

D = Total follower axis preset distance commanded 

D 1 = Follower travel during accel and decel ramps 

D 2 = Follower travel during constant ratio 

D max = Maximum follower distance possible 

(assuming no accel or decel) 

R max = Maximum ratio = FOLRN ÷ FOLRD 

These Profiles 

depict ratio vs. 

distance 

Trapezoidal profile if: 

D = (D 2 + 2 * D 1 ) < D max 

Rectangular profile if: 

D 2 = D 

D 1 = zero 

MD 2 = FOLMD 

MD 1 = zero 

R max 

Ratio Ratio 

R max 

D 1 D 2 D 1 

MD 1 MD 2 MD 1 

Distance 

D 2 

MD 2 

Distance 

Triangular 

Follower Moves 

D = R peak * FOLMD 

2 

where: 


R peak = Peak ratio reached during move 

D = Total follower distance 

Triangular profile if: 

R max 

D < 1/2 D max 

Ratio 

D 

R peak 

This Profile depicts 

ratio vs. distance 

FOLMD 

Distance 

Distance 

Calculation 

Example 

In the example below, the desired travel during constant ratio is already contained in numeric 

variable #1 (VAR1), and may have been read from thumbwheels or a DATA command. The 

corresponding follower move distance (D) and FOLMD are calculated as shown: 

VAR2=2 

; Desired follower travel during accel and decel combined 

VAR3=2 * VAR2 ; Required master travel during these ramps 

VAR4=VAR1 + VAR2 ; Move distance is constant ratio portion plus ramps 

VAR5=VAR1 + VAR3 ; Master travel for entire follower move 

FOLMD(VAR5) ; Establish calculated master travel 

D(VAR4) 

; Establish calculated follower travel 

GO1 

; Make desired follower move 

Similar calculations may be done for a series of continuous move ramps to ratios, separated 

by GOWHEN for master cycle positions. These ramps may be repeated in a loop to create a 


continuous cyclical follower profile.. 

Beware of Roundoff 

Error (Scaling only) 

Some potential for roundoff error exists if the scaling of a move distance or master distance by 

SCLD and SCLMAS does not result in an integer number of steps. Some additional care must 

be taken in the segment by segment construction of profiles using ramps to continuous ratio. 

The Gem6K maintains a follower position command which is calculated from the commanded 

constant ratios, the ramps to the new ratios, and the master travel over which these take place. 

At the end of each ramp or constant ratio portion, this commanded position is calculated to the 

nearest integer follower step. If the ratios and master travel result in a non-integer follower 

travel for a segment, the fractional part of that segment's calculated travel will be lost. In a 

cyclical application, repeated truncations could build up to a significant error. This may be 

avoided through careful attention to design of the profile. 

Using Other Features with Following 

The Gem6K has many features that may be used in the same application as its Following 

features. In some cases, having configured an axis as a follower with the FOLMAS command 

will affect, or be affected by, the operation of other features, as described below. 

Setups used by 

FOLMAS 

(Stepper Axes Only) 

S (Stop) & K (Kill) 

Commands 

The FOLMAS command uses the drive resolution (DRES) and the velocity range (PULSE) data 

to configure an axis as a follower. In order for this data to be used correctly, these commands 

must be given before FOLMAS. These commands are not allowed after FOLMAS is given. 

After FOLMAS is executed, the MC command may be used to change from incremental to 

absolute positioning and back. 

Stop (S) and Kill (K) commands cause the follower to do a non-Following decel, even if the 

follower is in Following mode. A stop or a kill, buffered or immediate, will clear a pending 

GOWHEN condition (clears AS bit #26). 

Kill Conditions 

GO Command 

Registration 

Moves 


Under default operation (FOLK0), certain error conditions (i.e., drive fault input active, or max. 

position error limit exceeded) will cause the Gem6K to disable the drive and kill the Following 

profile (follower’s commanded position loses synchronization with the master). 

If you enable Following Kill (FOLK1), these error conditions will still disable the drive 

(DRIVE0), but will not kill the Following profile. Because the Following profile is still running, 

the controller keeps track of what the follower’s position should be in the Following trajectory. 

To resume Following operation, resolve the error condition (drive fault, excessive position 

error), enable the drive (DRIVE1), and command the controller to impose a shift to compensate 

for the lapse/shift that occurred while the drive was disabled and the follower was not moving. 

To impose the shift, assign the negative of the internally monitored shift value (PSHF) to a 

variable (e.g., VAR1 = -1 * PSHF) and command the shift using a variable substitution in the 

FSHFD command (e.g., FSHFD(VAR1)). 

The FOLK command only preserves Following profiles; normal velocity-based profiles will be 

killed regardless of the FOLK command. 

If a follower axis is in Following mode (FOLEN1), moves will ramp to a ratio (set with FOLRN 

and FOLRD). If it is not in Following mode, moves will ramp to a velocity (V). Switching in 

and out of Following mode does not change the value for final ratio or final velocity goals, but 

simply changes which parameter is used as the goal. 

Registration inputs may be enabled with the INFNCi-H command while an axis is a follower, 

and registration moves may interrupt either a Following mode move or a time-based move. 

The registration move itself, however, is always a time based move, and implements the 

registration velocity with respect to a stationary reference. Any trigger input may be used as a 

registration input or for any Following feature which uses triggers, even at the same time. 


Enter/Exit 

Following Mode 

While Moving 

Pause and 

Continue 

TVEL and TVELA 


TASF, TAS & AS 

Axis Status Bits 

Changing 

Feedback Sources 

(Servo Axes only) 

Following and 

Other Motion 

Conditional 

Statements Using 

PMAS 

The FOLENØ command may be executed while a follower axis is moving at constant ratio. In 

this case, the current velocity becomes the constant velocity, and the follower may accelerate 

or decelerate to other velocities. The FOLEN1 command may not be executed while the 

follower axis is moving in the non-Following mode. Attempting to do so will result in the 

error response “MOTION IN PROGRESS”. 

A program may be paused and continued, even if configured as a follower. The program does 

not lose track of the master input, even though motion is stopped. As usual, if a program 

finishes normally, or if COMEXS is set to zero (COMEXSØ), the program may not be continued. 

If a program is resumed, partially completed Following moves will be completed; however, the 

remainder of the move is completed over the entire original master distance (FOLMD value). 

The TVEL and VEL commands have always reported an unsigned value (i.e. magnitude), 

consistent with the fact that the V command is always positive, even if the move direction is 

negative. When Following is enabled (FOLEN1), TVEL and VEL report the net magnitude of 

commanded velocity due to following and/or shifting. For example, if the follower axis is 

Following in the positive direction at 1 rps, TVEL reports 1.000. If a shift in the negative 

direction of 1.5 rps is then commanded, TVEL will report 0.5 – still positive, even though the 

net direction is negative. 

By contrast, TVELA and VELA have always been signed. In the above example, TVELA will 

report -0.5. 

Axis Status (TASF, TAS and AS) bits 1-4 represent the motion status of an axis. Bits 1 and 2 

represent the moving and direction status of the net motion of an axis, including the 

combination of following and shifting. 

Bits 3 and 4 represent acceleration and velocity, respectively. With Following disabled 

(FOLENØ), the accel and velocity can only be due to a commanded time-based profile. With 

Following enabled (FOLEN1), the net commanded velocity and accel could be due to 

following the master and/or a simultaneous shift (time-based profile). Bits 3 and 4 only reflect 

the acceleration and velocity status of the time-based profile, not the combined command. 

For example, if the follower axis is Following in the positive direction at 1 rps, TAS reports 

1ØØØ. If a continuous shift (FSHFC2) of 0.8 rps in the negative direction is then commanded, 

TAS will report 1Ø1Ø, while the shaft is decelerating to 0.2 rps. When the continuous shift 

velocity is reached, TAS will report 1ØØ1. 

Changing feedback sources (SFB) may result in a follower axis Following its own feedback. 

For this reason, changing feedback sources is not allowed while a master is specified 

(FOLMAS). 

Following motion is initiated with the GO command, just like normal motion. Other motion, 

which does not depend on the motion of an external master, may not be used while a follower 

axis is in Following mode (FOLEN1). These motion types include jog mode, joystick mode, 

and homing. To use these motion types, Following must be disabled (FOLENØ) — see 

Enter/Exit Following Mode While Moving above for precautions. 

The master cycle position (PMAS) value may be used in the comparison argument of these 

commands: 

• WAIT & GOWHEN: If it is desired to WAIT or GOWHEN on a master cycle position of the 

next master cycle, one master cycle length (value of FMCLEN) should be added to the 

master cycle position specified in the argument. This allows commands that sequence 

follower axis events through a master cycle to be placed in a loop. The WAIT or 

GOWHEN command at the top of the loop could execute, even though the actual master 


travel had not finished the previous cycle. This is done to allow a PMAS value which is 

equal to the master cycle length to be specified and reliably detected. 

• IF, UNTIL, & WHILE: These arguments use the instantaneous PMAS value. Be careful 

to avoid specifying PMAS values that are nearly equal to the master cycle length 

(FMCLEN), because rollover may occur before a PMAS sample is read. 

Compiled Motion 

Following profiles may be pre-compiled to save processing time. For details, refer to 

page 142. 

Troubleshooting for Following (see also Chapter 8) 

Following applications are often more complex than others, because motion of the followers is programmed as a function 

of the motion of the master. This requires the motion of the master to be well characterized and accurately specified in the 

program. It often requires an unfamiliar way of thinking about the motion of the desired follower. The table below offers 

some possible reasons for troubles which may be encountered in achieving the desired follower motion. 

Symptom 

Follower does not follow master 

Follower motion is 

Ratio seems wrong 

Follower profile wrong, or unrepeatable 

Master/follower alignment drifts over 

many cycles 

Follower lags Following position 

(steppers only) 

Possible Causes 

• Improper FOLMAS 

• Poor connection if master is encoder 

• Master running backward 

• No encoder power (when the encoder is selected as the master) 

• FFILT command value too low 

• Unnecessary FPPEN amplifies master roughness 

• FOLRN and FOLRD follower-to-master ratio values are inaccurate, 

possibly reversed 

• SCLD or SCLMAS wrong 

• Following limited by FMAXV or FMAXA (steppers only) 

• WAIT used where GOWHEN should be 

• Too little master travel between GOWHEN and GO1, desired PMAS is 

missed 

• Roundoff error due to fractional steps resulting from SCLD or SCLMAS 

and user's parameters 

• Ratios and master distances specified result in fractional follower 

steps covered during ramps, constant ratio 

• Inhibited by FMAXV 

• FMAXA clips acceleration peaks resulting from attempt to follow rough 

master 



If an illegal programming condition is discovered while programming or executing programs, the Gem6K responds with an 

error message. If a program execution error is detected, the program is aborted. 

The table below lists all the error messages that relate to Following, and indicates the command and cause that may 

generate them. These error messages are displayed only if the error level is set to level 4 with the ERRLVL4 command 

(this is the default setting). 

Error Message 

FOLMAS NOT SPECIFIED 

INCORRECT DATA 

INVALID CONDITIONS FOR 

COMMAND 

INVALID DATA 

Cause 

No FOLMAS for the axis is currently specified. It will occur if FMCNEW, FSHFC, or 

FSHFD commands are executed and no FOLMAS command was executed, or 

FOLMASØ was executed. 

Velocity (V), acceleration (A), or deceleration (AD) command is zero. (used by 

FSHFC & FSHFD) 

The FOLMD command value is too small to achieve the preset distance and still 

remain within the FOLRN/FOLRD ratio. 

A command phase shift cannot be performed: 

FSHFD.............Error if already shifting or performing other time based move. 

FSHFC.............Error if currently executing a FSHFD move, or if currently executing another 

FSHFC move in the opposite direction. 

The FOLEN1 command was given while a profile was suspended by a GOWHEN. 

The parameter supplied with the command is invalid. 

FFILT.............Error if: smooth number is not 0-4 

FMCLEN...........Error if: master steps > 999999999 or negative 

FMCP...............Error if: master steps > 999999999 or 999999999 or negative 

FOLRD.............Error if: master steps > 999999999 or negative 

FOLRN.............Error if: follower steps>999999999 or negative 

FSHFC.............Error if: number is not 0-3 

FSHFD.............Error if: follower steps>999999999 or 999999999 or 999999999 or 127 when a GO is executed. 

Attempting a preset Following move with a FOLMD value that is too small. 

The FOLEN1 command was given while that follower was moving in a non-Following 

mode. 

A GO command was given while moving in the Following mode (FOLEN1) and while 

in the preset positioning mode (MCØ). 

A GO command was given while moving in a Following ramp and while in the 

continuous positioning mode (MC1). Following status (FS) bit #3 will be set to 1. 


Following Commands 

Detailed information about these commands is provided in the 

Gem6K Series Command Reference. 

ANIMAS ........................Assigns an analog input to be used as a master in a FOLMAS assignment (requires a ANI SIM located on an 

expansion I/O brick). 

ERROR...........................Enable bit #14 to check for when a GOWHEN condition is already true when a subsequent GO, GOL, FGADV, 

FSHFC, or FSHFD command is given. 

ERRORP ........................ If ERROR bit #14 is enabled, a GOSUB branch to the error program occurs if a GOWHEN condition is already 

true when a subsequent GO, GOL, FGADV, FSHFC, or FSHFD command is given. 

FFILT...........................Sets the bandwidth for master position filtering. 

FGADV...........................Defines the geared advance distance. 

FMAXA...........................Stepper axes only: Sets the max. acceleration a follower may use while Following. 

FMAXV...........................Stepper axes only: Sets the max. velocity at which a follower may travel. 

FMCLEN ........................Defines the length of the master cycle. 

