Manual Laser

ICS 5000 Support Software
User Manual
Version 1.0
Part Number 571 701 721
F
Revision 1.0
March 2004
Corporate Office Warranty Remedies
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North America that (i) the Products and Software are properly and correctly
installed, configured, interfaced, maintained, stored, and operated
Trimble Construction Instruments Division in accordance with Trimble's relevant operator's manual and
5475 Kellenburger Road specifications, and; (ii) the Products and Software are not modified
Dayton, Ohio 45424-1099 or misused. The preceding warranties shall not apply to, and
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PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL
This is the March 2004 release (Revision 1.0) of the ICS 5000 TRIMBLE OR ITS SUPPLIERS BE LIABLE FOR ANY INDIRECT,
Support Software User Manual, part number 571 701 721. It applies SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES
to version 1.0 of the ICS 5000 Support Software. WHATSOEVER UNDER ANY CIRCUMSTANCE OR LEGAL
This product is unsupported and is provided “AS IS” as a courtesy. THEORY RELATING IN ANY WAY TO THE PRODUCTS,
Trimble does not manufacture or offer support services for this SOFTWARE AND ACCOMPANYING DOCUMENTATION AND
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OF THE POSSIBILITY OF ANY SUCH LOSS AND REGARDLESS OF
The following limited warranties give you specific legal rights. You THE COURSE OF DEALING WHICH DEVELOPS OR HAS
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state/jurisdiction. STATES AND JURISDICTIONS DO NOT ALLOW THE EXCLUSION
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INCIDENTAL DAMAGES, THE ABOVE LIMITATION MAY NOT
This Trimble software product, whether provided as a stand-alone APPLY TO YOU.
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EULA included with the Software providing different limited INFORMATION.
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Contents
1 Introduction
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Related Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Your Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
2 Getting Started
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Support Computer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Installing The Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
InstallShield Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Installed Directory Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Starting the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Software Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Status Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Shortcut Key Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Opening An Existing Data File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
Existing .i5k Data Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
Importing DOS Software .dat Data Files . . . . . . . . . . . . . . . . . . . . . . 2.14
Going On Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Establishing Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Synchronizing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Working On Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
3 General Configuration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Output Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Skew Control TCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Sample Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Alignment Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Alignment Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ICS 5000 Support Software User Manual a .i
Normal Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Temporary Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Offset and Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Direction Sense/Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Memory Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
4 Basic Communications Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Default Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
User Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Direct Connection Menu Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
RS-232 Interface Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
RS-422 Interface Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Communications Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Port Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Line Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Read Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Write Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ASCII Format - User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
ASCII Options - User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Serial Communications Port Information . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
RS232 Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
RS422 Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Troubleshooting Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . 4.17
No Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
Poor Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Multi-Drop Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
Multi-Drop Connection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
Multi-Drop Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
Multi-Drop Step By Step Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
5 Advanced Communications Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Choosing A Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Communication Protocol Switch-Over . . . . . . . . . . . . . . . . . . . . . . . 5.3
Configuring DF1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Communications Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
PLC/SLC Communications Configuration . . . . . . . . . . . . . . . . . . . . . 5.8
PLC-5/XX Series Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
SLC 5/0X Series Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
a.ii ICS 5000 Support Software User Manual

Message Instruction Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Modbus® Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
DeviceNet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
ICS 5000 Software Configuration for DeviceNet . . . . . . . . . . . . . . . . . . 5.21
DeviceNet Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
DeviceNet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
PROFIBUS Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35
General Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35
ICS 5000 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
Communications Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
Parameterization Telegram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
Network Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
PROFIBUS Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
Interbus Communications Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
ICS 5000 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54
INTERBUS Network Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 5.56
Custom Read and Write Data Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.62
Default Register Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
Custom Register Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
A Word About Number Conventions . . . . . . . . . . . . . . . . . . . . . . . . 5.66
Advanced Communications Command Listing . . . . . . . . . . . . . . . . . . . 5.67
6 Station Configuration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Stations Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Station Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Modify Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
7 Motion Control Overview

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TCS Algorithm - Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
PID Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
System Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BCS Algorithm - Open Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
PDM Algorithm - Feedback Only and Collision Avoidance . . . . . . . . . . . . . . . . 7.5
ICS Integrated Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Advanced Position Control - In Search of the Trapezoidal Response . . . . . . . . 7.6
System Integration with the ICS 5000 . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Motor Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
PLC or Host Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
8 Tools & Utilities

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
ICS 5000 Support Software User Manual a . i ii

Tools Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Over-/Undershoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Motor Tuning Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Random Moves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Chart Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
Flash Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
9 TCS Control Algorithm Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
System Integration Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Safe Shutdown of System Operations . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Status Interrogation and Response . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Configuration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Format “A” Configuration - Bi-Polar Output versions (–10 to + 10 VDC) . . . . . 9.6
Format “B” Configuration - Uni-Polar Output versions (0 to +10 VDC) . . . . . . 9.7
Format C Configuration - Uni-Polar Output versions (0 to +10 VDC) . . . . . . . 9.8
Sampling Frequency Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
Continuously Self Adaptive Function (Auto Gain Limit) . . . . . . . . . . . . . . 9.10
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
Hardware Output Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
TCS Parameters Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Common Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Advanced Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
Acceleration and Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
Noise and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Beam Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
Wake Up Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
Sync Input Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
ASC Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
Characterize Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
Characterization Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
Settling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
Accuracy/Time Trade -off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
Horizontal vs. Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
Ramp Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
Ending Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35
Automatic Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
Delayed Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
a.iv ICS 5000 Support Software User Manual
Characterization Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.37
Offset Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.39
Deadband and Polarity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.40
Speed Regulation or Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
Acceleration and Velocity Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.41
Pink Noise Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
Pink Noise Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.44
Step Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.45
Transient Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46
Disturbance Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.49
Finalizing the Characterization. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.50
Software Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.51
Not Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.51
High Deadband. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52
Change Direction Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52
Bad Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52
Track or Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.53
Non-Linearity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.53
Speed Overshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.54
10 BCS Control Algorithm Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Safe Shutdown of System Operations . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Status Interrogation and Response . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
Format A Configuration: Bi-Polar Output versions (-10 to +10VDC) . . . . . . . . 10.5
BCS1 Configuration Codes for Control Format A. . . . . . . . . . . . . . . . . . 10.6
Format B Configuration: Uni-Polar Output Version (0 to +10 VDC) . . . . . . . . 10.6
BCS1 Configuration Codes for Control Format B . . . . . . . . . . . . . . . . . . 10.7
Format C Configuration: Uni-Polar Output Version (0 to +10 VDC) . . . . . . . . 10.8
BCS1 Configuration Codes for Control Format C . . . . . . . . . . . . . . . . . . 10.9
Format D Configuration: Two Speed Output Version . . . . . . . . . . . . . . . . 10.9
BCS2 Configuration Codes for Control Format D. . . . . . . . . . . . . . . . . 10.10
Sampling Frequency Configuration . . . . . . . . . . . . . . . . . . . . . . . . 10.10
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
Hardware Output Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
BCS Parameters Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
Top Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Beam Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Wakeup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
Sync Input Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
Control Parameters Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Choosing Control Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . 10.22
ICS 5000 Support Software User Manual a.v
Selecting Other Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Tuning The Speed Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
Adding Multiple Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
Optimizing Velocity Failure Level . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
Finalizing the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
11 PDM Control Algorithm Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Sampling Frequency Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
Filter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
Collision Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
PDM Parameters Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
Beam Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
Collision Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
Digital Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
Wakeup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
Finalizing the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23
A Commands and Diagnostics

