1. EM 253 Position Module Programming Wizard
Generates the PLC code from user’s inputs.
Actually makes motion configurations easy!
Allows user to complete the entire EM253 motion module setup parameterization in just minutes.
New in Micro/WIN Version 3.2
Included with the PLC Programming SW
No add-on tools to purchase
Also includes a Control Panel online interface to optimize and adjust after the wizard configuration has been downloaded

2. Tutorial for Configuring the EM253 Position Module
PART 1: System Settings
PART 2: Machine (Drive) Data
PART 3: Setting Reference Point Search (RPS) Sequence
PART 4: Profile Definitions
PART 5: Wizard Results (Data Areas and PLC Code )
PART 6: EM253 Control Panel
PART 7: EM253 Configuration FAQ’s

3. Launch the Position Control Wizard
Launch the wizard from the icon in the Tools menu
The following slides take you through each EM253 wizard screen, explaining all the input parameters, their meaning, and the significance of each one.

4. Select the EM 253 Configuration
PART 1: System Settings
Select the EM 253 Configuration
PLC on-board PTO/PWM
PLC with EM 253 Module
This slide set does not cover screens in the PTO/PWM of the wizard. F1
Press F1 for help on any Wizard screen.

5. Intelligent Module Rack Position
PART 1: System Settings
Intelligent Module Rack Position
If connected to online PLC, Press ‘Read Modules’ button to automatically read intelligent module’s rack position.
NOTE: If you have already configured one EM253 motion module in your project, and you run the wizard a second time, then (right before this screen appears) the wizard will ask whether you wish to edit the existing motion configuration (to make changes) or to create a ‘New’ configuration for this project.
PLC’s with firmware Version (or greater) can use the EM253 module in any slot.
However, if PLC’s with earlier firmware are used with the EM253, then only other intelligent modules (such as EM241, EM253, EM277) can be between your EM253 and the S7-200 PLC.
Manually setting the Intelligent Module Rack Position (in offline configurations):
Example:
Digital
I/O
1st
EM253
Analog
I/O
2nd
EM253
CPU
Physical Position: - 1 2 3
Intelligent Module Number:
CPU
Digital
I/O
EM253
Analog
I/O
EM253
Intelligent Modules include: EM 241, EM 253 and EM277

6. Select a Measurement System
PART 1: System Settings
Select a Measurement System
A measurement system is
selected by the user, based
on the user’s preference.
Engineering Unit Selections:
inch
foot
millimeter
centimeter
degree
radian
any user-defined unit
The default ‘units’ are based on the project’s ‘Regional Settings’ from the Micro/WIN Options menu.
All data input into the fields in the wizard, on every dialog, are stored in the EM253 module upon completion (pressing ‘Finish’ button on the last screen) of the wizard.
IMPORTANT NOTE:
After user selects to “FINISH” the wizard configuration (on last very wizard dialog screen), the “Engineering Units” or “Number of Pulses” selection can no longer be changed. For instance, after wizard configuration is ‘Finished’, if the user wants to change from Engineering units to Number of Pulses, or vice versa, IT IS NOT POSSBILE. The wizard configuration creates code that uses data types based on the units selections. The only way to switch would be to delete the existing configuration and re-run the wizard to generate a new configuration.
The measurement system, Engineering Units or Number of Pulses, selected on this screen is used throughout the wizard configuration.
The motor’s Data Sheet specifies the pulses per revolution.
Specifying units is convenient because the wizard handles all conversions for the user.

7. Advanced I/O Options (1 of 3)
PART 1: System Settings
Advanced I/O Options (1 of 3)
EM253
LED’s:
STP
LIM -
LIM +
RPS
Activation
Level
Settings
Inputs:
STP
RPS
LMT -
LMT +
Module Reference
Settings:
The Module Reference on this page only points out those inputs and LED’s that have settings on this particular wizard dialog.
Other LED’s and Inputs exist for the EM253 module, although they are not referenced on this slide.
High - a logic 1 will be read when current is flowing in the input.
Low - a logic 1 will be read when there is no current flow in the input.
A logic 1 level is always interpreted as meaning the limit has been reached. The module LED’s will be ON if there is current flow to the corresponding input, regardless of the active level configured.

8. Filter Time for the RPS input
PART 1: System Settings
Advanced I/O Options (2 of 3)
Input Filter Time for EM inputs
(applies to LMT+, LMT-, STP)
Filter Time for the RPS input
Selection Range:
0.20 – millisecond
‘None’ is also an option
Input Filter Time is delay time. The input must remain at the new state for the duration of the delay time in order to be accepted as valid.
Purpose: The filter rejects noise impulses and forces input lines to stabilize before the data is accepted.

9. Advanced I/O Options (3 of 3)
PART 1: System Settings
Advanced I/O Options (3 of 3)
The Pulse Type is determined by the nature of the device.
Linear
Rotary
Left to right CW
Right to left
CCW
Positive Direction
Negative Direction
An estimated 90% of users will use devices with this default setting.

10. Set up how the H/W inputs will Respond
PART 2: Machine Data
Set up how the H/W inputs will Respond
Choices for each response are:
Decelerated Stop.
Immediate Stop.
No action. (Ignore input)
These settings should not be substituted for an Emergency Stop (E-Stop).
Choices: Descriptions:
Decelerated Stop : decelerates to a stop and indicates LIMIT reached (LIM activated).
Immediate Stop : stops by terminating pulses and indicates LIMIT reached (LIM activated).
No Action : ignores input condition.