FMCNEW ........................Restarts new master cycle counting immediately. To make this a trigger-based operation instead of issuing 

the FMCNEW command, use the TRGFNcx1 command. 

FMCP.............................Defines the initial position of a new master cycle. 

FOLEN...........................Enables or disables Following mode. 

FOLK.............................Allows drive fault or maximum position error to disable drive without killing the Following profile. 

FOLMAS ........................Defines master for follower. 

FOLMD...........................Defines the master distance over which ratio changes or moves are to take place. 

FOLRD...........................Establishes the DENOMINATOR ONLY for the max. follower-to-master ratio for a preset move or the final 

ratio for a continuous move (use in combination with the FOLRN command). 

FOLRN...........................Establishes the NUMERATOR ONLY for the max. follower-to-master ratio for a preset move or the final 

ratio for a continuous move (use in combination with the FOLRD command). 

FPPEN...........................Allows master position prediction to be enabled or disabled. 

FSHFC...........................Allows continuous advance or retard (shift) of follower position during continuous Following moves. 

FSHFD...........................Allows preset advance or retard (shift) of follower position during continuous Following moves. 

FVMACC ........................Establishes the rate at which the virtual master count frequency (FVMFRQ) may change for an axis. 

FVMFRQ ........................Defines the frequency of the virtual master count. 

GOWHEN ........................ A GOWHEN command suspends execution of the next follower move until the specified conditional statement 

(based on T, IN, LIM, PC, PE, PMAS, PSLV, or PSHF) is true. To make this a trigger-based operation 

instead of issuing the GOWHEN command, use the TRGFNc1x command. 

SCLD.............................Sets the follower distance scale factor. 

SCLMAS ........................Sets the master scale factor. 

SINAMP ........................Defines the amplitude of the internal sine wave. 

SINANG ........................Defines the phase angle of the internal sine wave. 

SINGO...........................Initiates the internal sine wave. 

TRGFN...........................aTRGFNc1x initiates a GOWHEN. Suspends execution of the next follower move on follower axis (a) until the 

specified trigger input (c) goes active. 

aTRGFNcx1 allows master cycle counting to be restarted on axis (a) when the specified trigger input (c) 

goes active. 


Status and Assignment Commands: 

TASF, TAS & [ AS ]......Bit 26 of each axis status is set (1) if a motion profile suspended by a GOWHEN (including TRGFNc1x) is 

pending on that axis. The bit is cleared when the GOWHEN is true, or when a stop (S) or kill (K) command is 

executed. 

TERF, TER & [ ER ]......Bit 14 is set if the GOWHEN condition is already true when a subsequent GO, GOL, FGADV, FSHFC, or 

FSHFD command is given. (The corresponding error-checking bits must be enabled with the ERROR 

command before the error will be detectable.) 

TFSF, TFS & [ FS ]......Transfers or assigns/compares the Following status or each axis. 

TNMCY and [ NMCY ] ....Transfers or assigns the current master cycle number. 

TPCMS and [ PCMS ] ....Transfers or assigns the current captured master cycle position. 

TPMAS and [ PMAS ] ....Transfers or assigns the current master cycle position. 

TPSHF and [ PSHF ] ....Transfers or assigns the net position shift since constant ratio. 

TPSLV and [ PSLV ] ....Transfers or assigns the follower's current commanded position. 

TVMAS and [ VMAS ] ....Transfers or assigns the current velocity of the master axis. 

WAIT .............................A WAIT command suspends program execution until the specified conditional statement (based on PMAS, 

FS, NMCY, PCMS, PSHF, PSLV, or VMAS) is true; 

WAIT(SS.i=b1) suspends program execution until a trigger input is activated (“i” is the input bit number 

corresponding to the trigger input—refer to the Gem6K Series Command Reference). 



Multi-Tasking 

7 

CHAPTER SEVEN 

Multi-Tasking 


• Introduction to Multi-Tasking .........................................................................202 

• Using Gem6K Resources While Multi-Tasking..............................................210 

• Multi-Tasking Performance Issues..................................................................214 

• Multi-Tasking Application Examples .............................................................215

Introduction to Multi-Tasking 

What is Multi-Tasking Multi-tasking is the ability of the Gem6K to run more than one 

program at the same time. This allows users to manage independent activities, aside from just 

motion. 

Why use Multi-Tasking 

• Multiple independent tasks can act on the same process or same axis. 

• A supervisory program can control and coordinate multiple processes. 

What is a Task A system task is a program execution environment, not a program. Each 

task runs independently. Each task can be used to run independent programs. Any task may 

run any program. Multiple tasks could even be running the same program simultaneously. 

Each task may either be: 

• Running a program 

• Monitoring ON, ERROR, or INSELP conditions 

• Inactive (not running a program or monitoring conditions) 

Using Multi-Tasking to Run Programs 

Use the Wizard 

Motion Planner provides 

a Multi-Tasking wizard, 

accessed from the 

Editor. The wizard leads 

you, step by step, 

through the process of 

setting up for multitasking. 

Multi-tasking is initiated by the Task Supervisor. The supervisor is the Gem6K’s main 

program execution environment — it runs the STARTP program and contains the command 

buffer and parser. If the multi-tasking feature is not being used, the supervisor is the lone 

program execution environment of the Gem6K, as shown in Figure 1. When multi-tasking is in 

operation, the supervisor is referred to as “Task 0”. 

Resources 

I/O 

Inputs 

Outputs 

Limits 

Triggers 

Serial Ports 

PORT1 (RS-232) 

PORT2 (RS-232/485) 

Ethernet 

Axis 

GEM6K 

Supervisor 

Run Start-up Program 

Execute Programs 

Monitor Conditions 

Command Buffer & Parser 

Program Memory 

move1 

math 

inout 

fill 

move2 

seal 

gohome 

move3 

main 

Variables 

VAR 

VARB 

VARI 

VARS 

Figure 1: Gem6K Supervisor, with no Multi-Tasking 

The Gem6K can have a maximum of 10 tasks, in addition to the Task Supervisor (Task 0). 

Each task acts as an individual program execution environment. The boxes shown under 

Resources in Fig. 1, and the following Figures, represent the resources that the supervisor and 

tasks monitor and manipulate (see list below). These resources can be shared with other tasks. 

• I/O..................................Inputs and Outputs (onboard I/O and expansion I/O bricks) 

• Communication ports ....“RS-232”, “RS-232/485”, and “ETHERNET” 


• Axis .............................. The Gem6K axis can be shared with any tasks 

• Variables ...................... Real (VAR), binary (VARB), integer (VARI), and string (VARS) 

“Program Memory” is the Gem6K’s non-volatile memory where programs are stored. Any 

task may run any program. Multiple tasks could even be running the same program 

simultaneously. Programs in multi-tasking are defined as they typically are with the Gem6K 

GEM6K 

Resources 

I/O 

Inputs 

Outputs 

Limits 

Triggers 

Serial Ports 


PORT2 (RS-232/485) 

Ethernet 

Axis 

Supervisor 





Task 1 



Task 2 




move1 

math 

inout 

fill 

move2 

seal 

gohome 

move3 

main 

Variables 

VAR 

VARB 

VARI 

VARS 

Task 10 



Figure 2: Gem6K8 - Multi-Tasking with 10 tasks. 

The Task Identifier (%) prefix is used to specify that the associated command will affect the 

indicated task number. For most simple multi-tasking applications, the % prefix will only be 

used to start a program running in a specific task. Multi-tasking programs can be started 

through the communication ports (see Figs. 3a-3c), or from a program (see Figs. 4a-4d). Note 

that the programs are run in the tasks specified with the % prefix. 

Starting Tasks from 

a Communications 

Port 

Resources 

GEM6K 

Supervisor 


I/O 

1%move1 

RUN main 

1%move1 

1%move1 

Serial Ports 

Ethernet 

1%move1 

move1 

DEF move1 

Axis 

Task 1 

END 

RUN move1 

Variables 

Figure 3a: Multi-Tasking initiated from a computer terminal. 

Chapter 8. Troubleshooting 203

GEM6K 

Resources 

Supervisor 


I/O 

2%inout 

2%inout 

Serial Ports 

Ethernet 

Axis 

2%inout 

Task 1 

Running move1 

move1 

DEF move1 

_ 

_ 

_ 

END 

Task 2 

Run inout 

inout 

DEF inout 

_ 

_ 

_ 

2%inout 

END 

Variables 

Figure 3b: Multi-Tasking initiated from a computer terminal (cont’d). 

GEM6K 

Resources 

Supervisor 


I/O 

3%fill 

3%fill 

move1 

3%fill 

Serial Ports 

Ethernet 

Task 1 

DEF move1 

_ 

_ 

_ 

Axis 

Running move1 

END 

inout 

Task 2 

Running inout 

DEF inout 

_ 

_ 

_ 

END 

Variables 

3%fill 

Task 3 

Run fill 

fill 

DEF fill 

_ 

_ 

_ 

END 

Figure 3c: Multi-Tasking initiated from a computer terminal (cont’d). 

Starting Tasks from 

a Program 

GEM6K 

Resources 

Supervisor 


I/O 

RUN main 

RUN main 

main 

DEF main 

_ 

_ 

_ 

RUN main 

Serial Ports 

Ethernet 

1%move1 

2%inout 

3%fill 

END 

Axis 

Variables 

Figure 4a: Multi-Tasking initiated from a program. 


GEM6K 

Resources 

I/O 

Serial Ports 

Ethernet 

Axis 

Variables 

Supervisor 

Running main 

1%move1 

1%move1 

Task 1 

RUN move1 

1%move1 


main 

DEF main 

_ 

_ 

_ 

1%move1 

2%inout 

3%fill 

END 

move1 

DEF move1 

_ 

_ 

_ 

END 

Figure 4b: Multi-Tasking initiated from a program (cont’d). 

GEM6K 

Resources 

Supervisor 


I/O 

Serial Ports 

Ethernet 

Running main 

2%inout 

Task 1 

2%inout 

main 

DEF main 

_ 

_ 

_ 

1%move1 

2%inout 

3%fill 

END 

Axis 

Running move1 

move1 

DEF move1 

_ 

_ 

_ 

Task 2 

END 

Variables 

2%inout 

RUN inout 

inout 

DEF inout 

_ 

_ 

_ 

END 

Figure 4c: Multi-Tasking initiated from a program (cont’d). 

GEM6K 

Resources 

Supervisor 


I/O 

Serial Ports 

Ethernet 

Running main 

3%fill 

Task 1 

3%fill 

main 

DEF main 

_ 

_ 

_ 

1%move1 

2%inout 

3%fill 

END 

Axis 

Running move1 

move1 

DEF move1 

_ 

_ 

_ 

Task 2 

END 

Running inout 

inout 

Variables 

Task 3 

DEF inout 

_ 

_ 

_ 

END 

3%fill 

RUN fill 

fill 

DEF fill 

_ 

_ 

_ 

END 

Figure 4d: Multi-Tasking initiated from a program (cont’d). 


Interaction Between Tasks 

A new task is initiated by identifying the task number with the Task Identifier (%) prefix, 

followed by the name of the program to be run in the specified task. Because the % prefix 

specifies the task number that the associated command will affect, new tasks can be started 

from within other tasks. Fig. 5b shows the move1 program in task 1 being started by the 

main program in the supervisor. Fig. 5c shows the fill program in task 3 being started by 

the move1 program in task 1 with the 3%fill command. Fig. 5d shows the inout 

program in task 2 being started by the fill program in task 3 with the 2%inout command. 

Program execution in a task is controlled by commands executed from the program the task is 

running. In the example shown in Figs 5a-5d, program execution in Task 1 is controlled by 

commands executed from the move1 program, program execution in Task 2 is controlled by 

commands executed from the inout program, and program execution in Task 3 is controlled 

by commands executed from the fill program. 

GEM6K 

RUN main 

Resources 

I/O 

Serial Ports 

Ethernet 

RUN main 

Supervisor 

RUN main 


main 

DEF main 

1%move1 

_ 

_ 

_ 

END 

Axis 

Variables 

Figure 5a: Initiating multi-tasking. 

GEM6K 

Resources 

I/O 

Serial Ports 

Ethernet 

Supervisor 

Running main 

1%move1 

1%move1 

1%move1 


main 

DEF main 

1%move1 

_ 

_ 

_ 

END 

Axis 

Variables 

Task 1 

RUN move1 

move1 

DEF move1 

3%fill 

_ 

_ 

END 

Figure 5b: Task initiated from another task (cont’d). 


GEM6K 

Resources 

Supervisor 


I/O 

Serial Ports 

Ethernet 

Running main 

Task 1 

main 

DEF main 

1%move1 

_ 

_ 

_ 

END 

Axis 

Running move1 

3%fill 

3%fill 

move1 

DEF move1 

3%fill 

_ 

_ 

Variables 

END 

3%fill 

Task 3 

RUN fill 

fill 

DEF fill 

2%inout 

_ 

_ 

END 

Figure 5c: Task initiated from another task (cont’d). 

GEM6K 

Resources 

Supervisor 


I/O 

Serial Ports 

Ethernet 

Running main 

Task 1 

main 

DEF main 

1%move1 

_ 

_ 

_ 

END 

Axis 

Running move1 

move1 

DEF move1 

3%fill 

_ 

_ 

Variables 

Task 2 

END 

2%inout 

RUN inout 

inout 

DEF inout 

_ 

_ 

_ 

Task 3 

END 

Running fill 

fill 

2%inout 

2%inout 

DEF fill 

2%inout 

_ 

_ 

END 

Figure 5d: Task initiated from another task (cont’d). 


Tasks 

Refer to page 210 for 

more details about 

associating axes with 

tasks. 