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.II
ACK/NAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.II
Special Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.II
Commands and Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.III
Single or grouped Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VII
Status Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VII
Self-Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VII
E Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.VIII
W Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IX
Warning Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.IX
Diagnostic Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.X
Beam Break Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.X
Motor Failure Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.XI
Settling Time Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.XII
Laser Pointer (U3;J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.XIII
B Advanced Protocol Specifics

DF1 Protocol Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.I
Supported DF1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.I
Message Framing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.I
Function 0, Word Range Write. . . . . . . . . . . . . . . . . . . . . . . . . . . . B.II
a.vi ICS 5000 Support Software User Manual

Function 0, Word Range Read . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.III
Function 67, Typed Write . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.III
Function 68, Typed Read. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.IV
Exception Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.V
MODBUS Protocol Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.V
Supported MODBUS Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . B.V
C Network Configuration Files

DeviceNet EDS File Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.II
PROFIBUS GSE File Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.III
Index
ICS 5000 Support Software User Manual a .v ii

a.viii ICS 5000 Support Software User Manual
CHAPTER
1
Introduction 1
In this chapter:
• Overview
• Getting Started
• Related Information
• Technical Assistance
• Your Comments
ICS 5000 Support Software User Manual 1.1

1 Introduction
1.1 Overview
The purpose of this manual is to acquaint you with the ICS 5000 Support Software.
This manual covers the software’s use for setup and support of an ICS 5000 in any
of it’s various configurations.
Trimble assumes that you are familiar with Microsoft Windows and know how to
use a mouse, select options from menus and dialogs, make selections from lists, and
refer to online help. Trimble also assumes you are familiar with the devices with
which the ICS 5000 will be connected to and know how to configure this devices.
1.2 Getting Started

Trimble recommends that, after reading this chapter and installing the software, you
work through Chapter 2, Getting Started on page 2.1. This chapter shows you how
to get started with the software, and how to set up a new project.
The remaining chapters describe the extended functionality of ICS 5000 Support
Software.
1.3 Related Information

Sources of related information include the following:
• Help – the software has built-in, context-sensitive help that lets you quickly
find the information you need. Access it from the Help menu. Alternatively,
click the Help button in a dialog, or press [F1].
• Readme.txt file – a Readme.txt file contains information added after the
documentation was completed. To read this file, double-click it or use a text
editor to open it. The installation program also copies it into the program
directory.
• Release notes – the release notes describe new features of the product,
information not included in the manuals, and any changes to the manuals.
They are provided as a .doc file on the CD and are installed in the program
directory (typically C:\Program Files\Trimble\ICS 5000 Support Software)
when you install the software. Use a text editor to view the contents of the
release notes.
• Trimble training courses – consider a training course to help you use your
Factory Automation system to its fullest potential. For more information,
visit the Trimble web site at: www.trimble.com/factoryautomation.html.
1.4 Technical Assistance

If you have a problem and cannot find the information you need in the product
documentation, contact your local Trimble Representative. Alternatively, do one of
the following:
• Request technical support using the Trimble web site at
www.trimble.com/support/support.htm
1.2 ICS 5000 Support Software User Manual

Introduction 1
• Send an e-mail to trimble_support@trimble.com.
1.5 Your Comments

Your feedback about the supporting documentation helps us to improve it with each
revision. To forward your comments, do one of the following:
• Send an e-mail to ReaderFeedback@trimble.com.
• Complete the Reader Comment Form at the back of this manual and mail it
according to the instructions at the bottom of the form.
If the reader comment form is not available, send comments and suggestions to the
address in the front of this manual. Please mark it Attention: Factory Automation.

1 Introduction

CHAPTER
2
Getting Started 2
• Introduction
• Support Computer Requirements
• Installing The Software
• Installed Directory Overview
• Starting the Software
• Software Overview
• Opening An Existing Data File
• Going On Line

2 Getting Started
2.1 Introduction
This chapter covers the installation and initial operation of the ICS 5000 Support
Software. The software has been designed to follow the normal Windows design
criteria, and should feel comfortable to you if you are familiar with common
Windows based applications.
Navigation is accomplished using either the Menu bar shown below
or the Toolbar shown below.
both of which are located at the top of the main program window.
In addition to the Menu bar and Toolbar, the basic program window includes a
series of tabs which are used to display the major configuration sections of the
program. In the figure that follows, the program window is depicted as it would be
on startup. The default tabs are: General (do first), Communications, Stations and
Tools. Finally, on the left side of each tab is a list of configuration screens that it
contains. Some of the screen options will be unavailable when offline and depicted
in a different shade of gray and made un-selectable until the software is ON Line
with an ICS 5000.
2.2 Support Computer Requirements

The support computer used to run this software must be using a Microsoft Windows
operating system (9x, NT, 2000, XP) and have a serial communications port. If no
serial port is installed on the computer, there are USB to serial converters that will
work as well.

Getting Started 2
2.3 Installing The Software

To install the ICS 5000 Support Software simply insert the Trimble ICS 5000
Resource CD-ROM and wait for the autorun feature to start the CD-ROM
Navigation application. Follow the Welcome path to the screen shown in the figure
that follows. Select the Install ICS 5000 Support Software link to launch the
IInstallShield Wizard. If CD-ROM Navigation application does not start, use
Windows Explorer to select the drive were your CD-ROM is located and run the
Setup.exe application located in the root directory.
You can also use the CD-ROM Navigation application to view the Support
Documents and provided Sales and Marketing literature by following their
associated links.
2.3.1 InstallShield Operation

Once the Setup.exe file executes, it will load the InstallShield to preform the
installation of the ICS 5000 Support Software. This is shown in the following
image.

2 Getting Started
Welcome Screen
Once the InstallShield application is loaded, the following welcome screen for the
InstallShield Wizard will be displayed. The navigation keys at the bottom of the
window are used throughout the progress of the software installation. Click Next to
continue.
License Agreement
In order to proceed with the software installation, you must first accept the Trimble
License Agreement shown in the following image. This agreement can be viewed by
using the scroll bar on the right side of the text window. Once it is viewed, select the
I accept... option and click Next. If you do not choose to accept this agreement, then
the software installation will terminate.
User Information and Destination Folder

The InstallShield Wizard will then display the User name and Company name
entered when Windows was installed. You can change either of these by entering
new information or simply click Next to continue.

Getting Started 2
The InstallShield Wizard will now display the destination folder for the software
installation shown in the figure that follows. The default installation folder is
C:\Program Files\Trimble\ICS5000\. You can change this by clicking Change.
Clicking the Change button displays the Change Current Destination Folder
window shown below. Use this window to select an alternate destination folder for
the software installation. Once the destination folder has been selected, click OK to
continue.

2 Getting Started
Installation Type
The InstallShield Wizard will then ask you to select an installation Type: Typical,
Minimal or Custom. Select the option that best suits your needs from the Setup Type
window, shown below, then click Next to continue.
If you selected Custom as the Setup Type, then the following window will be
displayed to assist you with configuring your custom installation.
Clicking the button next to either the Manuals or Firmware option will
display the following configuration selection. Select the desired action from the list
then click Next to continue.