11. MOST Important !!! Use the Motor’s Data Sheet
PART 2: Machine Data
Use the Motor’s Data Sheet
MOST Important !!!
Certain Motor parameters are vital in setting up the next wizard screens.
You must gather information from the Motor’s Data Sheet.
Motor Speeds:
Data Sheet Example:
Max. torque
Typically found as a waveform on the data sheet:
For MAX_SPEED, on the motor’s data sheet, find:
Maximum torque
Determine the Max. Torque for the application Pick a range where application will most likely work. This is NOT the same as maximum motor torque.
Speed at which that torque can be achieved (This is the MAX_SPEED to input in wizard)
Max. torque for the Application
NOTE:
If it’s a guess:
The Curve Knee is good place to start.
Pick from a approx. range and experiment
For SS_SPEED, on the motor’s data sheet, find:
Start Speed (also called “Pull-in”)
Stop Speed (also called “Pull-out”)
SS_SPEED is the minimum of these 2 values.
Typically, a useful SS_SPEED value is 5% to 15% of
the MAX_SPEED value.
Selection of the MAX_SPEED parameters is not always easy. Users typically do not know what the ‘Torque for the application’ is going to be.
If you have no idea, then guess by picking a value near on the waveform’s ‘knee’, and then adjust it later.
“MOST IMPORTANT” is shown in bold on the slides that discuss (1) Motor speeds and (2) Acceleration/Deceleration times.
Why? These parameters are most critical in getting the EM253 set up to work properly.
In general, if a user can set these parameters with reasonable data for his/her application, then the EM253 will basically work with the application.
All other parameters are also important in getting a system to work optimally. In the initial start up phase, the parameters (marked as ‘MOST IMPORTANT’) are most critical.
If customer has a motor whose data sheet parameters are not sufficient for the what the application needs, then the customer probably needs a bigger motor.
If the “start-speed” is given in ‘steps/sec’, and user is using units other than pulses/sec, then user will need to convert from pulses/sec to units, such as inches.
Example:
If 1000 pulses = 1 inch
Then 80 step/second will be 80/1000 inches/second
Max. torque speed
Max. torque speed
for the
application
Pull-in:
~ 80 Step/sec. (pulses/sec)
Click for More Details
NOTICE: As load inertia increases, the curve drops.

12. MOST Important !!! Set Motor Speeds
PART 2: Machine Data
Set Motor Speeds
MOST Important !!!
To achieve maximum resolution at higher speeds, range checking is enforced: the EM253 selects a time-base to work with based on the maximum speed. With this strategy, the EM253 calculates and enforces a minimum speed.
Notes about SS_SPEED:
if too high, motor can ‘stall’
or ‘overshoot’
if too low, motor can ‘cog’.
The SS_SPEED is mandatory.
All other calculations (In subsequent screens like when specifying Profiles, Jog parameters, Accel/Decel parameters, etc.) the SS_SPEED is used by the module in calculating and making the programmed moves.
When you set MAX value, the EM253 selects the range for you as seen in the MIN_SPEED read-only field. It means that the pulse rate will not go any lower than the calculated MIN_SPEED.
SS_SPEED cannot be lower than MIN_SPEED, and this is enforced by a range check performed by the wizard.
The EM253 module supports the following ranges:
12 PPS to 2K PPS
60 PPS to 10K PPS
300 PPS to 50K PPS
1200 PPS to 200K PPS
Start-Stop Speed (SS_SPEED) is the guaranteed speed at which motor can start and stop. It is the speed plus the application’s ‘load’ factored in.
SS_SPEED value must be greater than the minimum speed displayed from your specification of
MAX_SPEED.
Click for More Details
The SS_SPEED is a mandatory setting.

13. Set JOG parameters (for manual debugging)
PART 2: Machine Data
Set JOG parameters (for manual debugging)
Achieved by constantly enabling the Jog command
Achieved with a 1-shot Jog instruction - or- with one click on the Jog button
Jog Commands are enabled from (1) the Control Panel or (2) an EM253 pre-defined profile
or (3) a Micro/WIN Motion instruction (these are described in more detail in later slides).
JOG_INCREMENT is the distance you want the tool to move with each JOG Command.
JOG_SPEED is the maximum speed that can be obtained while the JOG command remains active. When the JOG command is de-activated, the EM253 automatically executes a command that causes the tool to decelerate until it reaches STOP.

14. MOST Important !!! Set Acceleration & Deceleration Times
PART 2: Machine Data
Set Acceleration & Deceleration Times
MOST Important !!!
ACCEL_TIME: Time required for the motor to accelerate from SS_SPEED to MAX_SPEED.
DECEL_TIME: Time required for the motor to decelerate from MAX_SPEED to SS_SPEED
Note About Defaults:
1 second default should work for most applications. Typically, motors can work with less than 1 second.
MAIN POINT TO REMEMBER:
The motor’s Acceleration & Deceleration times are strictly determined by trial and error.
Times set too short can cause the motor to stall.