The default condition in multi-tasking is that each task is associated with motion, as shown in 

Fig. 6a. This means that when a task associated with motion hits an end-of travel limit, 

program execution will be killed within that task. It may therefore be necessary to unassign 

motion association for a given task to allow an independent program execution environment. 

When this is done, the unassigned task cannot control or quary any information about the 

motor or motion. 

The TSKAX command allows you to unassign the motion from the task. By assigning the task 

to no motion(TSKAX0), the task can not control or query information on the Gem6K motor or 

motion.. 

GEM6K 

Resources 

I/O 

Inputs 

Outputs 

Limits 

Triggers 

Serial Ports 


PORT2 (RS-232/485) 

Ethernet 

Supervisor 





Task 1 



Default = All Axes 


move1 

math 

inout 

fill 

move2 

seal 

gohome 

move3 

main 

Task 2 

Axes 




Variables 

VAR 

VARB 

VARI 

VARS 

Task 10 




DEF main ; Begin definition of program called "main" 

1%TSKAX1 ; Associate task 1 with motion 

2%TSKAX0 ; Do not associate task 2 with motion) 

1%move1 ; Execute the "move1" program in Task 1 

2%inout ; Execute the "inout" program in Task 2 (Will not affect any 

; motion) 

END 

; End definition of program called "main" 


How a “Kill” Works While Multi-Tasking 

The general rule of command execution within a task is that the command affects only the 

task in which it was executed or to which it was directed via the % prefix. This includes 

almost all motion commands when tasks have an associated (TSKAX) axis. The exception is 

the Kill command. A “K” or “!K” without prefix or parameters will kill all controller axes, 

and programs running in all tasks. This exception is made to allow one short, familiar 

command to effectively stop all controller processes. As usual, a “K” with parameters (e.g., 

Kx11) will kill motion only on the specified axis, and will not kill the program. A “K” 

prefixed with a task specifier but without parameters (e.g., 3%K) will kill the program and 

motion if the task has an associated axis. 

Certain inputs can be used to kill programs and motion. These inputs and their results under 

multi-tasking are: 

• Drive Fault input. Kills program execution and the associated axis for all tasks that are 

associated with the faulted axis. 

• Kill input (INFNCi-C or LIMFNCi-C). If prefixed with the task identifier (e.g., 

2%INFNC3-C), it will kill the designated task, its program and the associated axis. If not 

prefixed with a task identifier, it will kill the controller axis, and all programs running 

in all tasks. It will also cause a branch to the task’s error program if the task’s errorchecking 

bit 6 is enabled (n%ERROR.6-1). 

• User fault input (INFNCi-F or LIMFNCi-F). This input functions the same as the kill 

input noted above, with the exception that it will also cause a branch to the task’s error 

program if the task’s error-checking bit 7 is enabled (n%ERROR.7-1). 


Using Gem6K Resources While Multi-Tasking 

Associating Axes with Tasks 

The default condition in multi-tasking is that each task is associated with motion. The TSKAX 

command allows you to unassign the task from the motion, thus constraining task response 

and control to I/O only. The TSKAX command allows you to specify motion (1) or no motion 

(0). This association covers all interaction between axes commands, conditions or inputs and 

task program flow, including the following: 

• Motion data commands (e.g., A, V, D). These commands will apply only if the task is 

associated with motion. 

• Stop, pause, and continue commands and inputs. These commands will affect motion 

only on tasks associated with motion: S (stop) command — without parameters, PS 

(pause) command, and C (continue) command. Inputs programmed with these functions 

will affect motion only on tasks associated with motion and specified in the input 

function assignment (with the n% prefix): Kill input (n%INFNCi-C or n%LIMFNCi-C), 

stop input (n%INFNCi-D or n%LIMFNCi-D), pause/continue input (n%INFNCi-E or 

n%LIMFNCi-E), and user fault input (n%INFNCi-F or n%LIMFNCi-F). 

• Drive fault and limit inputs. If a drive fault or end-of-travel limit occurs, only tasks 

assocaited with motion will be killed. 

• ON conditions. Axis status bits are only monitored if the task is associated with 

motion. 

• ERROR conditions. Each task has its own error status register (ER, TER, TERF), errorchecking 

bits (ERROR), and error program (ERRORP). 

• Command buffer control: 

− COMEXC. Pauses command processing of that task until the associated motion 

has stopped 

− COMEXL. Allows the specified associated motion to not kill that task’s 

program. 


Sharing Common Resources Between Multiple Tasks 

Controller resources other than processing time must also be shared between multiple tasks. 

All physical inputs and outputs are shared (i.e., each task may read all inputs and write to all 

outputs). Some of the functions associated with that I/O (defined with LIMFNC, INFNC and 

OUTFNC commands) are unique for each task. All variables (VAR, VARI, VARB, VARS), 

DATA programs, and the DATPTR are shared. If one task modifies a variable, a DATA 

program, or DATPTR, the new value is the same for all tasks. There are no “private” variables. 

The serial ports are shared (i.e., any task may read from, or write to, any serial port). When a 

task writes to a serial port, the characters are all sent to the output buffer at once, but 

execution proceeds to the next command without waiting for those characters to be 

transmitted. 

The data assignment functions READ, DREAD, or DREADF, and TW are also shared between 

tasks, but in these cases, the task is not allowed to execute the next command until the data 

has been received and assigned. This requires waiting for human or host input, or 

thumbwheel strobe time. During this time, that task is “blocked”, and that data assignment 

function (READ, DREAD, or DREADF, or TW) is owned by the blocked task. If another task is 

active, it will continue to execute commands. If this second task attempts to access a data 

assignment function which is still owned by the first task, the second task becomes blocked 

also. This situation persists until the first task receives and assigns its data. At that point, 

ownership of the data assignment function passes to the second task, until it too receives and 

assigns its data. All this blocking and ownership is automatic, not requiring coordination by 

the user. 

Locking Resources to a Specific Task 

Examples: 

LOCK1,1 locks COM1 

LOCK1,0 unlocks COM1 

LOCK2,1 locks COM2 

LOCK2,0 unlocks COM2 

LOCK3,1 locks swapping 

LOCK3,0 unlocks swapping 

The LOCK command may be used by a system task to gain or release exclusive ownership of a 

resource. This will allow that task to complete a sequence of commands with that resource 

while preventing another task from using the resource in between commands. Any other task 

attempting to access or LOCK that resource will become blocked (i.e., become temporarily 

totally inactive) until the resource is released by the task that owns it. Resources which may be 

LOCKed are: 

• COM1 — the “RS-232” connector or the “ETHERNET” connector 

• COM2 — the “RS-232/485” connector 

• Task Swapping — When task swapping is locked to a specific task, command 

statements in all other tasks will not be executed until the task swapping is again 

unlocked. For more information on task swapping, refer to page 214. 

NOTE: A resource may be locked by a task only while that task is executing a program. If 

program execution is terminated for any reason (e.g., stop, kill, limit, fault, or just reaching the 

END of a program), all resources locked by that task will become unlocked. 

For example, to report the current position of a robotic arm, one might program: 

VAR10 = 1PM 

; position of axis one 

LOCK1,1 

; lock COM1 ("RS-232" port) resource 

WRITE "Arm Position is" ; write string 

WVAR10 

; write position 

WRITE "inches\13" 

; write string and carriage return 

LOCK1,0 

; release COM1 to other tasks 

; Between the LOCK commands, other tasks will run unless they 

; attempt to access COM1, in which case they become 

; temporarily blocked. 

How Multi-tasking and the % Prefix Affect Commands and Responses 

Multi-tasking affects many, but not all, of the Gem6K commands and features. The table 

below lists the commands that are affected by multi-tasking and the task-identifier (%) prefix. 

Any command that is not listed may be considered unaffected by multi-tasking. Any 


command which has motion data (e.g., A, V, D) is only affected if the task has been associated 

with motion via the TSKAX command. Any command listed below as affected by the % prefix 

may also accept the @ character as a task number; in this case, all tasks will be affected by the 


The response (if any) sent to the terminal by the command will be prefixed with the task 

number and % sign if the command had been executed by any task other than Task 0, the 

Supervisor Task. For commands executed in Task 1, if the command itself had the 1% prefix, 

then the response will also have the prefix. Otherwise, the response will not be prefixed. 

Therefore, if no multi-tasking is used, no responses will have task prefixes. If multi-tasking is 

used, however, you can determine which task originated the response. A response could be 

the result of a transfer command (e.g., TER), a command with no parameters (e.g. MC), 

TRACE output, or an error message. 

Command(s) Effect of % Prefix Effect of Multi-tasking 

GOTO, IF, ELSE, NIF, 

WHILE, NWHILE, REPEAT, 

UNTIL, L, LN, LX 

None (ignored) 

These commands direct program flow 

only on the task from which they are 

executed. 

GOSUB, RUN, , 

JUMP, HALT, BP, PS, T, 

WAIT, C 

COMEXC, COMEXR, COMEXS 

Effectively inserts 

command into 

numbered task’s 

program 

Affects mode on 

numbered task 

S, K Specifies affected 

task only 

ERROR, ERRORP, TER, 

TERF, ER 

TCMDER, TSS, TSSF, SS, 

TSTAT 

TTIM, TIMINT, TIMST, 

TIMSTP, TIM 

TRACE, TRACEP, TEX, 

STEP, # 

ONCOND, ONIN, ONP, ONUS, 

ONVARA, ONVARB 

Affect/report on 

numbered task 

Report on numbered 

task 

Command refers to 

timer of numbered 

task 


numbered task 


numbered task 

These commands initiate, interrupt or 

continue program flow only on 

implicitly or explicitly specified task. 

These commands affect program flow 

only on implicitly or explicitly specified 

task. 

These commands affect program flow 

(depending on parameters given) 

only on implicitly or explicitly specified 

task. A “K” with no prefix or 

parameters kills all tasks. 

These commands affect/report error 

conditions and programs only on 

implicitly or explicitly specified task 

(each task has its own error status 

register and error program). 

These commands report command 

errors and status only on implicitly or 

explicitly specified task. 

Each task has an independent timer. 

Also, TIMST0,# resets the timer to # 

msec., TIMST1,# restarts the timer 

with the TIM value of task #. 

Each task has its own trace and step 

mode. This allows tracing on a single 

task, or combined tasks commands. 

Each task has its own set of ON 

conditions and its own ONP program. 

LIMFNCi-C, LIMFNCi-D, 

LIMFNCi-E, LIMFNCi-F, 

LIMFNCi-P, 

INFNCi-C, INFNCi-D, 

INFNCi-E, INFNCi-F, 

INFNCi-P, 

INSELP, OUTFNCi-C 


numbered task 

These functions are task specific. All 

others affect the entire controller and 

cannot be affected by the % prefix. 


Input and Output Functions and Multi-tasking 

The Gem6K has inputs and outputs (onboard and on external optional I/O bricks) that may be 

assigned various I/O functions with these function assignment commands: 

LIMFNC........Assigns input functions to the dedicated limit inputs on the “LIMITS/HOME” 

connectors (factory default functions are the respective R, S, and T limit 

input functions). 

INFNC..........Assigns input functions to the onboard digital inputs (trigger input on the 

“TRIGGERS/OUTPUTS” connectors) and to the digital inputs on external I/O 

bricks. 

OUTFNC........Assigns output functions to the onboard digital outputs (outputs on the 

“TRIGGERS/OUTPUTS” connectors) and to the digital outputs on external I/O 

bricks. 

The Gem6K’s I/O and events involving programmed I/O are related to tasks only if: 

• The input or output function assignment is associated with a specific task. For example, 

because of the 1% prefix, the 1%INFNC3-F command assigns the “user fault” function 

to onboard input 3 and directs its function to be specific to Task 1. 

• An input or output is assigned a specific function and the input or output is associated 

with a specific task. For example, if Task 1 is associated with motion (1%TSKAX1) and 

onboard input 4 is assigned as a “stop” input (INFNC4-D), then when onboard input 4 

goes active motion is stopped; thus Task 1 is affected by input 4. 

Each input or output group (LIMFNC, INFNC, and OUTFNC) is limited to a maximum of 32 

function assignments at one time. Exceptions are: function A, LIMFNC functions R, S, and T, 

and INFNC function H. A given input or output may be assigned only one function, although 

for task-specific functions, this I/O point may perform the same function for multiple tasks 

(by using the % prefix). This only counts as one function against the maximum total of 32, 

even though it is shared by multiple tasks. A given I/O point may not perform different 

functions for different tasks. Re-assigning a I/O point’s function in any (same or different) 

task will result in removing the assignment of the previous function in the previous task(s). 

For example: 

1%2INFNC4-C ; module 2's 4th input will kill task 1 

2%2INFNC4-C ; module 2's 4th input now kills tasks 1 & 2 

3%2INFNC4-D ; module 2's 4th input will stop task 3, 

; it no longer has a kill function for tasks 1 & 2 


Multi-Tasking Performance Issues 

When is a Task Active 

Tasks are always ready to become active if commanded to do so. No special command is 

required to allow a task to do something. A task is active if it is: 

• Executing a program (SS.3=B1) 

• Executing a T or WAIT command (even if not running a program) 

• Monitoring drive faults conditions (DRFEN1) 

• Monitoring ONCOND conditions (SS.15=B1) 

• Waiting in Program Select Mode (INSELP1 and SS.18=B1) 

• Monitoring ERROR conditions (ERROR has any non-zero bit) 

A task becomes active when it receives a command to perform something from the list above. 

A task which is not active does not create any overhead (delays) in command processing for 

tasks which are active. Once a task becomes active, however, it takes its turn in the sequence 

of swapping (see below), and checks for all of the conditions listed above. This adds a 

processing burden which will slow the command execution rate of programs running in other 

tasks. 