Getting Started 2
Completing the Installation

The InstallShield Wizard has now configured the software for installation. Use the
Back button to make changes or click Install to proceed with the installation.
Once the installation has completed, the InstallShield Wizard will display the
following screen. A shortcut to the software has been installed in the Programs
folder under the Windows Start Menu. Select how you would like to complete the
installation from the options depicted in the following figure, then click Finish to
end the InstallShield Wizard.
2.4 Installed Directory Overview

The InstallShield Wizard creates two directories or folders under the destination
folder that is specified. These folders, Data and Manuals, may or may not contain
files depending upon the Installation Type you selected. See Installation Type,
page 2.6. The Data folder is the default location for placement of the data (*.i5k)
files created by the ICS 5000 Support Software and the Manuals folder contains the
on-line documentation files if installed.

2 Getting Started
The .i5k data files can be stored in any location on the support computer, but it is
recommended that the Data folder of the installation folder be used. Because of the
nature of the data contained within the file, a unique .i5k file will be needed for each
vehicle to be controlled.
A detailed print out of the data can be created by selecting File / Print from the
menu bar. Only one data file can be open at a time, and it is a good idea to create a
unique description of the data contained in each file for easy identification at a later
time.
2.5 Starting the Software

To start the ICS 5000 Support Software, use the shortcut installed under the
Programs folder of the Start menu. After a brief splash screen, the General tab with
the Setup Description window appears. From here you can create a new setup, open
an existing one, or go on line with an ICS 5000 unit. The initial display window also
contains a description text box where information about each setup should be
recorded. At startup, the software does not load any data file.
In it ally there are three paths to follow:
1. Open an existing data file using File / Open from the menu bar or the
icon on the toolbar.
2. Retrieve data from the ICS 5000 using the Synchronize feature.
3. Start a new configuration using the File / New from the menu bar or the
icon on the toolbar.
2.6 Software Overview

The ICS 5000 Support Software’s usage revolves around the main program window.
Within this window all software and hardware configuration takes place. The
contents of the program window will change depending upon which control
algorithm (TCS, BCS or PDM) is loaded and the connection status (ON Line or
OFF Line). Details of these changes are presented where appropriate.
The main features of this window are:
a. the Menu bar
b. the Toolbar
c. assorted navigation Tabs (e.g. General, Communications, Stations,
Tools, etc.)
d. the Status bar

Getting Started 2
Each of these elements has been designed to optimize navigation and ease of use.
2.6.1 Menu Bar

The Menu Bar provides access to the main menus used to navigate through the basic
operations of the software (Open file, Close file, Go ON Line, etc.).
References to items selected from the Menu Bar are made as follows:
File / Open
File Menu
Use the File menu to perform basic functions (open, save, and new for example) on
the data file created for each ICS 5000 configuration.
From this menu you have the following options:

2 Getting Started
• File / New - Closes the current data file and creates a new ICS 5000 setup.
When a New command is executed, a Warning window appears prompting
the user to save the existing file before continuing.
• File / Import - Launches the file import utility allowing the user to import
data files created by our old DOS based Support Software.
• File / Open - Opens an existing .i5k file.
• File / Save - Save the existing data to the open .i5k file. If no file is open, then
this selection functions the same as Save As.
• File / Save As - Save the existing data to a new .i5k file.
• File / Print - Prints the current data loaded in the software.
• File / Exit - Exits the software prompting the user to save the data before
exiting.
Plus a list of recently opened files is displayed.
Connections Menu
Use the Connections menu to handle all communications related tasks. This menu
contains everything you need to connect to the ICS 5000 and upload or download
the configuration file. Item availability varies depending upon connection status.
The Off Line version of the Connections menu provides access to only the COM
Port Settings, Work ON Line and Direct connection menu items.
The On Line version of the Connections menu provides access to the COM Port
Settings, Work OFF Line, Upload from ICS, Download To ICS and Direct
connection menu items.
See Chapter 2.8, Going On Line on page 2.15 for details on the function of each of
these menu items.

Getting Started 2
Options Menu
Use the Options menu to access program options such as Language, Password,
View “P” array and View ICS file.
From this menu you have the following options:

• Options / Language - Use this option to configure the language used for the
program interface.
• Options / Password - This option is used by Trimble engineers to enable
advanced diagnostics. Features enabled by this password can cause
unexpected operation, so it should only be used by qualified personnel.
• Options / View “P” array - Use this option to display the “P” or parameter
array used by the ICS 5000.
• Options / View ICS file - Use this option to display the .i5k file used by the
ICS 5000.
Utilities Menu
Use the Utilities menu to reach the various maintenance tools provided for the ICS
5000. These include the Flash Loader for firmware updates and the Hardware
Configuration.
ICS 5000 Support Software User Manual 2 . 11

2 Getting Started
Help Menu
Use the Help menu to activate the ICS 5000 Support Software Help System or view
the About information which contains important revision information about the
software.
2.6.2 Toolbar
The Toolbar contains quick links to commonly used features of the ICS 5000
Support Software. Some of the features are not available until the software is ON
Line with an ICS 5000 as shown figure below.
Once communications have been established with an ICS 5000, the Toolbar changes
to reflect the additional features activated as shown below.
2.6.3 Status Bar

The Status Bar (shown below) located at the bottom of the program window
displays the current working data path and file along with the communications
settings (COM1: 19200,N,8,1). Also, if the data has been changed using the
software, the word Modified will be displayed until it has been synchronized with
the ICS 5000.
2.6.4 Shortcut Key Combinations

Shortcut Key combinations may be used to reach any of the program screens in the
ICS 5000 Support Software. These three key combinations are presented throughout
this manual and are displayed as follows:
[Alt] + [T] + [1]
Simply substitute the letter for the desired tab (G, M, S, P, Z, or T) and the number
for the desired item on that tab (typically 1 through 9).
Note – Destinations of the Shortcut Key Combinations will very based upon the
control algorithm selected.

Getting Started 2
2.7 Opening An Existing Data File
2.7.1 Existing .i5k Data Files

There are two methods which can be used to open an existing data file. From the
Menu Bar by selecting File / Open
or from the Toolbar by using the tool.

When opening a file, the following dialog appears:
Use the Look in list to select the location of your data file.
All valid data files (.i5k) will be displayed. Once the file has been located, double click
on the file name or select it then click Open to open the file.

2 Getting Started
This will display the Setup Description window complete with any description that
has been entered. The configuration shown in the following figure is for an ICS
5000 configured with the TCS control algorithm.
Read the description carefully to insure it matches the setup for the ICS 5000 that is
being used before continuing on to the next section Going On Line. If the
description does not match, then open another file or create a new setup using the
File / New menu item or the Erase current ICS file tool on the Toolbar.
C
Warning – Starting a new setup will erase the existing data for the project you are
working with. You will be prompted to save the current data before continuing.
2.7.2 Importing DOS Software .dat Data Files

The ICS 5000 Support Software also has the capability of importing data created
using Trimble’s previous DOS based Support Software. Simply select File / Import
from the Menu Bar to begin. This will display the Browse for Folders window
shown in the figure that follows. Use this window to locate the folder that contains

Getting Started 2
the data you wish to import then click OK to finish. When finished, the program will
display the Setup Description window complete with any description that was
entered.
2.8 Going On Line

To go On Line with the ICS 5000 unit either select Connection / Work ON Line or
the Go ON Line tool on the toolbar. Once the connection is established, the Go
ON Line icon changes to indicate the connection and an ICS 5000 icon will
appear in the lower left corner of the program window. The software can be returned
to the Off Line mode by selecting Connection / Work Off Line or click the Go ON
Line tool on the toolbar.
Note – ICS 5000 units are shipped from the factory with default communications
parameters only. These settings are:
Baud rate - 9600; Parity - None; Bits per word - 8; and Stop bits - 1.
2.8.1 Establishing Communication

If the initial communication attempt should fail, then the Following dialog box will
be displayed:
Unless the User settings are known, select the Set PC to DEFAULT settings option
and click Test.