15. Data Sheets show a (theoretical) example:
PART 2: Machine Data
Acceleration & Deceleration Times
MOST Important !!!
Practical Way to input the Values:
Data Sheets show a (theoretical) example:
‘THEORETICAL’ vs. ‘PRACTICAL’
Theoretically, the values could be calculated (as on data sheet)
‘Trial and Error’ approach is the efficient way of setting the values.
USE TRIAL & ERROR
Approximate values should be entered on the wizard once. Specifically, start with a large value in the wizard setting to get the application going.
During the start-up phase, adjust the values as needed with the EM253 Control Panel (EM253 Control Panel is explained later).
Optimize these settings for the application by gradually reducing the times until the motor starts to stall.
It is theoretically possible to calculate the Acceleration/Deceleration times from inertia, friction torque, etc. as shown on a motor’s data sheet.
However, 90%-100 % of average users are not able to obtain or calculate these values. (It is too scientific, data such as ‘inertia’ is unknown, etc. )
This is where the Micro/WIN Wizard & Control Panel makes it easy for the users!!!
As stated on the slide, the practical way to set up the Acceleration/Deceleration times is with “trial and error” in the initial set up:
Start with a large value.
After you get the application going, start gradually reducing the time until motor stalls.
How the values are used by EM253:
Based on the wizard inputs for the times and motor speeds, the
EM253 calculates the Accel and Decel rates (number of pulses to accomplish the target speed).
Click for More Details

16. Set ‘Jerk’ Time parameters
PART 2: Machine Data
Set ‘Jerk’ Time parameters
Jerk time provides smoother motion control by reducing the “jolt” (rate of change) in acceleration and deceleration parts of the move profile.
Reducing “jerk” improves position tracking performance.
“Jerk” time is also known as “Jolt” or “S-Curve” profiling.
Jerk Time can only be applied to simple 1-step profiles. (Profiles are explained later).
NOTE:
A good first value for JERK_TIME is 40% of ACCEL_TIME.

17. PART 3: Setting RPS Sequence
Reference Point
The Reference Point (RP) is only for applications using Absolute moves (moves that are relative to a specified RP)
If you select not to use the Reference Point, the wizard dialogs for setting RP will be skipped.
‘Homing sequence’ is a term often used interchangeably with Reference Point.
In a subsequent wizard screen, the user will select a ‘Mode’ for the tool movements.
Unlike all other modes, the Absolute ‘Mode’ is based on a Reference Point setting.
Note: ‘Homing sequence’ is a term often used interchangeably with Reference Point.

18. PART 3: Setting RPS Sequence
Reference Point Seek: A Working Example
Seek RPS Zone to the Right
Measure RPS Zone Width
Approach RP to the Right
50% of the RPS Zone is in the Work Zone, RP is in its Middle 4 2 3 1
Work Zone
RP Seek Direction
LIMIT
Active
RP Approach Direction
RPS
Here’s a working example of how a RP Seek would work in an application. As described on following slides, this is only one of many RP seek sequences available; the different RP seek sequences are selected depending on the specific application.
Note: This is a working example of how a RP Seek would work in an application. As described on following slides, this is only one of many RP seek sequences available; the different RP seek sequences are selected depending on the specific application

19. PART 3: Setting RPS Sequence
How the RP (Reference Point) is used
Wizard settings for RP are used in a ‘Seek Sequence’.
A ‘Seek Sequence’ is executed (is command driven) when a tool abnormally stops or malfunctions (when the exact location of the tool is unknown).
Workspace
Where's the Tool ???
RP Offset
The tool is present, although it’s location is unknown
- LMT
+ LMT
Zero Position RP
The EM253 uses pre-defined searches to locate the tool to a known position in the workspace.
The tool is located according to a RP Seek Sequence that is selected by the user (the PLC programmer).
The wizard allows the user to select the Seek Sequence that will fit best their application, and it enhances the optimization of the user’s system.
Absolute Move - A position move relative from a specified "zero position."
Relative Move - (incremental move) where the position move is relative from the current position. The two settings (INITIAL & APPROACH) can be set opposite. For instance, initial direction can be opposite the approach direction.
Relative Move - (incremental move) where the position move is relative from the current position. NOTE: These slides show ‘linear’ motion (rotary motion is also possible with EM253)
WORKSAPCE AREA:
EM253 applications take place within a Workspace area.
BOUNDARY LIMITS:
The workspace has boundary LIMITS on each side.
The LMT boundaries are typically sensor devices that provide inputs to the EM253.
The application reacts to LMT inputs based on the LMT responses.
ABSOLUTE MOVES:
To perform an Absolute Move, the important positions are:
A known Tool Position (not shown on the slide) that can be in or out of the workspace area.
A Reference Point (RP) is used as the target of the tool’s movement (for initialization).
3. A Zero Position is at a fixed, constant location
A Seek Sequence essentially consists of direction settings and starting location settings.
The two settings (INITIAL & APPROACH) can be set opposite. For instance, initial direction can be opposite the approach direction.
Why does seeking need to be time efficient?
Seeking is typically used between an application’s transition between builds, or at the beginning of work cycles, etc. The seek sequence reduces time and effort needed to place the work tool in the correct starting position. Otherwise, manual intervention to move the tool could be required, which would require extra man power and would cost more time.
Click for More Details