A task becomes inactive if nothing from the above list is occurring. There is no special 

command “kill task” to disable all these modes/conditions/activities at once. The standards 

methods for terminating these (S, INSELP0, ERROR0, etc.) are needed to make a task 

completely inactive, and therefore not creating command processing overhead. Task 0, the 

Task Supervisor, will always be active, even if nothing from the above list is occurring, 

because Task 0 always checks the input command buffer for commands to execute. 

The TSWAP command reports a binary bit pattern indicating the tasks that are currently active. 

Bit 1 represents task 1, bit 2 represents task 2, etc. A “1” indicates that the task is active, and 

a “0” indicates that the task is inactive. The SWAP assignment operator allows the same 

information to be assigned to a binary variable, or evaluated in a conditional statement such as 

IF or WAIT. This is useful for determining which tasks have any activity, whereas the system 

status (SS) and error status (ER) states reveal exactly what activity a given task has at that 

time. 

Task Swapping 

The Gem6K has only one processor responsible for executing programs, therefore, multiple 

tasks are not actually executing simultaneously. Tasks take turns executing when they are 

active. A task’s “turn” consists of executing one command and checking its input, output, ON, 

ERROR and INSELP conditions before relinquishing control to the next task. The process of 

changing from one task to the next is called task swapping. The Gem6K determines when to 

swap tasks. The user is not required (or allowed) to determine how long a task should run, or 

when to relinquish control to another task. 

Although the user does not determine how long a task should run, or when to relinquish 

control to another task, the number of “turns” a task gets before swapping may be set with the 

TSKTRN command. The default value is one for all active tasks. Thus, each task has equal 

weight, swapping after every command. If a task needs a larger share of processing time 

however, the TSKTRN value for that task can be increased. For example, if task 2 issued a 

TSKTRN6 command, while the others stayed at 1, programs running in task 2 would execute 

six commands before relinquishing. The TSKTRN value for a task may be changed at any 

time, allowing a task to increase its weight for an isolated section of program statements. 

The TTASK command reports to the display the task number of the task which executed the 


command. This could be used for diagnostic purposes, as a way to indicate which task is 

executing a given section of program. The corresponding TASK assignment allows the 

program itself to determine which task is executing it. The current task number TASK may be 

assigned to a variable or evaluated in a conditional statement such as IF. This allows a single 

program to be used as a subroutine called from programs running in all tasks, yet this routine 

could contain sections of statements which are executed by some tasks and not others. 

Task Execution Speed 

Two terms describe the execution speed of tasks in multi-tasking environments. 

Performance 

Performance is a measure of how fast a task executes commands, and could be described in 

terms of commands per second. Because tasks must take turns executing, performance will 

decrease when tasks are added. For example, the performance of a task sharing the controller 

with two other tasks will be just one third of its performance if it were running by itself. Using 

the TSKTRN command described above, the relative performances of tasks may be altered. 

Determinism 

Determinism is a measure of how independent the performance of one task is from the 

commands and conditions involved in another task. If task swapping were done via a periodic 

interrupt (time slicing), task performance would be completely determinate, i.e., each task 

would run exactly for its time slice, not more or less. In the Gem6K products, task swapping is 

not time sliced, rather each task is allowed to execute one command and check its input, 

output, ON, ERROR and INSELP conditions before relinquishing control to the next task. For 

this reason, the performance of each task is somewhat determined by the commands and 

conditions underway in the other tasks. Most commands execute in approximately the same 

time. The others (some math commands, and line and arc commands) are broken into sections 

with durations that approximate those of the average command (approximately 2 ms). 

Swapping also takes place between these sections, allowing all task performance to be 

reasonably determinate regardless of which commands are being executed by other tasks. 

Although time slicing would give completely determined task performance, the task swapping 

would need to include additional task save and restore functions to completely protect the task 

from the interrupt. This additional overhead would effectively rob processor time from the 

time slice, resulting in lower task performance. Task swapping in the Gem6K product does not 

add this overhead, and is therefore extremely efficient, taking less than 0.5% of task execution 

time. 




8 

CHAPTER EIGHT 



• Troubleshooting basics ..............................................................................218 

• Solutions to common problems (problem/cause/remedy table).................218 

• Program debug tools 

- Status commands ............................................................................222 

- Error messages................................................................................229 

- Trace mode......................................................................................232 

- Single-step mode.............................................................................234 

- Break points ....................................................................................235 

- Simulating programmable I/O activation........................................235 

- Simulating analog input activation..................................................237 

- Motion Planner’s Panel Gallery......................................................237 

• Technical support.......................................................................................238 

• Operating system upgrades........................................................................238 

• Product return procedure ...........................................................................238

Troubleshooting Basics 

When your system does not function properly (or as you expect it to operate), the first thing 

that you must do is identify and isolate the problem. When you have accomplished this, you 

can effectively begin to resolve the problem. 

The first step is to isolate each system component and ensure that each component functions 

properly when it is run independently. You may have to dismantle your system and put it 

back together piece by piece to detect the problem. If you have additional units available, you 

may want to exchange them with existing components in your system to help identify the 

source of the problem. 

Determine if the problem is mechanical, electrical, or software-related. Can you repeat or recreate 

the problem Random events may appear to be related, but they are not necessarily 

contributing factors to your problem. You may be experiencing more than one problem. You 

must isolate and solve one problem at a time. 

Log (document) all testing and problem isolation procedures. Also, if you are having 

difficulty isolating a problem, be sure to document all occurrences of the problem along with 

as much specific information as possible. You may need to review and consult these notes 

later. This will also prevent you from duplicating your testing efforts. 

Once you isolate the problem, refer to the problem solutions contained in this chapter. If the 

problem persists, contact your local technical support resource (see Technical Support below). 

Electrical Noise 

If you suspect that the problems are caused by electrical noise, refer to your Gem6K product's 

Installation Guide for help. 

Solutions to Common Problems 

NOTES 

• Some hardware-related causes are provided because it is sometimes difficult to identify a 

problem as either hardware or software related. 

• Refer to other sections of this manual for more information on controller programming 

guidelines, system set up, and general feature implementation. You may also need to 

refer to the command descriptions in the Gem6K Series Command Reference. Refer to 

your product’s Installation Guide for hardware-related issues. 

Problem Cause Solution 

Communication (Ethernet) 

errors. 

Communication (serial) not 

operative, or receive garbled 

characters. 

1. Ethernet card not installed 

correctly. 

2. Ethernet IP address 

conflict. 

3. Connection to Ethernet port 

is compromised or miswired. 

1. Improper interface 

connections or communication 

protocol. 

1. Refer to the user instructions that came with your Ethernet 

card. 

2. Change IP address with the NTADDR command. (make sure it is 

matched by the setup in Motion Planner) 

3. Refer to the connection instructions in the Installation Guide. 

1. See troubleshooting section in your product’s Installation Guide. 

2. COM port disabled. 2.a. Enable serial communication with the E1 command. 

2.b. If using RS-485, make sure the internal jumpers are set 

accordingly (see Installation Guide). Make sure COM 2 port is 

enabled for sending Gem6K language commands (execute the 

PORT2 and DRPCHKØ commands). 

3. In daisy chain, unit may not 

be set to proper address. 

3. Verify DIP switch settings (see Installation Guide), verify proper 

application of the ADDR command. 



Direction is reversed. 

(stepper axes only) 

Direction is reversed, servo 

condition is unstable. 

(servo axes only) 

Distance, velocity, and accel 

are incorrect as programmed. 

1. Phase of step motor 

1. Switch A+ with A- connection from drive to motor. 

reversed (motor does not 

move in the commanded 

direction). 

2. Phase of encoder reversed 2. Swap the A+ and A– connection at the ENCODER connector. 

(reported TPE direction is 

reversed). 

1. Not tuned properly. 1. Refer to tuning instructions in your product's Installation Guide. 

2. Phase of encoder reversed. 2. Software remedy for encoder feedback only: For the affected 

axis, issue ENCPOL1. 

Hardware remedy: If using encoder feedback, swap the A+ and 

A- connections to the Gem6K product. If using ANI feedback, 

change the mounting so that the counting direction is reversed. 

1. Incorrect resolution setting. 1.a. Stepper axes: Set the resolution on the to match the Gem6K 

product’s DRES command setting (default DRES setting is 4,000 

steps/rev). 

1.b. Match the Gem6K product's ERES command setting (default 

ERES setting is 4,000 counts/rev) to match the post-quadrature 

resolution of the encoder. 

ERES values for Compumotor encoders: 

Stepper axes: 

• RE, -RC, -EC, & -E Series Encoders:..... ERES4000 

• HJ Series Encoders:............................... ERES2048 

Servo axes (SM, BE, N or J Series Servo Motors): 

• SM/N/JxxxxD-xxxx:................................. ERES2000 

• SM/N/JxxxxE-xxxx:................................. ERES4000 

• BExxxxJ-xxxx: ........................................ ERES8000 

2. Wrong scaling values. 3. Check the scaling parameters (SCALE1, SCLA, SCLD, SCLV, 

SCLMAS) – see also page 67. 

Erratic operation. 1. Electrical Noise. 1. Reduce electrical noise or move product away from noise 

source. 

2. Improper shielding. 2. Refer to the instructions in your product’s Installation Guide. 

Feedback device (encoder or 

resolver) counts missing. 

3. Improper wiring. 3. Check wiring for opens, shorts, & mis-wired connections. 

1. Improper wiring. 1. Check wiring. 

5. Encoder frequency too 

high. 

Following problems — See page 196 

2. Feedback device slipping. 2. Check and tighten feedback device coupling. 

3. Encoder too hot. 3. Reduce encoder temperature with heatsink, thermal insulator, 

etc. 

4. Electrical noise. 4a. Shield wiring. 

4b. Use encoder with differential outputs. 

5. Peak encoder frequency must be below 8 MHz postquadrature. 

Peak frequency must account for velocity ripple. 

Index 219

Diagnostic LEDs: 

All other LED states indicate 

hardware conditions; refer to 

your product's Installation 

Guide for details. 

Note: There are two diagnostic LED’s on the Gem6K. The left 

hand LED shows Green or Red, the right hand LED shows Yellow 

or Green. 

Both LED’s are off. 1. No power. 1. Check 120/240VAC power connection and 24VDC power 

connection and restore power as necessary. 

Left LED is Red, Right LED is 

Green 

Left LED is Red, Right LED is 

not illuminated. 

Left LED is not illuminated, 

Right LED is Yellow. 

Left LED is Green, Right LED 

is flashing Yellow/Green 

Motion does not occur. 

1. 24VDC power only, no AC 

applied. 

2. Operating system download 

in progress. 


aborted before successful 

completion. 

1. Drive faulted. 


in progress. 


aborted before successful 

completion. 

1. Initialization in progress. 

This occurs during power-up 

and reset. 

1. Drive is in auto-run mode 

(DMODE13) 

1. LED’s not lit at all (no 

power) or red LED is 

illuminated 

2. End-of-travel limits are 

active. 

1. Check 120/240VAC power connection and restore power as 

necessary. 

2. Wait for download to finish before resetting drive or cycling 

power. 

3. Contact Applications for help on recovering after an aborted 

operating system download (or see web site FAQ). 

1. Check status with TASF and TASXF commands to determine 

cause and correct error condition as necessary. 

2. Wait for download to finish before resetting drive or cycling 

power. 

3. Contact Applications for help on recovering after an aborted 

operating system download (or see web site FAQ). 

1. Wait for unit to complete its power up or reset process. 

1. Change mode back to position mode (DMODE12). 

1. See LED troubleshooting as noted above. 

2.a. Move load off of limits or disable limits by sending the LHØ 

command to the affected axis. 

2.b. Software limits: Set LSPOS to a value greater than LSNEG. 

3. Improper wiring. 5. Check enable & limit connections.. 

4. ENABLE input is not 

grounded. 

6. Ground the ENABLE input connection. 

5. Load is jammed. 7. Remove power and clear jam. 

6. No torque from motor. 8. See problem: Torque, loss of. 

7. Max. position error (SMPER 

value) exceeded. (servo axes 

only) 

9. Check to see if TAS/TASF bit #23 is set, and issue the DRIVE1 

command to the axis that exceeded the position error limit. 

8. Drive has faulted. 10. Check to see if TAS/TASF bit #14 is set. 

Power-up Program does not 

execute. 

Program access denied: 

receive the message 

*ACCESS DENIED when 

trying to use the DEF, DEL, 

ERASE, LIMFNC, INFNC, or 

MEMORY commands. 

1. ENABLE input is not 

grounded. 

2. STARTP program is not 

defined. 

1. Program security function 

has been enabled (INFNCi-Q 

or LIMFNCi-Q) and the 

program access input has not 

been activated 

1. Ground the ENABLE input to GND and reset the product. 

2. Check the response to the STARTP command. If no program is 

reported, define the STARTP program and reset (see page 13, or 

refer to the STARTP command description). 

1.a. Activate the assigned program access input, perform your 

programming changes, then deactivate the program access input. 

1.b. Refer to the instructions on page 104, or to the INFNC or 

LIMFNC command descriptions. 

Program execution: the first 

time a program is run, the 

move distances are incorrect. 

Upon downloading the 

program the second time, 

move distances are correct. 

1. Scaling parameters were 

not issued when the program 

was downloaded; or scaling 

parameters have been 

changed since the program 

was defined. 


1. Issue the scaling parameters (SCALE1, SCLA, SCLD, SCLV, 

SCLMAS) before saving any programs. 

Torque, loss of. 1. Improper wiring. 1. Check wiring to the drive, as well as other system wiring. 

Velocity & acceleration is 

incorrect as programmed. 