2 Getting Started
The ICS 5000 Support Software will attempt to establish communications using the
default communications parameters (9600, N, 8, 1). If communications are still not
established, then you will be prompted to cycle power to the ICS 5000 unit (power
down the unit for approximately 5 seconds then reapply power). After power is
reapplied, the ICS 5000 will switch to the default communication parameters
automatically allowing the software to establish communications.
See Chapter 4, Basic Communications Configuration on page 4.1 for information
on the USER settings and for details on configuring the RS-232 and RS-422
interfaces on the ICS 5000.
2.8.2 Synchronizing Data

Upon connecting with the ICS 5000 the Support Software displays following status
window:
During the synchronization process data is exchanged between the ICS 5000 and the
computer running the ICS 5000 Support Software to insure that both sets of
parameters are the same.
After communications are established, the Support Software will preform a Self-
Test and Firmware/Version Check to insure proper operation and compatibility.
Once this is confirmed, synchronization of the data will begin.
If changes have been made to the data in either the ICS 5000 or the ICS 5000
Support Software project files, then the synchronization will pause and prompt you
for direction. If, however, no data is loaded into the ICS 5000 Support Software,
then the data within the ICS 5000 will automatically be uploaded to the computer.
Synchronization of the Control Parameters and Station Locations is handled
independently. Therefore it is possible to select Write to ICS from one dialog box to
download one set of parameters and Read from ICS from the other to upload.
Clicking Cancel will terminate the synchronization and return the software to the
OFF Line mode.

Getting Started 2
If changes have been made to the Control Parameters then the following dialog box
will be displayed. Click Write to ICS to download the Control Parameters from the
open Support Software project file to the ICS 5000. Click Read from ICS to upload
the Control Parameters from the ICS 5000 to the Support Software, overwriting the
data in the open project file.
If changes have been made to the Station Look up table then a similar dialog box
will be displayed asking you to decide what action to take. Click Write to ICS to
download the Station Lookup Table from the open Support Software project file to
the ICS 5000. Click Read from ICS to upload the Station Lookup Table from the
ICS 5000 to the Support Software, overwriting the data in the open project file.
2.8.3 Working On Line

When the ICS 5000 Support Software is ON Line with an ICS 5000 unit, the ICS
5000 icon appears at the bottom left corner of the program window as shown in the
figure that follows.
Updating The Data In The ICS 5000

When changes are made to the setup using ICS 5000 Support Software, they need to
be written to the ICS 5000 before they become active. For example: If you move a
Station Location using the Support Software, the change will not effect the vehicle
positioning until the changes are written to the memory of the ICS 5000. The

2 Getting Started
Support Software alerts you that changes have been made and need to be sent to the
ICS 5000 by changing the icon displayed in the bottom left corner of the program
window as follows:
To write all changes made by the Support Software to the ICS 5000 unit, simply
click the icon displayed with the yellow arrow, or click the icon on the Toolbar.
This will synchronize the data files, insuring that both sets of parameters are the
same.
C
Warning – Writing changes made to the ICS 5000 does not also save the data file on the
computer. To do this the user must select the File / Save menu item or click the Save
icon on the Toolbar.

CHAPTER
3
General Configuration 3
In this chapter:
• Introduction
• Description
• Control Options
• Sample Rate
• Alignment
• Travel Limits
• Offset and Polarity
• Memory Protection
• Tolerance

3.1 Introduction
This chapter covers the general configuration of the ICS 5000 (TCS, BCS and PDM
control algorithms) using the General (do first) [Alt] + [G] tab shown in the following
figure. Each new configuration should begin here.
The ICS 5000 Support Software has been structured so that the order of the program
tabs follows the typical order of tasks completed during an installation. The General
(do first) tab contains links to the following screens:
• Description
• Control Options
• Sample Rate
• Alignment
• Travel Limits
• Offset and Polarity
• Memory Protection
• Tolerance
The function of each of these screens will be discussed in detail in the following
sections. The shortcut key combinations for reach each screen are also provided at
the beginning of each section.

3.2 Description
[Alt] + [G] + [1]
Use the Description screen to uniquely describe the setup data that is contained in
the .i5k data file. This description is particularly helpful if there are multiple ICS
5000 units being supported. Data displayed above the Setup Description window
gives detailed information about the ICS 5000 unit to which the data was last loaded
(Serial Number and Firmware Revision) along with details about the units
configuration (Algorithm, Output Format and Protocol).
3.3 Control Options

[Alt] + [G] + [2]
The configuration of an ICS 5000 begins by selecting the Algorithm and Output
Format needed to interface with the hardware of the axis to be controlled (PLC and
Motor Drive). This is done from the Control Options screen shown in the following
figure.

3.3.1 Algorithm
If you want to use the ICS 5000 to control the vehicle (motion control), choose TCS
or Skew Control TCS for closed-loop control or BCS for open loop control. If you
only require position, velocity and/or acceleration data or you want the ICS 5000 to
be used for collision avoidance then choose PDM.
Changing the Algorithm type (from TCS to BCS for example) requires that the ICS
5000 Support Software erase the existing data file before continuing. The following
message will be displayed, but the user will not be prompted to save the data.
C
Warning – Changing the Algorithm type used by the ICS 5000 will require that the ICS
5000 Support Software erase the current setup.
3.3.2 Output Format

Once the control algorithm has been selected, you must select an Output Format
that is supported by the motor controller you are using. There are four Output
Formats supported by the ICS 5000, and they are labeled A through D. Selecting an
option from this group formats the ICS 5000 I/O as stated. For more information on
the operation of the ICS 5000 I/O, please consult the ICS 5000 Installation Manual
Publ. No.571 701 451.
Note – The TCS algorithm only supports formats A through C while the BCS
algorithm supports all formats. The outputs for the PDM algorithm are not
configurable in this manner.
3.3.3 Skew Control TCS

The Skew Control TCS algorithm option refers to a special implementation of the
ICS 5000’s TCS algorithm designed to interface with a Trimble ASC (Advanced
Skew Controller) module. This solution is used to control the skew of wide vehicles
such as bridge cranes, and it’s installation and operation are covered in the
Advanced Skew Controller Installation Manual Publ. No. 571 701 327. The ICS
5000 is configured just as it would be for the TCS algorithm. Subtle differences in
the operation of the software are present when working with an ASC based system,
and they will be documented where they occur.