20. PART 3: Setting RPS Sequence
Reference Point ‘Seek’ Parameters
RP_FAST
Speed
RP_SLOW
RP_SEEK_DIR
Direction
RP_APPR_DIR
Click for More Details
The tool will start the seek at a faster speed because seeking needs to be time efficient. This is called RP_FAST. It is used in positioning the tool (As Quickly As Possible) near the RP.
Since the tool can only stop at certain speeds, it must be going that speed when it reaches the RP. This is called the RP_SLOW (NOTE: This speed must be less than SS_SPEED).
The two settings (INITIAL & APPROACH) can be set opposite. For instance, initial direction can be opposite the approach direction.
SEEK BEGINS with:
RP_SEEK_DIR - For each seek, will the initial seek direction be positive (right) or negative (left)?
RP_FAST – (consider motor size & SS_SPEED) How fast should seek be set?
During the SEEK :
(1) The tool begins to move. Tool will move towards the RP -or- towards a LIM, depending on set direction.
(2) If tool reaches a LIM, tool movement reverses and continues in the other direction towards the RP.
(3) Tool speed is reduced (to the settings below) as it approaches the RP and prepares to stop.
SEEK FINISHES with:
RP_APPR_DIR - will the seek direction be positive (right) or negative (left)?
RP_SLOW – (consider motor size & SS_SPEED) how fast should seek be set?
APPLICATION NOTE:
Normally, with linear moves, the application direction and seek direction will be opposite.
With rotary moves, they will be the same.
Purpose of inputs on this screen:
RP_SLOW – search slows down as it approaches the target point, and will not miss it (~ SS_SPEED).
RP_FAST – search speeds up to expedite the search (typically this will be 2/3 the MAX_SPEED)
RP_SEEK_DIR – direction that the application’s searches generally move in most of the time; this avoids switching directions often, which would ultimately slow down the overall search RP_APPR_DIR – same direction as the normal work cycle proceeds in; this reduces backlash and provides more accuracy

21. PART 3: Setting RPS Sequence
Advanced RP Options
Workspace
- LMT
+ LMT
RP Offset
Zero Position RP
RP Offset (RP_OFFSET) is at a fixed, constant location, at an exact distance from the zero position.
When appropriately used, Backlash compensation allows the use of a lower cost equipment (such as the cheaper worm gears).
Backlash compensation would be used when a tool is not moved in the same direction ( not for constant back & forth motion).
Note: When appropriately used, Backlash compensation allows the use of a lower cost equipment (such as worm gears).

22. PART 3: Setting RPS Sequence
Setting a Reference Point Search (RPS) Sequence
4 possible Seek (Mode) Sequences:
MODE 1: The reference point is where the RPS input goes active on the approach from the work zone side.
MODE 2: The reference point is centered within the active region of the RPS input.
MODE 3: The reference point is located outside the active region of the RPS input.
MODE 4: The reference point is located within the active region of the RPS input.
There are 4 possible Reference Point (RP) definitions.
With RP_SEEK_DIR and RP_APPR_DIR settings, there are 16 different sequences.
The graphic shown is dependent on your previous wizard inputs:
(a) Seek Sequence
(b) ‘Direction of RP Seek’
(c) RP_APPR_DIR
ZP (Zero Pulse) input count is the number of pulses issued after the home search trigger condition is met.
Note: There are 4 possible Reference Point (RP) definition. With RP_SEEK_DIR and RP_APPR_DIR settings, there are 16 different sequences.

23. Distance / Number of Pulses
PART 4: Profile Definitions
Setting the number of User Profiles
A Profile is created from a set of parameters associated with a tool’s movement.
A profile is shown graphically as a function of speed and distance (see the diagram)
Distance / Number of Pulses
Speed
A ‘Step’ is a fixed distance for a tool to be
moved, including distance covered during acceleration & deceleration times.
One ‘Step’
You input the number of profiles to be defined for this EM253 project (25 is maximum profiles allowed)
This Q-memory area is used to trigger commands that get executed by the module.
The programmer defines number of profiles for the project on this screen. Parameters for each profile are specified on a subsequent screen.
Note: The programmer defines number of profiles for the project on this screen. Parameters for each profile are specified on a subsequent screen.

24. PART 4: Profile Definitions
Start address for the wizard configuration data
You input the starting PLC memory address of where the profile data will be placed into the PLC memory (34 bytes for each profile)
-or-
Press ‘Suggest Address’ button and Micro/WIN inserts the start address of an unused, available area
Each instruction is created from a subroutine that is placed into the project. The subroutine is hidden so the user will not be able to modify it.
The instructions are added to the Micro/WIN PLC project under the ‘Call Subroutine’ folder.
The programmer can then call the instructions where necessary in his PLC project.

25. Examples of ‘Workable’ Profiles
PART 4: Profile Definitions
Examples of ‘Workable’ Profiles
(a.) 1-Step Profile
The only thing changing will be Accel. & Decel. rates. At minimum, this profile requires the Wizard profile configuration to set the ‘type’.
(b.) 1-Step Profile
(c.) 4-Step Profile
Different colors represent the different steps.
(d.) 4-Step Profile
Refer to the notes in figure (a.)
Different colors represent different steps within the profile.
The maximum number of steps for any profile is 4. This is a fixed limitation of the module.
The maximum number of profiles in each module is 25.
These are not the only profiles allowed. There are many other combinations.