2. No power to drive. 2. Check power to drive. 

3. Drive failed. 3. Check drive status. 

4. Drive faulted. 4. Check drive status. 

5. Shutdown issued to drive. 5. Re-enable drive by sending the DRIVE1 command. 

See Distance problem noted 

above. 


Program Debug Tools 

After creating your programs, you may need to debug the programs to ensure that they 

perform as expected. The Gem6K provides several debugging tools. Detailed descriptions 

are provided on the following pages. 

• Status Commands: Use the “Transfer” commands (e.g., TAS, TSS, TIN) to display 

various controller status information. Multi-Tasking: System (TSS) and Error (TER) 

status information is task specific; to check the status for a specific task, you must 

prefix the status command with the task identifier (e.g., 2%TSS to check the system 

status for task 2). 

• Error Messages: You can enable the Gem6K to display error messages when it 

detects certain programming errors as you enter them or as the program is run. When 

the controller detects an error with a command, you can issue the TCMDER command to 

find out which command caused the error. 

• Trace mode: Trace a program as it is executing. 

• Single-Step mode: Step through the program one command at a time. 

• Break Points: Establish locations in your program, where command processing will 

halt and a message will be transmitted to the PC. 

• Simulate Programmable I/O Activation: You can set the desired state of the 

Gem6K’s inputs and outputs via software commands. 

• Simulate Analog Input Activation: Without an actual voltage present, you can 

simulate a specific voltage on the Gem6K’s analog input channels using the ANIEN 


• Motion Planner’s Panel Gallery: Motion Planner’s Panel Gallery provides an 

assortment of test panels you can use to verify various system I/O and operating 

parameters. 

Index 221

Status Commands 

Status commands are provided to assist your diagnostic efforts. These commands display 

status information such as, axis-specific conditions, general system conditions, error 

conditions, etc. 

Checking Specific Setup Parameters 

One way to check the conditions that are established with a specific setup command is to 

simply type in the command name without parameters. For example, type “ERES” to check 

the encoder resolution setting; the response would look something like: *ERES4ØØØ. 

Refer to page 64 for a list of most setup parameters and their respective commands. 

TIP: To send a status 

command to the Gem6K 

product during program 

execution, prefix the 

command with an “!” (e.g., 

!TASF). 

Below is a list of the status commands that are commonly used for diagnostics. Additional 

status commands are available for checking other elements of your application (see List of All 

Status Commands below). For more information on each status command, refer to the 

respective command description in the Gem6K Series Command Reference. 

SPECIAL NOTATIONS 

* The command has a binary report version (just leave the “F” off when you type 

it in—e.g., TAS). This is used more by experienced Gem6K programmers. 

Using the binary report command, you can check the status of one particular 

bit (e.g., The TAS.1 command reports “1” if motor is moving or “Ø” if it is not 

moving.). In the binary report the bits are numbered left to right, 1 through n. 

A “1” in the binary report correlates to a “YES” in the full text report, and a “Ø” 

correlates to a “NO” in the full text report. 

† The command has an assignment/comparison operator that uses the bit status 

for conditional expressions and variable assignments. For example, the 

WAIT(1AS.1=bØ) command pauses program execution until status bit 

number 1 (1AS.1) reports a binary zero value (indicates that the motor is notmoving). 

See page 7 and page 25 for more information on using assignment 

and comparison operators in conditional expressions and variable 

assignments. 


TASF Reports axis-specific conditions. * (TAS) † (AS) 

1. Axis is in motion (commanded) 17. Positive-direction software limit (LSPOS) 

encountered 

2. Direction is negative 18. Negative-direction software limit (LSNEG) 

encountered 

3. Accelerating (n/a to deceleration) 19. Within Deadband (steppers) Within deadband 

(EPMDB) — steppers only 

4. At velocity 20. RESERVED In position (COMEXP) 

5. Home Successful (HOM) 21. RESERVED 

6. In absolute positioning mode (MA) 22. RESERVED 

7. In continuous positioning mode (MC) 23. Position error limit is exceeded (SMPER) (servos) 

8. In Jog Mode (JOG) 24. Load is within Target Zone (STRGTD & STRGTV) 

(servos) 

9. In Joystick Mode (JOY) 25. Target Zone timeout occurred (STRGTT) (servos) 

10. RESERVEDIn Encoder Step Mode (ENC) — 

steppers 

11. Position Maintenance Mode (steppers)Position 

Maintenance on (EPM) — steppers 

26. Motion suspended, pending GOWHEN 

27. RESERVED 

12. Stall detected (ESTALL) (steppers) 28. Registration move occurred since last GO 

13. Drive shutdown occurred 29. GOWHEN Error: Input or position true before Go 

14. Drive fault occurred 30. Pre-emptive (OTF) GO or Registration profile not 

possible 

15. Positive-direction hardware limit hit 31. Compiled GOBUF profile is executing 

16. Negative-direction hardware limit hit 32. RESERVED 

Index 223

TASXF Reports extended axis-specific conditions. * (TASX) † (ASX) 

1. Motor Fault 

2. Low voltage Fault 

3. Drive over-temperature Fault 

4. RESERVED 

5. Resolver failure detected (servos) 

6.RESERVED 

7. Motor configuration error 

8. RESERVED 

9. Velocity error limit (SMVER) (servos) 

10. Bridge fault 

11. Bridge temperature fault (servos) 

12. Over-voltage (servos) 

13-16. RESERVED 

17. Stall detected (ESTALL or DSTALL) (steppers) 

18. Override mode invoked 

19. Bridge in foldback mode (servos) 

20. Power dissipation circuit active (not applicable on some servos) 

21. Bad Hall state (servos) 

22. Unrecognized hardware (consult factory) 

23.User fault input active 

24. Keep alive active 

25. Power dissipation circuit fault (not applicable on some servos) 

26. RESERVED 

27. RESERVED 

28. Motor configuration warning 

29. ORES failure 

30. Motor thermal model fault (servos) 

31. Command torque/force at limit (TTRQ=DMTLIM) (servos) 

32. RESERVED 


TSTAT 

Reports general system setup and current conditions. 

Sample response for the Gem6K: 

*Gem6K revision: 92-XXXXXX-01-6.0 Gem6K GV6K-L3E D1.72 F1.3 

*Ethernet address: xxxxxxxxxx; IP address: 192.168.10.30 

*Power-up program assignment (STARTP): SETUP 

*ENABLE input OK: Yes 

*Drive status (DRIVE): 0 

*Drive resolution (DRES): 25000 

*Encoder resolution (ERES): 4000 

*Hard Limit enable: LH3 

*Soft Limit enable: LS0 

*Current Motion Attributes: 

* Scaling enabled (SCALE1): 0 

* Acceleration scaler (SCLA): 4000 

* Distance scaler (SCLD): 1 

* Velocity scaler (SCLV): 4000 

* Commanded position (TPC): +0 

* A10.0000 

* AA10.0000 

* AD10.0000 

* ADA10.0000 

* V1.0000 

* D+4000 

*I/O Status: 

* Onboard limit inputs: 

* Hardware state (TLIM): 000 

* Expansion I/O bricks: See TIO response 

*Axis Status (see TASF for full text report): 

* Axis #1 (1TAS): 0010_0000_0000_1000_0000_0001_0000_0000 

*System Status (This is task 0 status if using multi-tasking.): 

*0 Programs Defined; Scale Enable 0 

* System status (TSSF): 1000_1100_0000_0000_0000_0100_0000_0000 

Index 225

TSSF Reports current system conditions. * (TSS) † (SS) 

Multi-tasking: Each task has its own system status; therefore, to check the 

system status for a specific task, prefix the TSSF command (e.g., 2%TSSF). 

1. System is ready 17. Loading Thumbwheel Data (TW operator) 

2. RESERVED 18. In External Program Select Mode (INSELP) 

3. Executing a Program 19. Dwell in Progress (T command) 

4. Last command was immediate 20. Waiting for RP240 Data (DREAD or DREADF) 

5. In ASCII Mode 21. RP240 Connected 

6. In Echo Mode (ECHO) 22. Non-volatile Memory Error 

7. Defining a Program (DEF) 23. Gathering servo data (servos) 

8. In Trace Mode (TRACE, TRACEP) 24. Suspend on Swap (multi-tasking) 

9. In Step Mode (STEP) 25. RESERVED 

10. FS Translate Mode 26. Suspended on COM1 (multi-tasking) 

11. Command error (check with TCMDER) 27. Suspended on COM2 (multi-tasking) 

12. Break Point Active (BP) 28. Program Pending (multi-tasking) 

13. Pause Active (PS or pause input) 29. Compiled memory partition is 75% full 

14. Wait Active (WAIT) 30. Compiled memory partition is 100% full 

15. Monitoring On Conditions (ONCOND) 31. Compile operation (PCOMP) failed 

16. Waiting for Data (READ) 32. EXE Failed (multi-tasking) 

TINOF Reports the status of the ENABLE input. * (TINO) † (INO) 

1-5. RESERVED 

6. ENABLE input OK (motion not inhibited 

7-8. RESERVED 

TFSF Reports Following Mode conditions (details on page 170). * (TFS) † (FS) 

1. Follower in ratio move 17. Master position prediction mode enabled (FPPEN) 

2. Current ratio is negative 18. Master position filtering mode enabled (FFILT) 

3. Follower is changing ratio 19. Performing FRC move 

4. Follower at ratio (constant non-zero ratio) 20. RESERVED 

5. FOLMAS Active 21. Master window given 

6. Following Mode enabled (FOLEN) 22. Inside master window 

7. Master is moving 23. OK to do a geared advance (FGADV) move 

8. Master direction is negative 24. Geared advance (FGADV) move is underway 

9. OK to Shift 25. RESERVED 

10. Shifting now 26. Present Following move is limited by FMAXA or FMAXV. 

11. FSHFC-based shift move is in progress 27. RESERVED 

12. Shift direction is negative 28. RESERVED 

13. Master cycle trigger input is pending 29. RESERVED 

14. Mas cycle length (FMCLEN) given 30. RESERVED 

15. Master cycle position is negative 31. RESERVED 

16. Master cycle number is > 0 32. RESERVED 


TERF Reports error conditions. ** * (TER) † (ER) 

Multi-tasking: Each task has its own error status; therefore, to check the 

error status for a specific task, prefix the TERF command (e.g., 2%TErF). 

1. Stall detected. 1st: Enable Stall Detection (ESTALL or DSTALL). 

2. Hardware end-of-travel limit encountered. 1st: Enable hard limits (LH). 

3. Software end-of-travel limit encountered. 1st: Enable hard limits (LH). 

4. Drive Fault is active. 

5. RESERVED 

6. A programmable input, defined as a “kill” input, is active. 

7. A programmable input, defined as a “user fault” input, is active. 

8. A programmable input, defined as a “stop” input, is active. 

9. ENABLE input not grounded. 

10. Pre-emptive (OTF) GO or Registration profile not possible. 

11. Target Zone settling timeout period (STRGTT) is exceeded. — servo only 

12. Max. position error (SMPER value) is exceeded. — servo only 

13. RESERVED 

14. GOWHEN condition already true. 

15. RESERVED 

16. Bad command detected (use TCMDER to identify the bad command). 

17. RESERVED 

18. Expansion I/O brick is disconnected or has lost power. 


23. Client connect error 

24. Client polling error 


** The error condition will not be reported until you enable the respective error-checking bit with the ERROR 

command (for details, see page 30 or the ERROR command description). NOTE that when the errorchecking 

bit is enabled and the error occurs, the controller will branch to the “error” program that you 

assigned with the ERRORP command. 

Other status commands commonly used for diagnostics: 

TDIR........ Identifies the name and number of all programs residing in the Gem6K product's memory. Also 

reports percent of available memory for programs and compiled path segments. 

TCMDER.... Identifies the bad command that caused the error prompt (). (see page 232 for details) 

TEX .......... Execution status (and line of code) of the current program in progress. Task specific. 

TIN .......... Binary report of all programmable and trigger inputs (“1” = active, “Ø“ = inactive). INFNC also 

reports the state and programmed function of each input. (see page 91 for bit assignments) 

TOUT........ Binary report of all programmable and auxiliary outputs (“1” = active, “Ø“ = inactive). OUTFNC 

also reports the state and programmed function of each output. (see page 91 for bit 

assignments) 

TLIM........ Binary report of all limit inputs (“1” = active, “Ø“ = inactive). LIMFNC also reports the state and 

programmed function of each limit input. (see page 91 for bit assignments) 

TIO .......... Reports current contents on all expansion I/O bricks connected to the Gem6K. Includes current 

state and function of the digital inputs and outputs, as well as voltage of analog inputs. 

TPER........ (servo axes) Reports the difference between the commanded position and the actual position 

as measure by the feedback device. 

TPC .......... Current commanded position. 

TPE .......... Current position of the encoder. 

TFB .......... (servo axes) Current position of the feedback device selected with the last SFB command. 

TPMAS...... Current position of the Following master 

TPSLV...... Current position of the Following slave 

TNMCY...... Current master cycle number. 

TNT .......... Reports the current Ethernet conditions (Ethernet enabled/disabled, IP address, Ethernet MAC 

address, Ethernet cable connected/disconnected). 

Index 227

List of All Status 


SPECIAL NOTATIONS 

* The command responds with a binary report. This is used more by experienced Gem6K 

programmers. Using the bit select operator (.), you can check the status of one particular bit 

(e.g., The TAS.1 command reports “1” if the motor is moving or “Ø” if it is not moving.). In the 

binary report, the bits are numbered left to right, 1 through n. A “1” in the binary report 

correlates to a “YES” in the full text report, and a “Ø” correlates to a “NO” in the full text report. 

∆ The command has a full-text report version (just add an “F” when you type it in—e.g., TASF). 