The first thing you may notice when choosing to use the Skew Control TCS
algorithm is that ICS 5000 Support Software checks the status of the Connection /
Direct Connection setting. If this is enabled, meaning the computer will be directly
connected to the ICS 5000, then you will see the following message:
Click Yes to disable Direct Connection allowing the ICS 5000 Support Software to
communicate through the ASC module.
B
Tip – Details on configuring the various control algorithms (TCS, BCS, and PDM) are
provided in separate chapters in this manual.
3.4 Sample Rate

[Alt] + [G] + [3]
Use the Sample Rate selection screen shown in the figure that follows to configure
the rate at which the ICS 5000 samples the distance data.
Using a high sample rate provides faster data updates, but also results in more noise
or distance fluctuation because less filtering is applied. Using a low sample rate
reduces the data update rate, but improves the stability of the distance reading. It is
generally preferred to start with a sample rate of 30 Hz. and adjust the frequency
only if the results are sub-standard.
B
Tip – When choosing a sample rate for the ICS 5000 consider the responsiveness of the
vehicle being controlled. The larger and less responsive the machine, the slower the
sample rate. Typical industrial vehicles do well with 30 or 49 Hz.

There is a trade-off between noise and performance, much like a filter. A high
sample rate gives higher performance but also higher noise. A low sample rate gives
lower performance but has less noise. The following are some examples of when to
use specific sample rates:
• For slowly moving vehicles with a huge mass and a high time constant a low
sampling frequency is recommended. - 19.35 Hz.
• For quickly moving vehicles with low mass and a low time constant a high
sampling frequency is recommended. - 69.50 Hz.
• For medium sized vehicles like stacker cranes and a time constant not too
high a medium sampling frequency is recommended. - 30.58 or 49.32.
• Most vehicles will have a good response with a sampling frequency of 30.58
or 49.32 Hz.
C
Warning – Changing the Sampling Frequency of the ICS 5000 once a Characterization
is complete will require you to re-Characterize the system.
B
Tip – If ICS 5000 is used as a replacement unit for an old system, 30.58 Hz should be
used to avoid having to re-characterize.
3.5 Alignment
[Alt] + [G] + [4]
Because the ICS 5000 uses infrared light to measure distance, the measurement
beam is not visible. Use the Laser Alignment screen shown below to check the
alignment of the ICS 5000 measurement beam with the reflector. This screen
provides a real-time feedback of the return signal strength and a check box to enable
the Pointing Laser alignment aid.

Typically the first step toward using the ICS 5000 involves aligning the unit with the
reflective target. This must be completed before distance measurement will be
possible.
3.5.1 Alignment Laser

Some models of the ICS 5000 are equipped with a visible pointing laser that is
aligned with the measurement beam. This laser, when enabled, will strike the target
or other surface approximately 30 mm below the measurement beam allowing un-
aided visual alignment of the unit. When you have enabled the Pointing Laser
selecting the box, the Laser Alignment screen changes as shown in the following
figure:
Select the Pointing Laser check box to turn the laser on. Un-selecting the box or
selecting another screen will turn the laser off. Remember to open the mechanical
shutter covering the laser opening (located on the front of the ICS 5000) to allow the
light to exit. If this is not done, then the laser will not be visible.
3.5.2 Alignment Statistics

At the bottom of the Laser Alignment window, there is an area titled Statistics. It
contains a Reset button along with the Maximum and Minimum values for Signal
Strength recorded since the screen was opened.Use these results to check the
alignment of the entire length of travel for the vehicle. Remember to reset the values
prior to beginning by clicking Reset. During this test the vehicle will have to be
moved using Manual control.

3.6 Travel Limits

[Alt] + [G] + [5]
Use the Travel Limits screen to define or redefine the operating limits of the system.
These limits, shown below, are the only way the ICS 5000 has of knowing what the
distance limitations of the system are.
There are two sets of limits that the ICS 5000 uses: Temporary Limits and Normal
Limits. The Normal Limits are the actual operational limits of the system, and are
captured by moving the vehicle to the limit. The Temporary Limits are used only
during restricted operation such as initial configuration or system maintenance.
3.6.1 Normal Limits

To set the Normal Limits move the vehicle to the desired limit (Near or Far) and
click the Capture button associated with the limit. The Normal limits are typically
just inside of the overtravel limitswitches, but beyond any destination to which the
vehicle needs to move.
3.6.2 Temporary Limits

Once the Normal Limits are set, Temporary Limits can be applied by dragging one
of the arrow markers below the scale or entering a value in either the Temporary
Near Limit or Temporary Far Limit field. The numeric readout these fields will also
change as the arrow marker is moved. The current vehicle position is displayed in
the middle of the screen and represented by the arrow marker above the scale.
The Normal limit values are displayed below the scale. These values are for
reference only and cannot be changed without re-capturing the limit
Note – To restore the Normal limits after you have finished using the temporary
ones, drag the Arrow markers to their original positions or enter the normal limit
values for each end.

Note – Remember to restore the Normal Limits before placing the system back into
service. Failure to do so will limit the range of motion for the system and may result
in system faults because some destination will be out of range.
B
Tip – Remember that the changes made will not be applied to the system until the
updates are transferred to the ICS 5000 unit by clicking on the Refresh icon.
3.7 Offset and Polarity

[Alt] + [G] + [6]
Use the Offset and Polarity screen to adjust the zero measurement point of the ICS
5000 and the direction in which distance increments. The screen, shown below, is
divided into two sections: Offset (mm) and Direction Sense/Polarity. For reference,
the end of travel limits and current position are also displayed.
3.7.1 Offset
There are four options from which you can select the method to use to adjust the
Offset:
a. Enter a new offset manually...
b. Adjust offset so position reads...
c. Position objects closer by...
d. Position objects farther by...
To apply an offset to the distance measurement, first you must select which of the
methods you would like to use. Then enter the desired value in the numeric field and
click Apply.

Enter a new offset manually...

When this Offset method is used, you simply enter a value which is used to offset
the measurement zero point of the ICS 5000.
Adjust offset so position reads...

You use this Offset method to enter an actual position which the ICS 5000 should
read. For example, if you want to move the ICS 5000 from its current location to a
new one, you can adjust the offset so the position reads the same value as when the
ICS 5000 what in it’s previous location. This eliminates the need to change
programmed destinations or look-up tables.
Position objects closer by... / Position objects farther by...

Use ether of the last two options (Position objects closer by... or Position objects
farther by...) to “tweak” the position reading to adjust position closer or farther from
the ICS 5000 by the specified amount.
3.7.2 Direction Sense/Polarity

The Direction Sense/Polarity effects the way the direction sense (incrementing and
decrementing of distance) is applied. Normal direction sense increments values as
the distance increases between the ICS 5000 and the reflective target. Reversed
direction sense decrements values as the distance increases.
For example, if the current distance you are reading with Normal direction sense
enabled and the offset set to 0 mm is 1000 mm, changing to Reversed direction
sense will result in a reading of -1000 mm.
B
Tip – Polarity and Offset can be used to position two vehicles from opposite ends of the
same length of travel using the same destination locations. Adjust the Offset in one ICS
5000 so that the distance at a known location matches the other ICS 5000. Then enable
Reversed direction sense in the same unit to which the Offset was applied.