26. Single-speed Continuous Rotation Two-speed Continuous Rotation
PART 4: Profile Definitions
Understanding the profile ‘Mode’ selections
Absolute Position
Desired ending position from the Zero Point.
0 (Zero Point)
Relative Position
Desired ending position from the Starting Point.
Starting Point
Zero
Point
Single-speed Continuous Rotation
Controlled by your program until another command (such as ‘Abort’) is issued
Single-speed Continuous Rotation with Triggered stop.
Target Speed
RPS signals Stop
Execution of commands shall cause the module to perform the motion operation specified in the MODE field of the Profile Block indicated by the command_code portion of the command. The specifications for Interactive Block motion operations are not cached, so they are read each time that the module receives this command.
In absolute position mode the motion profile block shall define from one to four steps with each step containing both the position (POS) and speed (SPD) that describes the move segment. The POS specification represents an absolute location, which is based on the location designated as reference point. The direction of movement is determined by the relationship between the current position and the position of the first step in the profile. In a multi-step move, a reversal of direction of travel shall be prohibited and shall result in an error condition being reported.
In relative position mode the motion profile block shall define from one to four steps with each step containing both the position (POS) and the speed (SPD) that describes the move segment. The sign of the position value (POS) shall determine the direction of the movement. In a multi-step move, a reversal of direction of travel shall be prohibited and shall result in the reporting of an error condition.
In the single-speed, continuous speed modes, the position (POS) specification shall be ignored and the module shall accelerate to the speed specified in the SPD field of the first step. One Mode is used for positive rotation and the other mode is used for negative rotation.
In the single-speed, continuous speed modes with triggered stop, the module shall accelerate to the speed specified in the SPD field of the first step. If and when the RPS input becomes active, movement shall stop after completing the distance specified in the POS field of the first step. One Mode is used for positive rotation and the other mode is used for negative rotation.
In two-speed, continuous speed modes the binary value of the RPS input selects one of two continuous speed values as specified by the first two steps in the profile block. One Mode is used for positive rotation and the other mode is used for negative rotation. The SPD controls the speed of movement. The POS values shall be ignored in this mode. The following table defines the relationship between the inputs and the step within the profile block.
Two-speed Continuous Rotation
Target Speed with RPS Inactive
Click for More Details

27. PART 4: Profile Definitions
Create Profile Definition(s)
1. Select a mode for this profile.
2. Input parameters to define the step:
(a.) Target Speed
(b.) Ending Position
4. Press to define another new step in the current profile.
3. Click ‘Plot Step’ button (Step appears in the window).
5. Repeat 1 – 4 for each step (up to 4 steps) in each profile.
Based on the programmer inputs for ‘Target Speed’ and ‘Ending Position’ for defining the step, the resulting, calculated units of measurement will be displayed (as read only field) beneath the input parameters.
6. Repeat entire process for each new profile definition (max. 25 profiles)
You can assign a name to each profile.
Note: Based on the programmer inputs for ‘Target Speed’ and ‘Ending Position’ for defining the step, the resulting, calculated units of measurement will be displayed (as read only field) beneath the input parameters.

28. Completing the Wizard Configuration
PART 5: Wizard Results
Completing the Wizard Configuration
The wizard screen now explains what changes will be made to your Micro/WIN program.
When you complete the wizard by clicking the ‘Finish’ prompt:
(1) the indicated changes are made to your Micro/WIN project.
(2) The instructions are added under the ‘Call Subroutines’ folder of the instruction tree.
(3) A Symbol table containing EM253 project symbols is added to the project

29. MOST Important !!! MOST Important !!!
PART 5: Wizard Results
Summary : Your Inputs into Motion Wizard
This is a review of the input fields on the wizard screens:
System Settings
Intelligent Module Position in the PLC Rack
Select Measurement System & Engineering Units
Module Response to LIM+/- Switch & Stop Input
Motor Speed (Starting, Maximum, Jog)
Motor Acceleration & Deceleration Times
Reference Point Seek Speed & Direction
Advanced Reference Point settings (Optional button)
Reference Point Search Sequence
Number of Profiles & Address of QB Command Byte
V-memory Start Address of Data Block Locations
Profile Definitions (Mode and Steps for every profile)
Last Screen shows summary of EM253 project entries
Machine Data
MOST Important !!!
MOST Important !!!
Seek Reference Point Settings
This is a review of all the different types of inputs fields on the wizard screens.
Profile Definition
& Data Areas
Finish

30. Review : What the Motion Wizard Generates
PART 5: Wizard Results
Review : What the Motion Wizard Generates
Data Block values
(V-memory):
One Q byte location is set as the EM253 ‘Command Control’ Byte:
SBR’s for Motion Instructions are placed in the Micro/WIN Instruction tree under ‘Call Subroutines’:
60-BYTES IN DATA BLOCK
(FOR MODULE CONFIGURATION SETTINGS)
Q-MEMORY BYTE
POS0_CTRL (SBR1)
POS0_MAN (SBR2)
POS0_RUN (SBR3)
POS0_SRATE (SBR4)
POS0_GOTO (SBR5)
POS0_DIS (SBR6)
POS0_LDOFF (SBR7)
POS0_LDPOS (SBR8)
POS0_RSEEK (SBR9)
POS0_CLR (SBR10)
POS0_CFG (SBR11)
40-BYTES FOR PROFILE #1
A Project Symbol Table containing EM253 Settings:
(OPTIONAL)
40-BYTES FOR PROFILE #2
GLOBAL SYMBOL TABLE CONTAINING THE POSITION MODULE PARAMETERS
This is a review of all data that gets inserted into the Micro/WIN project when the wizard is completed.
. . .
40-BYTES FOR
PROFILE X
(MAX: X = 25)
Each EM253 configuration created will place a set of instructions (one for ea. module in your rack). For example:
EM253 configuration 1 = POS0_ …
EM253 configuration 2 = POS1_ …
EM253 configuration 3 = POS2_ …
Etc.
Multiple EM253 configurations are possible. Each configuration will have it’s own set of DB values.