This makes it easier to check status information without having to look up the purpose of each 

status bit. (see full-text descriptions, beginning on page 222) 

† The command has an assignment/comparison operator that uses the bit status for conditional 

expressions and variable assignments. For example, the WAIT(1AS.1=bØ) pauses progress 

execution until the status bit number 1 (1AS.1) reports a binary zero value (indicates that the 

axis is not-moving). See page 7 and page 25 for more information on using assignment and 

comparison operators in conditional expressions and variable assignments. 

COMMAND STATUS SUBJECT 

TANI...............Voltage of ANI analog inputs on EVM32 bricks (servo products with ANI option) † 

TANO...............Voltage of ANO analog inputs on EVM32 bricks † 

TAS .................Binary Report of Axis Status * ∆ † 

TASX .............Binary Report of Axis Status – extended * ∆ † 

TCMDER...........Command Error (view command that caused the error prompt) 

TDIR...............Program Directory and Available Memory 

TDPTR.............Data Pointer Status † 

TER .................Error Status * ∆ † 

TEX .................Program Execution Status † 

TFB .................Position of Selected Feedback Devices † 

TFS .................Binary Report of Following Status * ∆ † 

TGAIN.............Current Value of Active Servo Gains 

TIN .................Binary Report of Status of Programmable Inputs * † 

TINO...............Status of the ENABLE input (bit #6) * ∆ † 

TIO .................Report of all I/O on expansion I/O bricks 

TLABEL...........Defined Labels (names of) 

TLIM...............Binary Report of Hardware Status of All Limit Inputs † 

TMEM...............Memory Usage (partition and available memory) 

TNMCY.............Master Cycle Number † 

TNT .................Current Ethernet Conditions, including the TNTMAC report 

TNTMAC...........Ethernet Address 

TOUT...............Binary Report of Status of Programmable Outputs * † 

TPANI.............Position of ANI Inputs † 

TPC .................Commanded Position † 

TPCC...............Captured Commanded Position † 

TPCE...............Captured Encoder Position † 

TPCME.............Captured Master Encoder Position † 

TPCMS.............Captured Master Cycle Position † 

TPE .................Position of Encoder † 

TPER...............Position Error † 

TPMAS.............Position of Master Axis † 

TPME...............Position of Master Encoder † 

TPROG.............Contents of a Program 

TPSHF.............Net Position Shift † 

TPSLV.............Current Commanded Position of the Slave † 

TREV ...............Firmware Revision Level 

TSC .................Binary Report of Controller Status * ∆ † 

TSCAN.............Scan Time of Last PLC Program 

TSGSET...........Servo Gain Sets 

TSEG ...............Number of Free Segment Buffers † 

TSS .................Binary Report of System Status * ∆ † 

TSTAT.............Statistics 

TSTLT.............Settling Time 

TSWAP.............Identify Currently Active Tasks (in multi-tasking) * † 

TTASK.............Task Number of the program that executes this command † 

TTIM ...............Time Value † 

TTRIG.............Status of “Trigger Interrupt” Activation * † 

TUS .................User Status * † 

TVEL ...............Current Commanded Velocity † 

TVELA.............Current Actual Velocity † 

TVMAS.............Current Velocity of the Master Axis † 



Depending on the error level setting (set with the ERRLVL command), when a programming error is created, the Gem6K will 

respond with an error message and/or an error prompt. A list of all possible error messages is provided in a table below. The 

default error prompt is a question mark (), but you can change it with the ERRBAD command if you wish. 

At error level 4 (ERRLVL4—the factory default setting) the Gem6K responds with both the error message and the error prompt. 

At error level 3 (ERRLVL3), the Gem6K responds with only the error prompt. 


ACCESS DENIED 


Program security feature enabled, but program access input (INFNCi-Q) not 

activated. 

ALREADY DEFINED FOR THUMBWHEELS Attempting to assign an I/O function to an I/O that is already defined as a 

thumbwheel I/O. 

ALTERNATIVE TASK NOT ALLOWED 

Attempting to execute a LOCK command directed to another task. 

AXIS NOT READY 

Compiled Profile path compilation error. 

COMMAND NOT IMPLEMENTED 

Command is not applicable to the Gem6K Series product. 

COMMAND NOT ALLOWED IN PROGRAM 

Command is not allowed inside a program definition (between DEF and END). 

COMMAND/DRIVE MISMATCH 

The command (or ≥ one field in the command) is not appropriate to the 

AXSDEF configuration (e.g., attempting to execute a servo tuning command on 

a stepper axis) 

ERROR: MOTION ENDS IN NON-ZERO 

VELOCITY - AXIS N 

Compiled Motion: The last GOBUF segment within a PLOOP/PLN loop does not 

end at zero velocity, or there is no final GOBUF segment placed outside the loop. 

FOLMAS NOT SPECIFIED 

No FOLMAS for the axis is currently specified. It will occur if FMCNEW, FSHFC, or 

FSHFD commands are executed and no FOLMASØ command was executed, or 

FOLMAS0 was executed. 

INCORRECT AXIS 

Axis specified is incorrect. 

INCORRECT BRICK NUMBER 

Attempted to execute a command that addresses an I/O brick that is not 

connected to your Gem6K. 

INCORRECT DATA 

Incorrect command syntax. 

Following: Velocity (V), acceleration (A) or deceleration (AD) command is zero 

(used by FSHFC & FSHFD). 

INPUT(S) NOT DEFINED AS 

JOYSTICK INPUT 

Attempted to execute JOYCDB, JOYCTR, JOYEDB, or JOYZ before executing 

JOYAXH or JOYAXL to assign the analog input to an axis. 

INSUFFICIENT MEMORY 

Not enough memory for the user program or compiled profile segments. This 

may be remedied by reallocating memory (see MEMORY command description). 

INVALID COMMAND 

Command is invalid because of existing conditions 

Index 229

Programming Error Messages (continued) 


INVALID CONDITIONS FOR COMMAND 

INVALID CONDITIONS FOR 

S_CURVE ACCELERATION—FIELD n 

INVALID DATA 


System not ready for command (e.g., LN command issued before the L 


Following (these conditions can cause an error during Following): 

• The FOLMD value is too small to achieve the preset distance and still 

remain within the FOLRN/FOLRD ratio. 

• A phase shift cannot be performed: 

FSHFD Error if already shifting or performing other time based move. 

FSHFC .... Error if currently executing a FSHFD move, or if currently 

executing another FSHFC move in the opposite direction. 

• The FOLEN1 command was given while a profile was suspended by a 

GOWHEN. 

Average (AA) acceleration or deceleration command (e.g., AA, ADA, HOMAA, 

HOMADA, etc.) with a range that violates the equation ½A ≤ AA ≤ A (A is the 

max. accel or decel command—e.g., A, AD, HOMA, HOMAD, etc.) 

Data for a command is out of range. 

Following (these conditions can cause an error during Following): 

• The parameter supplied with the command is valid. 

FFILT Error if: smooth number is not 0-4 

FMCLEN .. Error if: master steps > 999999999 or negative 

FMCP....... Error if: master steps > 999999999 or < -999999999 

FOLMD .... Error if: master steps > 999999999 or negative 

FOLRD .... Error if: master steps > 999999999 or negative 

FOLRN .... Error if: follower steps > 999999999 or negative 

FSHFC .... Error if: number is not 0-3 

FSHFD .... Error if: follower steps > 999999999 or < -999999999 

GOWHEN .. Error if: position > 999999999 or < -999999999 

WAIT....... Error if: position > 999999999 or < -999999999 

• Error if a GO command is given in the preset positioning mode (MCØ) and: 

FOLRN = zero 

FOLMD = zero, or too small 

(see Following chapter on page 177) 

INVALID FOLMAS SPECIFIED 

INVALID RATIO 

Following: An illegal master was specified in FOLMAS. A follower may never 

use its own commanded position or feedback source as its master. 

Following: Error if the FOLRN:FOLRD ratio after scaling is > 127 when a GO is 

executed 

INVALID TASK IDENTIFIER Attempting to launch a PEXE or EXE command into the supervisor task (task 0). 

LABEL ALREADY DEFINED 

MASTER SLAVE DISTANCE MISMATCH 

Defining a program or label with an existing program name or label name 

Attempting a preset Following move with a FOLMD value that is too small 

MAXIMUM COMMAND LENGTH EXCEEDED Command exceeds the maximum number of characters 

MAXIMUM COUNTS PER SECOND 

EXCEEDED 

MOTION IN PROGRESS 

Velocity value is greater than 1,600,000 counts/sec 

Attempting to execute a command not allowed during motion (see Restricted 

Commands During Motion on page 17.) 

Following: The FOLEN1 command was given while that follower was moving in 

a non-Following mode. 


Programming Error Messages (continued) 


NEST LEVEL TOO DEEP 

NO MOTION IN PROGRESS 

NO PATH SEGMENTS DEFINED 

NO PROGRAM BEING DEFINED 

NOT ALLOWED IF SFBØ 

NOT ALLOWED IN PATH 

NOT DEFINING A PATH 

NOT VALID DURING FOLLOWING 

MOTION 

NOT VALID DURING RAMP 

OUTPUT USED AS OUTFNC 

PATH ALREADY MOVING 

PATH NOT COMPILED 

STRING ALREADY DEFINED 

STRING IS A COMMAND 

UNDEFINED LABEL 

WARNING: POINTER HAS WRAPPED 

AROUND TO DATA POINT 1 

WARNING: ENABLE INPUT INACTIVE 

WARNING: DEFINED WITH ANOTHER 

TW/PLC 


IFs, REPEATs, WHILEs, or GOSUBs nested greater than 16 levels (for each type) 

Attempting to execute a command that requires motion, but motion is not in 

progress 

Compiled Profile compilation error 

END command issued before a DEF command 

Changes to tuning commands and SMPER are not allowed if SFBØ is selected 

Compiled Profile path compilation error 

Executing a compiled profile command while not in a path 

A GO command was given while moving in the Following mode (FOLEN1) and 

while in the preset positioning mode (MCØ). 

A GO command was given while moving in a Following ramp and while in the 

continuous positioning mode (MC1). Following status (FS) bit #3 will be set to 1. 

A FOLEN command was given during one of these conditions: 

• During a shift (FSHFC or FSHFD) 

• During a change in ratio (FOLRN/FOLRD) 

• During deceleration to a stop 

Attempted to change an output that is not a “general purpose” (OUTFNCi-A) 

output (see page 107) 

Compiled Profile compilation error 

Attempting to execute a individual profile that has not been compiled 

A string (program name or label) with the specified name already exists 

Defining a program or label that is a command or a variant of a command 

Command issued to product is not a command or program name 

During the process of writing data (DATTCH) or recalling data (DAT), the pointer 

reached the last data element in the program and automatically wrapped 

around to the first datum in the program 

ENABLE input is no longer connected to ground (GND) 

Duplicate I/O in multiple thumbwheel definitions 

Index 231

Identifying Bad 


To facilitate program debugging, the Transfer Command Error (TCMDER) command allows 

you to display the first command that the controller detects as an error. This is especially 

useful if you receive an error message when running or downloading a program, because it 

catches and remembers the command that caused the error. 

Using Motion Planner: 

If you are typing the command in a live terminal emulator session, the controller will 

detect the bad command and respond with an error message, followed by the ERRBAD 

error prompt (). If the bad command was detected on download, the bad command 

is reported automatically (see example below). 

NOTE: If you are not using Motion Planner, you’ll have to type in the TCMDER 

command at the error prompt to display the bad command. 

Once a command error has occurred, the command and its fields are stored and system status 

bit #11 (reported in the TSSF, TSS and SS commands) is set to 1, and error status bit #16 

(reported in the TERF, TER and ER commands) is set to 1. The status bit remains set until the 

TCMDER command is issued. 

Example Error 

Scenario 

1. In Motion Planner’s program editor, create and save a program with a programming error: 

DEL badprg ; Delete a program before defining and downloading 

DEF badprg ; Begin definition of program called badprg 

MA1 

; Select the absolute preset positioning mode 

A25 


AD11 

; Set deceleration 

V5 


VAR1=0 ; Set variable #1 equal to zero 

GO1 

; Initiate move on axis 

IF(VAR1 *NO ERRORS 

*INCORRECT DATA 

> *IF(VAR1 

Trace Mode 

Step 1 

You can use the Trace mode to debug a program. The Trace mode allows you to track, 

command-by-command, the entire program as it runs. The Gem6K will display all of the 

commands as they are executed. NOTE: Program tracing is also available on the RP240 

display (see page 127). 

The example below demonstrates the Trace mode. 

Create a program called prog1: 

DEF prog1 

; Begin definition of program prog1 




L3 

; Loop 3 times 

GOSUB prog3 

; Gosub to program #3 (prog3) 

LN 

; End the loop 

END 



Step 2 

Create a program prog3: 

DEF prog3 

; Begin definition of program prog3 

D50000 ; Sets the distance to 50,000 

GO1 

; Initiates motion 

END 


Step 3 

Enable the Trace Mode: 

TRACE1 

; Enables the Trace mode 

Step 4 

Execute the program prog1: (each command in the program is displayed as it is executed) 

EOT13,10,0 

; Set End-of-Transmission characters to , 

RUN prog1 

; Run program prog1 

The response will be: 

*PROGRAM=PROG1 




















COMMAND=A10.0000 

COMMAND=AD10.0000 

COMMAND=V5.0000 

COMMAND=L3 

COMMAND=GOSUB PROG3 LOOP COUNT=1 

COMMAND=D50000 LOOP COUNT=1 

COMMAND=GO1 LOOP COUNT=1 

COMMAND=END LOOP COUNT=1 

COMMAND=LN LOOP COUNT=1 











COMMAND=END 

The format for the Trace mode display is: 

Program Name ... Command ... Loop Count or 

Program Name ... Command ... Repeat Count or 

Program Name ... Command ... While Count 

Step 5 

Exit the Trace Mode. 