3.8 Memory Protection

[Alt] + [G] + [7]
The parameters from a Characterization are stored in an internal memory inside the
ICS 5000. There are four different ways of configuring the write protection for this
memory. Use the Memory Protection screen, shown below, to control how the ICS
5000’s memory reacts to enable the downloading of parameters to an ICS 5000 from
a PLC or computer.
Details of the four options available are as follows:

1. Use the ICS 5000 Support Software only to download new parameters to the
ICS 5000 unit. The memory is write protected when you exit the software.
2. Use your own program to perform the down loading of parameters. Send U-
1;J12345 to make the memory write enabled and U-1;J1 to make the memory
write protected.
3. The memory is always write enabled and you can use your own program to
download the parameters to the ICS 5000.
4. Configures how many seconds after start up or a reset the memory should be
write enabled. The BT command will reset the ICS 5000 unit. Your down
loading program must complete the down loading in less than the time you
enter. Valid times are from 1 to 3599 seconds.
C
Warning – Care must be taken when making the memory in the ICS 5000 writable. If the
memory is left in this condition during normal vehicle operation, then unexpected results
can occur.

3.9 Tolerance
[Alt] + [G] + [7]
Use the Positioning Tolerance/Accuracy screen, shown in the following figure, to
control positioning repeatability of the control loop in the ICS 5000. The Tolerance
value is changed by entering, or using the arrow keys to select, the desired
Tolerance value.
The Tolerance setting controls two aspects of the ICS 5000’s operation:
• The accuracy of the measuring process by controlling the time interval
between auto-calibrations. This works out to about 1 minute per mm of
tolerance.
• The accuracy to which the TCS and BCS algorithms position the machine.
Before the ICS 5000 will change the status to “on station” (E=16), two
conditions must be met:
– The position error must be 1/2 of the tolerance for 3 consecutive
readings.
– The first and last readings must be on the same side of 0.
Three Example Scenarios are provided at the bottom of the screen to aid you in
selecting the proper tolerance. Two of the examples depict the combinations of
readings that result in a status of “on station”, while the final example depicts three
readings within tolerance that did not result in a status of “on station”.
The following figure contains the result of the first Example Senario.
Note – Avoid excessively small tolerances; they increase positioning time and
usually exceed the mechanical capabilities of the system the ICS 5000 is controlling.

CHAPTER
4
Basic Communications
Configuration 4
In this chapter:
• Introduction
• Communications Configuration Tab
• Serial Communications Port Information
• Troubleshooting Communications Problems
• Multi-Drop Configuration

4.1 Introduction
This chapter covers the configuration of the ICS 5000’s serial communications
interfaces. The unit has one RS-232 port and one RS-422 port which support ASCII,
DF1, MODBUS and INTERBUS. A secondary RS422 port is used to implement
Multi-Drop, Interbus, and for advanced troubleshooting.
4.1.1 Default Communication Parameters

During the first five seconds after a start up or reset, the ICS 5000 is configured for
a Default set of communication parameters. If no communication is established
during the first five seconds the system is switched to the User set of configuration.
If no communication parameters are configured in User Mode the system will
remain in Default Mode. The Default communication parameters are: Baud rate
9600, No parity, 8 Data bits and 1 Stop bit.
4.1.2 User Communication Parameters

The ICS 5000 Support Software automatically displays the Communications
Settings dialog box (shown below) whenever an attempt to go ON Line fails. You
can also access this screen by selecting Connection / COM Port Settings from the
File menu or clicking the Settings button on the Terminal screen of the Tools tab.
Select Set PC to DEFAULT settings: to communicate with the ICS 5000 using the
Default parameters, and select Set PC to USER settings: to communicate with the
ICS 5000 using some other user defined settings. When the User Settings option is

Basic Communications Configuration 4
selected, click Next to proceed to the PC Lines Settings screen (pictured below).
This screen allows you to custom configure the Baud Rate, Parity, Data Bits, and
Stop Bits for the PC interface.
The next screen that is displayed allows you to configure additional PC

communications settings. From the PC Format Settings screen you can change the
Address, Preamble, and Postamble settings. If you are OFF Line when you entered
this screen, then click Done to finish. If you are ON Line when you entered this
screen, then click Test to attempt communication.
4.1.3 Direct Connection Menu Item

The Connection / Direct Connection item on the Menu Bar is used to determine if
the ICS 5000 Support Software will be communicating directly with an ICS 5000
(Direct Connection checked) or with an ICS 5000 via an external device such as the
Trimble ASC or a modem (Direct Connection unchecked).
The default setting is checked, or Direct Connection enabled. If you are configuring
a Skew Control TCS unit, the ICS 5000 Support Software will check the status of
the Direct Connection setting. If it is enabled, the software will prompt you to
disable Direct Connection if you intend on communicating with the ICS 5000
through the ASC unit. Alternatively, if you are configuring a unit other than a Skew
Control TCS unit and the Direct Connection setting is disabled, the software will
prompt you to enable the feature. It should be enabled unless you are
communicating through a modem.

4.1.4 RS-232 Interface Basics

The ICS 5000 uses a 16 pin connection socket for the RS 232C interface. This
connection is depicted in Figure 4.1 which follows. When using an IBM compatible
portable computer with the cable connected from COM1directly into the back of the
ICS 5000 the following hardware will be required for communication with the setup
software:
Figure 4.1 RS-232 Interface Wiring Details
• A female 9 pin D-sub miniature connector to the connection socket on the

computer.
• A shielded cable with three wires connected to the D-sub and the 16 pin
connection socket at the ICS 5000.
Note – Some older style ICS 5000 units will only have a 12 pin connection socket for
communications. The pin configurations for RS-232 and RS-422, however, remain
the same.
4.1.5 RS-422 Interface Basics

The 16 pin connection socket for communication also supports the RS-422
standard. This connection is depicted in Figure 4.2 which follows. If the PLC is
using the RS-422 standard when communicating with the ICS 5000 can the same

cable be used by an IBM compatible computer. (See Figure 4.3 for more details.)
The following hardware will be required for communication with the setup
software:
Figure 4.2 RS-422 Interface Wiring Details
• An RS-232/422 converter.
• A female 9 pin D-sub miniature connector to the connection socket on the
computer. A shielded cable with three wires connected to the D-sub and the
RS-232/422 converter.
• A shielded cable with at least two twisted pairs (four wires) connected to the
RS-232/ 422 converter and to the cable between the ICS 5000 and the PLC.
Type of connectors depends on the types the PLC system and the converter
used.
Figure 4.3 RS-232 to RS-422 Communication Wiring using Converter
The RS-422 standard implements balanced voltage and the suppression of common
mode interference is very good. If communication cables in lengths exceeding 15
meters are being used we always recommend RS-422 instead of RS-232. Use only
shielded, twisted pair interconnection cables.

4.2 Communications Configuration Tab

[Alt] + [M]
There are several different methods with which to interface an ICS 5000 depending
upon the type of PLC or Host Controller that is being used. The Communications
tab on the ICS 5000 Support Software, which is shown in the following figure, is
used to configure all aspects of the communications between the ICS 5000 and any
external device.
The Communications tab contains links to the following screens:

• Protocols
• Port Options
• Line Settings
• Addressing
• Read Table
• Write Table
• ASCII Format - User Settings
• ASCII Options - User Settings
B
Tip – At boot up, both serial ports on the ICS 5000 will use the ASCII protocol with
default communication parameters (9600, N,8,1) for 5 seconds. The unit will then
automatically switch to one of the other RS232/422 protocols if it has been enabled (see
Port Options).