31. Instruction Descriptions (1 / 3)
PART 5: Wizard Results
Instruction Descriptions (1 / 3)
POSx_CTRL
Control
Enables and initializes the Position module. Ensures that your program calls this instruction every scan. Use SM0.0 (Always On) as the input for the EN parameter.
POSx_MAN
Manual Mode
Puts the EM253 module into manual mode. This allows the motor to be run at different speeds or to be jogged in a positive or negative direction. You can enable only one of the RUN, JOG_P, or JOG_N inputs at a time.
Commands the Position Module to go to a desired location.
GOTO
POSx_RUN
Run Profile
Commands the Position module to execute the motion operation in a specific profile stored in the configuration/profile table.

32. Load Reference Point Offset POSx_LDPOS Load Position
PART 5: Wizard Results
Instruction Descriptions (2 / 3)
POSx_RSEEK
Seek Ref Pt Position
Initiates a reference point seek operation, using the search method in the configuration/ profile table.
POSx_LDOFF
Load Reference Point Offset
Establishes a new zero position that is at a different location from the reference point position.
POSx_LDPOS Load Position
Change the current position value in the Position module to a new value. You can also use this instruction to establish a new zero position for any absolute move command.

33. Turns DIS output of EM On or Off
PART 5: Wizard Results
Instruction Descriptions (3 / 3)
POSx_SRATE Set Rate
Commands the Position module to change the acceleration, deceleration, and jerk times.
The POSx_DIS instruction turns the DIS output of the Position module on or off. This allows you to use the DIS output for disabling or enabling a motor controller.
POSx_DIS
Turns DIS output of EM On or Off
Commands the Position module to generate a 50-ms pulse on the CLR output.
POSx_CLR
Pulse
CLR Output
Commands the Position module to read the configuration block from the location specified by the configuration/profile table pointer.
POSx_CFG
Reload Configuration

34. EM 253 Control Panel (for start-up & debugging)
PART 6: Control Panel
EM 253 Control Panel (for start-up & debugging)
Runs independently of the user’s program
Selected as separate icon under Tools
Verifies wiring of EM253 is correct
Verifies EM253 is configured correctly
Allows minor adjustments to be made to the EM253 configuration
Prompts user if adjustments should be made permanent to the EM253 configuration
PLC should be ONLINE and in STOP mode, to perform the commands or change parameter settings.
NOTE: An online EM253 module is required to execute the Control Panel.

35. ‘Operation’ tab Select Module Command Module Status Manual Operation
PART 6: Control Panel
‘Operation’ tab
Select Module Command
Module Status
Manual Operation
Profile Status

36. Profile & Module Status
PART 6: Control Panel
Profile & Module Status
Step 1
Step 2
Step 3
Step 4
EM253
Profile Status
Module Status
Examine the individual profiles.

37. Select a Module Command
PART 6: Control Panel
Select a Module Command
List-box of 13 Module Commands
Each command selection is different:
Necessary fields and buttons are enabled.
Instructions for the selected command are displayed.
Run a Motion Profile
Enable Manual Operation
Seek to a Reference Point
Use Manual controls to place the tool.
(1) Type in a profile number, and (2) click Execute. EM253 runs that profile one time (includes all steps).
Click Execute starts the EM command to search for a Ref. Point using the algorithm configured for the EM253.
Load Reference Point Offset
Reload Current Position
Activate/Deactivate DIS output
(1) Use Manual controls to place the tool at a new Zero Position. (2) Click Execute to save this as the RP_OFFSET .
(1) Type in the position to set, and (2) press Execute to initiate the move.
Click Execute to activate the DIS output.
Pulse the CLR output
Teach a motion Profile
Load Module Configuration
Click Execute to pulse the CLR output.
(1) After setting profile number and step, (2) use Jog buttons to position the tool, (3) then press Teach button to save it.
Loads a new configuration by commanding the EM module to read the configuration block from the V memory.
Move to An Absolute Position
Move by a Relative Amount
Reset the Command Interface
Moves to a specified position at a target speed. Before using this command, you must have already established the zero position.
Move a specified distance from the
current position at a target speed (Positive or Negative distance).
Clears the command byte for the Position module
and sets the Done bit.

38. PART 6: Control Panel
Manual Operation
This portion of the screen changes depending on what ‘Module Command is selected.
Used to reset, and set different values while
command is running.
Determines how fast the tool will move with manual operations.
Used to toggle the EM253 between Start and Stop
Determines whether tool moves backwards or forwards.
Only possible in STOP mode.
Hold down the Jog button
to reach JOG_SPEED.
Click once on Jog button
for JOG_INCREMENT

39. Reference Point Settings Application Parameters
PART 6: Control Panel
‘Configuration’ tab allows real-time user inputs
Determines
whether screen
fields can be
Edited or are
Read-only
Reference Point Settings
Application Parameters
If pressed, causes the screen values to be written to the PLC data block.
NOTE:
Upon exit of the Control Panel, the user is prompted about whether changes should be permanently written to the EM253 configuration.