TRACE0 

; Disables the Trace mode 

Tracing Program 

Flow 

Using the TRACEP command, you can monitor the entry and exit of programs and their 

associated nest levels. 

For example, let’s assume these four programs are defined: 

DEF PICK1 

GOSUB PICK2 

GOTO PICK3 

END 

DEF PICK2 

GOSUB PICK4 

END 

DEF PICK3 

END 

DEF PICK 4 

END 

Index 233

Now we’ll enable the TRACEP mode and launch the calling program (PICK1) to start tracing 

the program flow: 

>TRACEP1 

>PICK1 

*INITIATE PROGRAM: PICK1 NEST=1 



*END: PROGRAM NOW: PICK2 NEST=2 

*END: PROGRAM NOW: PICK1 NEST=1 


*END: 

PROGRAM EXECUTION TERMINATED 

>TRACEP0 

Single-Step Mode 

Step 1 

The Single-Step mode allows you to execute one command at a time. Use the STEP 

command to enable Single-Step mode. To execute a command, you must use the !# sign. By 

entering a !# followed by a delimiter, you will execute the next command in the sequence. If 

you follow the !# sign with a number (n) and a delimiter, you will execute the next n 

commands. The Single-Step mode is demonstrated below (using the programs from the Trace 

mode above). 

Enable the Single-Step Mode: 

STEP1 ; Enables Single Step Mode 

Step 2 

Step 3 

Step 4 

Step 5 

Enable the Trace Mode and begin execution of program prog1: 

TRACE1 

RUN prog1 

; Enables the Trace mode 

; Run program called prog1 

Execute one command at a time by using the !# command: 

!# ; Executes one command 



COMMAND=A10.0000 

To execute more than one command at a time, follow the !# sign with the number of 

commands you want executed: 

!#3 ; Executes three commands 





COMMAND=AD10.0000 

COMMAND=V5.0000 

COMMAND=L3 

To complete the sequence, use the # sign until all the commands are completed (!#16 would 

complete the example). 

To exit Single-Step mode, type: 

STEP0 ; Disables Single Step Mode 


Break Points 

The Break Point (BP) command allows you to establish a location in the program where 

command processing will halt and a message will be transmitted to the PC. There are 32 break 

points available, BP1 to BP32, all transmitting the message *BREAKPOINT NUMBER n 

where n is the break point number. 

After halting at a break point, command processing can be resumed by issuing an immediate 

continue (!C) command. 

The break point command is useful for stopping a program at specific locations in order to test 

status for debugging or other purposes. 

Example DEF prog1 ; Begin definition of program named prog1 

D50000 ; Set distance: 50000 units on axis 1 

MA1 ; Absolute mode for axes 1 

GO1 ; Initiate motion on axes 1 

IF(1PC>40000) ; Compare axis 1 commanded position to 40000 

BP1 ; If motor position is > 40000 units, set break point #1 

NIF 

; End IF statement 

D80000 ; Set distance: 80000 units on axis 1 

GO1 ; Initiate motion on axes 1 

BP2 ; Set break point #2 

END 


RUN prog1 ; Execute program prog1 

In the example above, when the IF statement evaluates true, the controller will transmit the 

message *BREAKPOINT NUMBER 1. A !C command must be issued before processing will 

continue. Once processing has continued, the second break point command will be 

encountered, and the message *BREAKPOINT NUMBER 2 will be transmitted, and processing 

of commands will pause until a second !C command is received. 

Simulating I/O Activation 

If your application has inputs and outputs that integrate the Gem6K with other components in 

your system, you can simulate the activation of these inputs and outputs so that you can run 

your programs without activating the rest of your system. Thus, you can debug your program 

independent of the rest of your system. 

There are two commands that allow you to simulate the input and output states desired. The 

INEN command controls the inputs and the OUTEN command controls the outputs. 

NOTE 

The INEN command has no effect on the trigger inputs when they are configured as trigger 

interrupt (position latch) inputs with the INFNCi-H command. 

The OUTEN command has no effect on the onboard outputs when they are configured as 

output-on-position outputs with the OUTFNCi-H command. 

You will generally use the INEN command to cause a specific input pattern to occur so that a 

program can be run or an input condition can become true. Use the OUTEN command to 

simulate the output patterns that are needed, and to prevent an external portion of your system 

from being initiated by an output transition. When you execute your program, the OUTEN 

command overrides the outputs and holds them in a defined state. 

Index 235

Outputs 

Step 1 

Step 2 

Step 3 

Step 4 

The following steps describe the use and function of the OUTEN command 

Display the state of the outputs with the TOUT command: 

TOUT 


*TOUT0000_000 

; Displays the state of the outputs 

Display the function of the outputs with the OUTFNC command: 

OUTFNC 



*OUTFNC1-A PROGRAMMABLE OUTPUT - STATUS OFF 






*OUTFNC7-A FAULT OUTPUT - STATUS OFF 

Disable outputs 1 - 4, leave them in the ON state. 

OUTEN1111 ; Disable outputs 1-4, leave them in ON state 

OUTFNC ; Displays the state of the outputs 


*OUTFNC1-A PROGRAMMABLE OUTPUT - STATUS DISABLED ON 







Change the output state using the OUT command. The status of all outputs, including auxiliary 

outputs, is displayed. The output bit pattern varies by product. To determine the bit pattern for 

your product, refer to the OUTEN command description. 

OUT1010 ; Activates outputs 1 and 3, deactivates outputs 2 and 4 

Display the state of the outputs with the OUTFNC command. 

OUTFNC 










Notice that output 2 and output 4 have not changed state because the output (OUT) command 

has no effect on disabled outputs. 

To re-enable the outputs, use the OUTEN command. 

OUTENEEEE ; Re-enables outputs 1-4 


Inputs 

Step 1 

Step 2 

Step 3 

Step 4 

Step 5 

The steps below describe the use and function of the INEN command. You can use it to cause 

an input state to occur. The inputs will not actually be in this state but the Gem6K treats them 

as if they are in the given state and will use this state to execute its program. 

This program will wait for an input state to occur and will then make a preset move: 

INFNC1-A ; Onboard input #1 is has no function 

INFNC2-A ; Onboard input #2 is has no function 

INLVL00 ; Set input #1 and #2 active level to low 


A100 ; Acceleration is set to 100 



D25000 ; Distance is 25,000 

WAIT(IN=b11) ; Waits for the input state to be 11 

GO1 


END 


Enable the Trace mode so that you can view the program as it is executed: 

TRACE1 ; Enables the trace mode 

Execute the program: 

RUN prog8 ; Runs program prog8 

The program will execute until the WAIT(IN=b11) command is encountered. The program 

will then pause, waiting for the input condition to be satisfied. Simulate the input state using 

the INEN command. Inputs with an E value are not affected. Note that the input bit pattern 

varies by product. To determine the bit pattern for your product, refer to the INEN command 

description. 

!INEN11 ; Disables inputs 1 and 2, leaving them in the ON state 

The motor will now move for 25000 steps. 

Deactivate the input simulation: 

INENEE ; Re-enables inputs 1 and 2 

Simulating Analog Input Channel Voltages 

Without actually applying any voltage, you can test any command or function that references 

the voltage on an analog input (located on an expansion I/O brick). For example, 

2ANIEN.1=1.2,1.6,1.8 overrides I/O brick 2’s hardware analog input 1 through 3 as 

follows: 1.2V on input 1, 1.6V on input 2, and 1.8V on input 3. 

Another application for the ANIEN command may be to use it in an ERRORP program to 

override the analog input voltage in response to a fault. 

Motion Planner’s Panel Gallery 

Motion Planner’s Panel Gallery provides diagnostic panels for testing your programs and 

monitor the following: 

• I/O (programmable I/O, analog I/O, limits) 

• Motion (motor and feedback device position, velocity) 

• Status (axis, system, interrupt, user-defined, Following) 

• Terminal (direct communication with the product, to check for error messages, etc.) 

Index 237

Technical Support 

For solutions to your questions about implementing Gem6K product software features, first 

look in this manual. Other aspects of the product (command descriptions, hardware specs, I/O 

connections, graphical user interfaces, etc.) are discussed in the respective manuals listed in 

Reference Documentation on page ii. 

If you cannot find the answer in this documentation, contact your local Automation 

Technology Center (ATC) or distributor for assistance. 

If you need to talk to our in-house application engineers, please contact us at the numbers 

listed on the inside cover of this manual. (The phone numbers are also provided when you 

issue the HELP command to the Gem6K.) 

Operating System Upgrades 

You may obtain an upgraded Gem6K operating system from our web site at 

http://www.compumotor.com. Instructions for downloading and upgrading the operating 

system are provided on the web page. 

Product Return Procedure 

If you must return your Gem6K Series product to affect repairs or upgrades, use this 

procedure: 

Step 1 

Step 2 

Get the serial number and the model number of the defective unit, and a purchase order number 

to cover repair costs in the event the unit is determined by the manufacturers to be out of 

warranty. 

Before you return the unit, have someone from your organization with a technical 

understanding of the Gem6K Series product and its application include answers to the 

following questions: 

• What is the extent of the failure/reason for return 

• How long did it operate 

• Did any other items fail at the same time 

• What was happening when the unit failed (e.g., installing the unit, cycling power, 

starting other equipment, etc.) 

• How was the product configured (in detail) 

• What, if any, cables were modified and how 

• With what equipment is the unit interfaced 

• What was the application 

• What was the system environment (temperature, enclosure, spacing, unit orientation, 

contaminants, etc.) 

• What upgrades, if any, are required (hardware, software, user guide) 

Step 3 

Call for a return authorization. Refer to the Technical Support phone numbers provided on the 

inside cover of this manual. The support personnel will also provide shipping guidelines. 


Index 

A 

absolute position 

absolute positioning mode 72 

absolute zero position 72 

establishing 72 

status 72 

acceleration 

change on the fly 71, 155 

maximum (Following) 189 

scaling 68 

s-curve profiling 136 

units of measure 71 

access to RP240 functions 129 

accuracy 

Following, factors affecting 189 

position capture 100, 159 

address 

Ethernet 

conflict 218 

multi-drop (RS-485) 60 

advance, geared (Following) 180 

alarm events 

trigger with an input 101 

analog inputs 

interface 132 

override voltage 237 

application examples 

cam profiling (using compiled 

Following) 148, 152 

continuous phase shift 179 

packaging (using on-the-fly motion) 

157 

PLC 117 

PLC scan mode 117 

preset phase shift 180 

registration 161, 162, 163 

scaling setup 70 

spindle (using compiled motion) 

147 

stamping (using compiled 

Following) 151 

teaching data points 112 

using a joystick 116 

using an RP240 116 

using analog inputs 116 

using programmable I/O 116 

assignment & comparison operators 7 

used in conditional expressions 25 

assignment of master and following 

170 

assumptions, skills required to 

implement features ii 

axis moving status 223 

axis scaling 67 

axis status 223 

extended 224 

relative to Following 195 

RP240 display 128 

B 

BCD program select input 97 

before you start programming iii 

binary value identifier (b) 6 

binary variables (VARB) 18, 22 

bit patterns, programmable I/O 91 

bit select operator (.) 6, 9 

bitwise operations (and, or, not, etc.) 

22 

Boolean operations 21 

branching 23 

conditional 25 

unconditional 23 

buffers 

buffered commands 

control execution of 14 

executed during motion 73, 155 

stored in a program 10 

command 73 

C 

cam profiling example 148, 152 

capture positions 99 

carriage return, command delimiter 6 

case sensitivity 6 

characters 

command delimiters 6 

comment delimiter 6 

field separators 6 

limit per line 6 

neutral (spaces) 6 

checksum 35 

closed-loop operation, steppers 84 

COM ports, controlling 56 

commanded position 

absolute position reference 72 

follower, tracking error 188 

status 227 

commands 

buffer 73 

after pause 99 

after stop 98 

command buffer execution 

after end-of-travel limit 

(COMEXL) 15 

after pause/continue input 

(COMEXR) 15 

after stop (COMEXS) 16 

continuous (COMEXC) 14 

command value substitutions 7 

delimiters 6 

errors in programming 232 

executed during motion 155 

Following (list of) 198 

immediate 4, 73 

restricted execution during motion 

17 

setup command list 64 

status 222 

syntax 4 

comment delimiter 6 

communication 37 

controlling multiple serial ports 56 

lock port during multi-tasking 211 

options 38 

problems 218 

RS-485 multi-drop 60 

compiled motion 139 

compare with on-the-fly motion 

changes 145 

Following profiles 142 

related commands 146 

sample applications 147, 148, 151, 

152 

conditional branching 25, 28 

conditional expression examples 25 

conditional go 163 

conditional GO 

pending trigger input 100, 166 

conditional looping 25, 28 

conditional statement using PMAS 

184 

configuration 

disable drive on kill 66 

drive resolution 66 

encoder-based stepper setup 84 

end-of-travel limits 77 

Following setup 170 

joystick 130 

memory allocation 11 

position modes 71 

Index 239

programmable inputs 94 

programmable outputs 105 

scaling 67 

setup commands, list 64 

setup program 13 

continous command execution mode 

(COMEXC) 

effect in continuous positioning 

mode 73 

continue 

effect on Following motion 195 

continue (!C) 16, 98 

continue execution on pause/resume 

(COMEXR) 15, 99 

continue execution on stop 

(COMEXS) 16, 98 

continue input 99 

continue key on RP240 123 

continuous positioning mode 71, 73 

Following 176, 191 

distance calculations 192 

controlling multiple serial ports 56 

count source (internally generated) 