Note – When an ICS 5000 is purchased, the required protocol support (DeviceNet,
DF1, PROFIBUS etc.) must be indicated. ASCII protocol is the only one enabled in
a standard unit.
4.2.1 Protocols
[Alt] + [M] + [1]
Use the Protocols screen to enable any of the advanced communications protocols
available in the ICS 5000. Remember that all protocols, except for the default
ASCII, must be purchased before they can be enabled. The Protocols screen is
divided into two groups: RS232/422 Protocols and Other Protocols.
RS232/422 Protocols
Use the RS232/422 Protocols group of the Protocols screen to enable the desired
RS232/422 protocol - ASCII, MODBUS, DF1, or Interbus. To enable a protocol
you must first select it from the Protocols screen, then enable it using Port Options
on page 4.8. The protocols in this section also require that the serial parameters
(baud rate, parity, data bits and stop bits) be configured as shown in Line Settings on
page 4.9. The default protocol selection is ASCII
B
Tip – At boot up, both serial ports on the ICS 5000 will use the ASCII protocol with
default communication parameters (9600, N,8,1) for 5 seconds. The unit will then
automatically switch to one of the other RS232/422 protocols if it has been enabled (see
Port Options, page 4.8).
Other Protocols
Additional protocols that require more advanced communication hardware
configuration are enabled using the Other Protocols group of the Protocols screen.
These protocols require a dedicated hardware interface port (such as DeviceNet or
PROFIBUS) or require the use of multiple serial ports (multi-drop). The default
selection is None of the above. Details on enabling and configuring the ICS 5000 to

support these protocols is presented in the next chapter - Chapter 5, Advanced

Communications Configuration on page 5.1. The default selection for the Other
Protocols group is None of the Above.
Communication Protocol Switch-over

For systems configured with the MODBUS or DF1 protocol, the switch-over from
ASCII to the selected protocol occurs as follows:
1. Directly after boot-up the units are set to communicate in the ASCII mode.
When connected to the PLC the first message will cause the protocol to
switch but it will not be answered.
2. The second and all other messages will be answered in the new protocol. To
go back to the ASCII protocol or to use the setup software again, reset the
unit. This arrangement makes it easy to shift back and forth between the PLC
and a PC running the setup software.
4.2.2 Port Options

[Alt] + [M] + [2]
The Port Options screen enables you to configure how the two serial ports are going
to function once the ICS 5000 switches to it’s User communication parameters. For
five seconds after boot-up, both serial ports operate using Default parameters (9600
baud, No parity, one stop bit, and eight bits/char). This provides the ICS 5000
Support Software a means to connect to the ICS 5000 even if user settings are not
known or incompatible. If no ASCII message using the Default parameters is
received, then the ports will switch automatically to their User settings based upon
how the options on Port Options screen, shown below, are configured. There are
separate settings for the RS-232 and RS-422 ports.

4.2.3 Line Settings

[Alt] + [M] + [3]
Use the Line Settings screen, shown below, to configure the User communication
parameters (baud rate, parity, data bits and stop bits) for the two serial ports
(RS232/422), and the baud rate for the FieldBus (DeviceNet or PROFIBUS) if used.
Five seconds after boot-up, each serial port has the option of switching to the USER
settings defined in the RS232/422 USER Settings group. This is NOT true for
INTERBUS which uses pre-defined settings.
Use the FieldBus group to control the DeviceNet or PROFIBUS baud rate which
goes into effect immediately. Once DeviceNet or PROFIBUS is selected, the
FieldBus group title will change to reflect the selected fieldbus and the Baud Rate
dropdown list will activate.

4.2.4 Addressing
[Alt] + [M] + [4]
The Addressing screen of the Communications tab allows you to configure the
unique addresses available to the various communications protocols. This screen is
comprised of three settings groups: ASCII Address - User Settings; MODBUS/DF1
Address; and Fieldbus Address.
ASCII Address - USER Settings

The ASCII protocol can use up to a 3 character address to uniquely represent each
unit. From the ASCII Address - USER settings group shown below, this address is
enabled by first clicking the Enable check box then entering the address
character(s). If the desired address consists of characters found on the keyboard,
enter them in the box to the left of the equal sign (=), otherwise enter the ASCII
code for each character in the boxes to the right. As you enter the ASCII code, the
character will be displayed.
MODBUS/DF1 Address
Use the MODBUS/DF1 Address group shown below to configure an address for the
ICS 5000 to use when using either of those protocols. The ICS 5000 using
MODBUS or DF1 protocols must have a unique address. If you use the
MODBUS/DF1 Address in combination with the ASCII Address then the
MODBUS/DF1 Address and the first character of the ASCII address are the same.

Fieldbus Address
The ICS 5000 needs a unique Network or MAC ID to be properly identified on the
network. You do this from the Fieldbus Address group of the Addressing screen
shown in the figure that follows. The FieldBus Address group title will change to
reflect the selected fieldbus as will the Network ID/MAC ID selector range. For
PROFIBUS enter a value from 0 to 126 and for DeviceNet, a value from 0 to 63.
4.2.5 Read Table

[Alt] + [M] + [5]
MODBUS, DFl, DeviceNet and PROFIBUS represent data in integer arrays (e.g.
40001-40006 or N7:0-N7:5). By default, the data in each array element is pre-
defined (e.g. Element0 = Status Register) but you can create your own definitions
by filling out the Read Table (ICS-to-host) shown in the figure that follows. This
lets you group important pieces of data together to simplify and speed up the
reading process. You MUST do this for DEVICENET and PROFIBUS.
Details on configuring the Read Table are presented in Custom Read and Write Data
Tables on page 5.62.
4.2.6 Write Table

[Alt] + [M] + [6]
MODBUS, DFl, DEVICENET and PROFIBUS represent data in integer arrays (e.g.
40001-40006 or N7:0-5). By default, the data in each array element is pre-defined
(e.g. Element0 = Status Register) but you can create your own definitions by filling

out the Write Table (host-to-ICS). This lets you group important pieces of data
together to simplify and speed up the writing process. You MUST do this for
DEVICENET and PROFIBUS.
Details on configuring the Write Table are presented in Custom Read and Write
Data Tables on page 5.62.
4.2.7 ASCII Format - User Settings

[Alt] + [M] + [7]
Use the ASCII Format -User Settings screen shown below to configure the basic
User communication settings in the ICS 5000. The User settings are activated
automatically unless communication is established with the unit using the Default
settings (9600, N, 8, 1) within the first five seconds after power up.
B
Tip – Unless you have specific requirements for communication, use the default settings
on this screen.