40. ‘Diagnostics’ tab has Module Information
PART 6: Control Panel
‘Diagnostics’ tab has Module Information
Whenever Error(s) occur, the Diagnostics Tab flashes: “New Error In Module”
This Error indicator is then visible from any screen in the Control Panel.
Module Information
Displays information about EM253 such as:
- Position of EM in I/O Chain
- Module Type
- Firmware Version
Command Byte
Error Codes
All Error codes
Are found in
The S7-200
Systems
Manual.

41. PART 7: EM253 Configuration FAQ’s
QUESTION: If user has already finished configuring the EM253 module with the wizard, how can subsequent changes be made to the configuration?
ANSWER: Re-run the wizard, or use the EM253 control panel.
QUESTION: Can the PLC programmer program the EM253 without using the EM253 wizard?
ANSWER: Yes, although this is not recommended because of the number of required data fields.
QUESTION: If user has selected engineering units, can the user change to different engineering units or to pulses/revolutions later in the configuration?
ANSWER: Yes, although no conversion will take place. However, on a re-edit of a configuration, the user cannot change between engineering units and pulses.
QUESTION: If user has more than one EM253 module, can the wizard be run for each module?
ANSWER: Yes. The user can run the wizard multiple times as long as sufficient memory is available. The programmer must set the start addresses so that multiple EM253 configurations do not overwrite one another.
QUESTION: A user has two EM253 modules and the user needs to copy the first configuration in order to make minor modification for the second EM253. How can the configuration be copied?
ANSWER: When existing configurations are present, the wizard can move a configuration to another slot. No copy is provided.
QUESTION: Can a PLC use the on-board PTO/PWM and the EM253 at the same time?
ANSWER: Yes. The wizard is run twice (once for the PLC’s onboard PTO and once for EM253).
QUESTION: Can the Accel. and/or Decel. Times be changed ‘on the fly’? How?
ANSWER: Yes. From the EM523 Control Panel, or by using the POSx_SRATE motion instruction.

42. PART 7: EM253 Configuration FAQ’s
QUESTION: Does the EM253 support ‘micro-stepping’?
ANSWER: Yes, up to the maximum speed of the module (200 KHz). To configure it in the wizard, increase the pulses required for one revolution.
QUESTION: Can each profile have a different mode?
ANSWER: Yes.
QUESTION: If I have 2 profiles that need to be run back-to-back, will there be a delay between the 2 profiles?
ANSWER: Yes, since it must stop & then start back up; length depends on: (1) whether the profile is ‘buffered’ and (2) PLC scan time.
QUESTION: Is it possible to enter a RP (Ref. Point) without a “home sequence”?
ANSWER: Yes. An instruction, POSx_LDPOS, is available for doing this.
QUESTION: Can I synchronize 3 devices in one system (PLC, motion data, position counter) ?
ANSWER: Yes. This would be done with the PLC logic (not done automatically with the EM253).
QUESTION: Can I use an HMI to control or monitor my motion module status?
ANSWER: Yes. Use HMI to control memory area associated with the EM253 inputs and outputs, or the motion instructions’ inputs and outputs.
QUESTION: Can I link the execution of more than 1 profile without stopping?
ANSWER: No. The EM253 must stop after each profile. A profile always starts with motor stopped, and always ends with the motor stopped.
QUESTION: Where can I find out more details and information about configuring the EM253 ?
ANSWER: The new S7-200 Systems Manual (Chapter 9) covers the EM253 Position Module
(Manual Order No.: 6ES FA22--8BH0)

43. Thanks for your Attention. For further information about the EM253:
The End.
The End.
Thanks for your Attention.
For further information about the EM253:
Refer to the S7-200 Systems Manual, Chapter 9

44. Use the Motor’s Data Sheet – More Details
Selection of the MAX_SPEED parameters is not always easy. Users typically do not know what the ‘Torque for the application’ is going to be.
If you have no idea, then guess by picking a value near on the waveform’s ‘knee’, and then adjust it later.
“MOST IMPORTANT” is shown in bold on the slides that discuss (1) Motor speeds and (2) Acceleration/Deceleration times.
Why? These parameters are most critical in getting the EM253 set up to work properly.
In general, if a user can set these parameters with reasonable data for his/her application, then the EM253 will basically work with the application.
All other parameters are also important in getting a system to work optimally. However, in the initial start up phase, the parameters (marked as ‘MOST IMPORTANT’) are most critical.
If customer has a motor whose data sheet parameters are not sufficient for the what the application needs, then the customer probably needs a bigger motor.
If the “start-speed” is given in ‘steps/sec’, and user is using units other than pulses/sec, then user will need to convert from pulses/sec to units, such as inches.
Example:
If 1000 pulses = 1 inch
Then 80 step/second will be 80/1000 inches/second
Return To Slides

45. Set Motor Speeds – More Details
The SS_SPEED is mandatory.
All other calculations (In subsequent screens like when specifying Profiles, Jog parameters, Accel/Decel parameters, etc.) the SS_SPEED is used by the module in calculating and making the programmed moves.
When you set MAX value, the EM253 selects the range for you as seen in the MIN_SPEED, which is a read-only field. It means that the pulse rate will not go any lower than the calculated MIN_SPEED.
SS_SPEED cannot be lower than MIN_SPEED, and this is enforced by a range check performed by the wizard.
The EM253 module supports the following ranges:
12 PPS to 2K PPS
60 PPS to 10K PPS
300 PPS to 50K PPS
1200 PPS to 200K PPS
Return To Slides