172 

creating programs 10 

D 

daisy-chaining 59 

with RP240s 60 

data 

fields, in command syntax 5 

read from serial or Ethernet port 26 

read from the RP240 26 

teach to variable arrays 110 

deadband for stall detection 84 

debounce time 

position capture 99 

program select input 97 


debugging tools 221 

analog input voltages, simulating 

237 

error messages 229 

I/O activation 235 

identify bad commands 232 

problem/cause/solution table 218 

RP240 menus 127 

single-step mode 234 

status commands 222 

trace mode 232 

deceleration 


scaling 68 

s-curve profiling 136 


delimiters 

command 6 

comment 6 

detecting a stall 84 

stall indicator output 108 

direction, changes in compiled motion 

144 

distance 

calculations, Following 192 



registration 159 


drive 

fault status 224 

resolution 66, 219 

effect on Following 194 

shutdown 

LED status 220 

on kill 66, 98 

stall detection 66 

status on RP240 129 

dwells & direction changes, compiled 

motion 144 

E 

electrical noise See installation guide 

electronic I/O devices 119 

electronics concepts ii 

enable input 

as safety feature 116 

status 226 

enable or disable Following 175 

status 169 

while moving 195 

encoder 

capture/counter enable (steppers) 85 

failure detection 

status 224 

feedback for steppers 84 

position 


resolution 84, 219 

setup example 

steppers 84 

Z-channel 79 

end-of-move settling 89 

end-of-travel limits See limits, end-oftravel 

error 

clearing 32 

error handling 30 

related to safety 116 

error message 

Following specific 197 


Following 188 

on-the-fly motion errors 156 

program, assignment 31 

status 227 

Ethernet 39 

example programs ii 

executing programs see program, 

execution options 

expansion I/O 93 

F 

fault output 108 

field separator 6 

Filter Adjustments 87 

filtering, master position See master, 

master position filtering 

follower 

commanded position 178 

Following error 188 

conditional go 163 

definition of 170 

distance 

scaling 174 

motor/drive accuracy 190 

move profiles 175 

ratio to master 174 

status 169 

resolution 190 

scaling 174 

shift See shift 

following 

distance 

move calculations 192 

Following 167 

cam profiling example 148, 152 

commands, list of 198 

compiled Following profiles 142 

conditions used in conditional 

expressions 27 

distance 

scaling 69 

enable or disable 175 

status 169 

while moving 195 

error 188 

geared advance 180 

master cycle concept 182 

maximum acceleration (steppers) 

189 

maximum velocity (steppers) 189 

performance considerations 186 

prerequisites to Following motion 

170 

ratio Following introduction 168 

set-up parameters 170 

status 169, 226 

technical considerations 186 

virtual master 172 

G 

geared advance (Following) 180 

general purpose input function 96 

general purpose output function 107 

global command identifier (@) 6 

GOSUB 23 

GOTO 23 

GOWHEN 163 

cleared by stop or kill 194 

error condition 227 

using PMAS 184 

usng PMAS 195 

via trigger input 100, 166 

H 

hard limit See limits, end-of-travel 

help (tech support services) iii, 238 

hexadecimal value identifier (h) 6, 22 

homing 

home See limits, home 

status 223 


zeroing the absolute position 79 

host computer operation 133 

I 

I/O activation (simulation) 235 

I/O device interface 118 

IF 25 


usng PMAS 195 

immediate commands 4, 73 

not stored in programs 10 

immediate data read from RP240 27 

immediate stop 16, 73 

in position, output function 107 

incremental positioning mode 72 

inputs 

analog 132 

application example 117 

enable 116 

status 226 

encoder See encoder 

end-of-travel limits 73, 77, 116 

home limits 79 

joystick 130 

PLC 119 

programmable 90, 118 

alarm event 101 

bit pattern 91 

debounce time 96 

end-of-travel limits 104 

function assignments 94, 105 

functions (INFNC), effect on 

system performance 35 

functions (LIMFNC), effect on 


general purpose function 96 

home limits 104 

jogging 101 

joystick 102 

kill 73, 98 

one-to-one program select 103 

operand (IN) 25 

pause/continue 99 

effect on command buffer 15 

polarity 96 

program security 14, 104 

program select 97 

simulating activation 235 

status 95 


stop 16, 73, 98 

update rate 90 

user fault 99, 116 

stop 16 

thumbwheel 119 

triggers 

debounce time 96 

position capture 99 

programmed functions (TRGFN) 

100 


virtual inputs 94 

interface options 116 

interrupts 

program (ON conditions) 29 

J 

jerk (acceleration), reducing 136 

jogging 

input functions 101 

RP240 jog mode 127 

setup 101 


joystick 

application example 112, 117 

interface 130 

release input 102 

velocity select input 102 

voltage override 237 

JUMP 23 

K 

kill 

assigned input function 98 

effect on drive 66, 98 


effect on multi-tasking 209 

kill on stall 84 

L 

labels ($) 23 

last motion segment, compiled motion 

141 

LEDs 220 

LEDs on RP240 123 

left-to-right math 6 

length, master cycle 182 

limits 

end-of-travel 77 


effect on command buffer and 

program execution 15 

programmed functions 104 

status 223 

used as basis to activate output 

108 

home 79 

programmed functions 104 


line feed, command delimiter 6 

linear interpolation 

acceleration scaling 69 

distance scaling 69 

velocity scaling 69 

linear motion parameter calculations 

74 

lockout distance for registration 160 

logical operators 25 

loops 

conditional 27 

unconditional 23 

M 

master 

definition of 170 

status 169 

direction, status of 169 

distance 

move calculations 192 

programming (FOLMD) 174 

master cycle 

counting 182 

restart 183 

status 182 

length 182 

number 184 

position 182 

assignment/comparison 184 

initial 183 

rollover 182, 195 

status 184 

synchronizing 185 

status 169 

master cycle concept 182 

master input (A.K.A.) 168 

master position filtering 186, 187 

effect on accuracy 191 

effect on position accuracy 190 

status 169 

master position prediction 186, 187 

effect on accuracy 190 

status 169 

move profiles 175 

moving, status of 169 

ratio to follower 174 

status 169 

resolution 190 

scaling 69, 174 

velocity 186 

virtual 172 

mathematical operations 19 

maximum position error 

output to indicate exceeded 108 

mechanical cam replacement 148, 152 

memory 

allocation 11 


cleared on bad checksum 35 

locking 14, 104 

non-volatile 35 

status 12 

menus, RP240 126 

messages, error 229 

motion 

Following motion status 170 

motion control concepts ii 

parameters used in conditional 


pre-compiled profiles See compiled 

motion 

restrictions while in Following 195 

rough 196 

synchronize 

conditional GOs 163 


triggered conditional GOs 163 

triggered start of master cycle 

163 

with PMAS 185 

motion parameters 

linear applications 74 

Motion Planner 2 

communication features 38 

Index 241

setup program tool 13 

move completion criteria 89 

moving/not moving status 107, 223 

multi-drop, RS-485 60 

multiple serial ports, controlling 56 

multi-tasking 201 

affected by kill 209 

conditions used in conditional 


performance considerations 214 

programmed I/O functions 213 

sharing system resources 210 

task identifier (%) 6, 206, 211 

task-specific resources 211 

N 

negative-direction end-of-travel limits 

See limit, end-of-travel 

Networking 39 

neutral characters 6 

noise, electrical See installation guide 

numeric variables 18 

in conditional expression 25 

NWHILE 28 

O 

on conditions (program interrupts) 29 

effect on system performance 35 

one-to-one program select input 103 

on-line help for Windows 2 

on-line manuals ii 

on-the-fly motion changes 71, 155 

compare with compiled motion 145 

operating system upgrades 238 

operator interface 

host computer operation 133 

RP240 remote panel 123 

operators 

assignment & comparison 7 

correlated to status commands 

228 

used in conditional expressions 

25 

bit select 9 

bitwise 9 

logic 9 

math 9 

relational 9 

outputs 

activate on position 109 

output on position 109 

programmable 90, 118 

bit pattern 91 

fault output 108 

function assignments 105 

functions (OUTFNC), effect on 


general purpose function 107 

limit encountered 108 

max position error exceeded 108 

moving/not moving 107 

operand (OUT) 25 

output on position 109 

P 

polarity 106 

program in progress 107 

simulating activation 235 

stall indicator 108 

status 106 




partitioning memory 11 

password, RP240 129 

pause active, status 226 

pause key on RP240 123 

pause, effect on Following motion 195 

pause/continue input 99 

effect on motion & program 

execution 15 

performance, effects on 35 

performance, Following 186 

performance, multi-tasking 214 

phase, shift 178 

PLC interface 119 


PLC scan mode 120 

point-to-point move 72 

polarity 

commanded direction 

causes reversed direction 219 


programmable outputs 106 

position 

absolute 72 

establish 72 

accuracy, Following 190 

analog inputs 132 

capture 99 

commanded 85 

encoder 85 


commanded 

capture 99 


commanded position calculation, 

Following 188 

encoder 26 

capture 99 


error 219 

exceeded max. limit 

status 223 

max. allowable 116 


follower axis 178 

incremental 72 

master See master 

positioning modes 71 


sampling period 186 

effect on Following accuracy 190 

status 


used to active an output 109 

zeroed after homing 79 

positive-direction end-of-travel limits 

See limit, end-of-travel 

power-up start program (STARTP) 13 

clear RP240 menus 125 

Following setup commands 171 

will not execute 220 

prediction of master position 187. See 

master, master position prediction 

pre-emptive GOs See on-the-fly 

motion changes 

preset positioning mode 72 

Following 177, 191 

distance calculations 193 

profiling, custom 135 

program 

branch 

conditionally 25 

unconditionally 23 

comments 6 

creating 10 

debug tools 221 

editing in Motion Planner 2 

error handling 30 

error responses 229 

examples, using ii 

execution 

controlling 14 

from RP240 menu 127 

options 13 

execution status 226 

interrupts 29 

labels ($) 23 

loop 

conditionally 25 

unconditionally 23 

memory allocation 11 

multi-tasking 202 

power-up program 13 

program example 10 

programming guidelines 1 

scan programs in PLC mode 120 

security 14 

setup (configuration) program 13 

storage 11 

program in progress 107 

programmable inputs See inputs, 

programmable 

programmable outputs See outputs, 

programmable 

programming 

creating programs 10 


debugging via RP240 127 


error programs 34, 116 

examples, using ii 

executing programs 

options 13 

preparing to program iii 

program example 10 

program security 104 

program selection 

BCD 97 

one-to-one 103 

sample programs provided ii 

scan programs in PLC mode 120 

set-up program 13 


R 

skills required ii 

storing programs 11 

ratio of follower to master 174 

status 169 

reading thumbwheel data 119 

reference documentation ii 



lockout distance 160 

sample application 161, 162, 163 

status 160 

related documentation ii 

relational operators 25 

REPEAT 25 

repeatability, Following 

position sampling rate 190 

sensors 191 

trigger inputs 191 

resetting the controller 65 

via the RP240 menu 130 

resolution 

drive 66, 219 


encoder 84, 219 

follower axis 190 

master axis 190 

resources used by multi-tasking 210 

responses, error 229 

restart master cycle counting 100, 166, 

183 

restricted commands during motion 17 

return procedure 238 

revision levels from RP240 display 

130 

rollover of master cycle position 182, 

184, 195 

rough Following motion 196 

RP240 123 

access security 129 


COM port setup 57 

connectoin verified 226 

data read 26 

front panel description 123 

in daisy chain 60 

menu structure 126 

RS-485 multi-drop 60 

S 

safety features 116 

sample programs ii 

scaling 67, 71 

acceleration & deceleration 68 

distance 69 

effect on system performance 35 

follower 174 

master 69, 174 

velocity 68 

scan programs (PLC scan mode) 120 

security, program 14, 104 

segment, definition of 11 

serial ports, controlling 56 

settling time, actual 89 

set-up commands 64 

set-up program 13 

shift 

advance 180 

continuous 178 


preset 178 


status 169, 178 

shift left to right (>>) 22 

shift right to left (

programmed 

conditional GO (GOWHEN) 

100, 166 

restart master cycle counting 

100, 166, 183 

status 169 

repeatability 191 

trigonometric operations 20 

troubleshooting 217 

command problems & solutions 218 


enable input status 226 


Following 196 

general product condition report 

225 

identify bad commands 232 

methods 218 

status commands 222 

test panels in Motion Planner 237 

truncation 

acceleration/deceleration 68 

velocity 68 

tuning 

effect on Following accuracy 191 

Tuning 

Filter Adjustments 87 

Position Mode 85 

Procedures 85 

U 

unconditional branching 23 

unconditional looping 23 

units of measurement 67 

linear motors 74 

UNTIL 25 


usng PMAS 195 

update rate, programmable I/O 90 

upgrade the Gem6K operating system 

238 

user fault input 99, 108 


user interface options 116 

user programs, memory allocation 11 

V 

value substitution, command fields 7 

variables 

binary 18, 22 


numeric 18 


teach data 110 

string 18 

variable arrays 110 

velocity 



maximum (Following) 189 

scaling 68 

TVEL & TVELA responses relative 

to Following 195 


virtual inputs 94 

virtual master 172 

W 

WAIT 25 

compared to GOWHEN 165 

status 226 


usng PMAS 195 

web site (www.compumotor.com) ii 

WHILE 25, 28 


usng PMAS 195 

X 

XON/XOFF, controlling 56 

Z 

Z-channel 79, 83 

status 224 

zero position after homing 79

Gemini GV6K and Gemini GT6K Programmer's Guide

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?