46. Acceleration & Deceleration Times – More Details
It is theoretically possible to calculate the Acceleration/Deceleration times from inertia, friction torque, etc. as shown on a motor’s data sheet.
However, 90%-100 % of average users are not able to obtain or calculate these values. (It is too scientific, data such as ‘inertia’ is unknown, etc. )
This is where the Micro/WIN Wizard & Control Panel makes it easy for the users!!!
As stated on the slide, the practical way to set up the Acceleration/Deceleration times is with “trial and error” in the initial set up:
Start with a large value.
After you get the application going, start gradually reducing the time until motor stalls.
Return To Slides

47. How the RP (Reference Point) is used – More Details
Absolute Move - A position move relative from a specified reference point or "zero position."
Relative Move - (incremental move) where the position move is relative from the current position. The two settings (INITIAL & APPROACH) can be set opposite. For instance, ‘initial’ direction can be opposite the ‘approach’ direction.
Relative Move - (incremental move) where the position move is relative from the current position.
NOTE: The slides show ‘linear’ motion (‘rotary’ motion is also possible with EM253)
WORKSAPCE AREA: EM253 applications take place within a Workspace area.
BOUNDARY LIMITS: The workspace has boundary LIMITS on each side.
The LIM boundaries are typically sensor devices that provide inputs to the EM253.
The application reacts to LIM inputs based on the LIM responses.
ABSOLUTE MOVES:
To perform an Absolute Move, the important positions are:
A known Tool Position (not shown) that can be in or out of the workspace area.
A Reference Point (RP) is used as the target of the tool’s movement (for initialization).
A Zero Point (ZP) is at a fixed, constant location
Why does seeking need to be time efficient?
Seeking is typically used between an application’s transition between builds, or at the beginning of work cycles, etc. The seek sequence reduces time and effort needed to place the work tool in the correct starting position. Otherwise, manual intervention to move the tool could be required, which would require extra man power and would cost more time.
Return To Slides

48. Reference Point ‘Seek’ Parameters – More Details
The tool will start the seek at a faster speed because seeking needs to be time efficient. This is called RP_FAST. It is used in positioning the tool (As Quickly As Possible) near the RP.
Since the tool can only stop at certain speeds, it must be going that speed when it reaches the RP. This is called the RP_SLOW (NOTE: This speed must be less than SS_SPEED).
The two settings (INITIAL & APPROACH) can be set opposite. For instance, initial direction can be opposite the approach direction.
SEEK BEGINS with:
RP_SEEK_DIR - For each seek, will the initial seek direction be positive (right) or negative (left)?
RP_FAST – (consider motor size & SS_SPEED) How fast should seek be set?
During the SEEK :
(1) The tool begins to move. Tool will move towards the RP -or- towards a LIM, depending on set direction.
(2) If tool reaches a LIM, tool movement reverses and continues in the other direction towards the RP.
(3) Tool speed is reduced (to the settings below) as it approaches the RP and prepares to stop.
SEEK FINISHES with:
RP_APPR_DIR - will the seek direction be positive (right) or negative (left)?
RP_SLOW – (consider motor size & SS_SPEED) how fast should seek be set?
APPLICATION NOTE: Normally, with linear moves, the application direction and seek direction will be opposite. With rotary moves, they will be the same.
Return To Slides

49. The profile ‘Mode’ selections – More Details
Execution of commands shall cause the module to perform the motion operation specified in the MODE field of the Profile Block indicated by the command_code portion of the command. The specifications for Interactive Block motion operations are not cached, so they are read each time that the module receives this command.
 In absolute position mode the motion profile block shall define from one to four steps with each step containing both the position (POS) and speed (SPD) that describes the move segment. The POS specification represents an absolute location, which is based on the location designated as reference point. The direction of movement is determined by the relationship between the current position and the position of the first step in the profile. In a multi-step move, a reversal of direction of travel shall be prohibited and shall result in an error condition being reported.
 In relative position mode the motion profile block shall define from one to four steps with each step containing both the position (POS) and the speed (SPD) that describes the move segment. The sign of the position value (POS) shall determine the direction of the movement. In a multi-step move, a reversal of direction of travel shall be prohibited and shall result in the reporting of an error condition.
 In the single-speed, continuous speed modes, the position (POS) specification shall be ignored and the module shall accelerate to the speed specified in the SPD field of the first step. One Mode is used for positive rotation and the other mode is used for negative rotation.
 In the single-speed, continuous speed modes with triggered stop, the module shall accelerate to the speed specified in the SPD field of the first step. If and when the RPS input becomes active, movement shall stop after completing the distance specified in the POS field of the first step. One Mode is used for positive rotation and the other mode is used for negative rotation.
 In two-speed, continuous speed modes the binary value of the RPS input selects one of two continuous speed values as specified by the first two steps in the profile block. One Mode is used for positive rotation and the other mode is used for negative rotation. The SPD controls the speed of movement. The POS values shall be ignored in this mode. The following table defines the relationship between the inputs and the step within the profile block.
Return To Slides