ACK Message
The ICS 5000 can acknowledge or ACK successfully received commands using a 1-
3 character ACK Message. Use the ACK Message group of the ASCII Format -User
Settings screen shown below to configure this. If the desired message consists of
characters found on the keyboard, enter them in the left-most box, otherwise enter
the ASCII code for each character in the right 3 boxes. Enter all zeros to disable the
ACK Message. ASCII code 6 is the default value.
NAK Message
The ICS 5000 can not-acknowledge or NAK commands received with Parity,
Framing, or Overrun errors using a 1-3 character NAK Message. Use the NCK
Message group of the ASCII Format -User Settings screen shown below to
configure this. Enter all zeros to disable the NAK Message. ASCII code 21 is the
default value.
Preamble
The ICS 5000 can attach and expect a Preamble character at the beginning of each
message much like an address. The Preamble character is activated from the
Preamble group of the ASCII Format -User Settings screen shown below by
selecting the Enable check box and entering the desired value. The default value is 0
to disable.
B
Tip – This feature is rarely used.
Postamble
The ICS 5000 terminates all messages with a Postamble character. You configure
this character plus enable the optional Line Feed character from the Postamble
group of the ASCII Format -User Settings screen which is shown below. ASCII
code 13 (Carriage Return) is the default. Select the Line Feed check box to add a
line feed to the termination.

4.2.8 ASCII Options - User Settings

[Alt] + [M] + [8]
Use the ASCII Options -User Settings screen shown below to configure additional
User communication settings in the ICS 5000. The User settings are activated
automatically unless communications is established with the unit using the Default
settings (9600, N, 8, 1) within the first five seconds after power up.
B
Tip – Unless you have specific requirements for communication, use the default settings
on this screen.
Enable ECHO
The ECHO option is enabled by selecting the Enable ECHO check box (shown
below), and causes the ICS 5000 to echo back each character it receives as a
confirmation.
NAK Slow Messages

The NAK Slow Messages option is enabled by selecting the NAK Slow Messages
check box (shown below), and causes the ICS 5000 to send the NAK message if
there is a large time interval between received characters. This is very useful in high
noise environments.

Enable INTERUPTS
The INTERUPTS option is enabled by selecting the Enable INTERUPTS check box
(shown below), and causes the ICS 5000 to send a status report (E command)
whenever the status changes.
MODEM Compatible
The MODEM compatible option is used when the ICS 5000 will be connected to a
MODEM for remote support. It is enabled by selecting the MODEM Compatible
check box (shown below).
ON Command Delay
The ON Command Delay option is used to pace the replies from an ON Command,
such as XON for continuous reading of distance, to reduce communication traffic.
When using multi-drop, it's best to set the ON Command Delay to the number of
ICS 5000 units in the network. Set the ON Command Delay by entering a number
from 1 to 15 in the box as shown below. The default value is 0 to disable.
4.3 Serial Communications Port Information

The ICS 5000 has two serial communications ports available for user configuration.
One RS-232 port and one RS-422 port. A second RS-422 port is available for use
with the Multi-Drop feature, INTERBUS, and Trimble Diagnostic software. All of

these ports are located on the 16 pin SERIAL COM PORTS plug-in terminal strip on
the rear of the unit, which is shown in Figure 4.4 below. The hardware configuration
of the serial communications ports is detailed in the next sections.
Figure 4.4 Rear Panel View
4.3.1 RS232 Port Configuration

The 16 pin SERIAL COM PORTS plug-in terminal strip on the rear panel uses the
terminals described in Table 4.1 below for RS-232 communication.
Table 4.1 RS-232 Port Pinout
Terminal Function Description
12 TXD This pin provides the serial output from the ICS
unit.
11 RXD This pin provides the serial input to the ICS
unit.
10 COM Tied to the opto-isolated ground of the
interface circuit.
4.3.2 RS422 Port Configuration

The 16 pin SERIAL COM PORTS plug-in terminal strip on the rear panel uses the
terminals described in Table 4.2 below for RS-422 communication.
6 RB Negative polarity of the serial input.
7 RA Positive polarity of the serial input.


8 TB Negative polarity of the serial output.
9 TA Positive polarity of the serial output.
10 COM Tied to the opto-isolated ground of the
interface circuit.
4.4 Troubleshooting Communications Problems

Experience has taught us that properly establishing ASCII serial communications
between the PLC and the ICS 5000 is about half of the work involved with the entire
integration of an ICS 5000. DF1 and Modbus greatly streamline this task by
removing all of the string manipulation required with ASCII, and DeviceNet and
PROFIBUS further simplify things by adding a predefined hardware interface. Time
should be spent to insure that the communications driver supports all error codes
and makes them easily accessible to maintenance personnel during troubleshooting.
A well developed driver will save time and money in the long run.
The following sections provide some basic background on troubleshooting serial
communication problems with the ICS 5000.
4.4.1 No Communication
RS-232 Troubleshooting
1. A default set of the communication parameters can be activated for five
seconds by resetting the power to the unit and selecting a menu item when
entering the software.
2. Check that the signal ground pin no. 10 is connected.
3. Check that the Transmission channel pin no. 12 on the ICS 5000 is connected
to your computer’s or PLC’s receiving channel.
4. Check that the Receiving channel pin no. 11 on the ICS 5000 is connected to
your computer’s or PLC’s transmission channel.
5. If after all of this there is still no communications, it may be helpful to obtain
a Break-out Box. This device uses LED’s to indicate the status of the various
signals on a serial link. Based upon the voltage level present at the pin the
LED’s will illuminate RED or GREEN or not illuminate at all. On a working,
correctly wired cable, usually all that needs to be done is swapping pins 11
and 12 on the ICS 5000 screw terminal. This can be done by inserting a null
modem adapter in series with the cable. If this still does not do the trick check
the cable for poor connections.

Table 4.3 RS-232 Communication Variables

VARIABLES DESCRIPTION OTHER INFORMATION
Hardware PIN # 12 Transmission channel 1 = -5 to -15 VDC
0 = +5 to +15 VDC
Pin # 11 Receiving channel 1 = -3 to -15 VDC

0 = +3 to +15 VDC
Pin # 10 Isolated Signal common
Software Baud Rate Transmission Speed in From 1200 to 38400 b/s

Bits/Second
Parity Error Detection Even, Odd or None
Word Length Length of transmitted word in 7 or 8 bits/word

bits
Stop Bits Number of termination bits 1 or 2

attached to each word
RS-422 Troubleshooting
1. A default set of the communication parameters can be activated for five
seconds by resetting the power to the unit and selecting a menu item when
entering the software.
2. Check that the positive transmission channel, TA (pin 9), on the ICS 5000 is
connected to your computer’s or PLC’s positive receiving channel, RA.
3. Check that the negative transmission channel, TB (pin 8), on the ICS 5000 is
connected to your computer’s or PLC’s negative receiving channel, RB.
4. Check that the positive receiving channel, RA (pin 7), on the ICS 5000 is
connected to your computer’s or PLC’s positive transmission channel, TA.
5. Check that the negative receiving channel, RB (pin 6), on the ICS 5000 is
connected to your computer’s or PLC’s negative transmission channel, TB.
4.4.2 Poor Communication

Serial communications can be effected by several different things including cable
length and electrical noise that is either radiated through the air or conducted over
the connection cable. Cable length is limited by the overall capacitance of the cable.
According to the EIA standard the total cable capacitance should not exceed 2500
pico-farads for RS232. For distances greater than 15 meters use the RS422
connection.

EMI (= Electro-Magnetic Interference) problems can be more difficult to solve. The

communications cable that connects the ICS 5000 to the PC (or PLC) acts as an
antenna when it passes through an electronic field. The following list presents the
most common cures for communication problems. If communications cable runs are
treated properly, your chances for success are greatly increased.
Keys to successful serial communications cabling

• Twisted Pair
• Insure that the cable selected is shielded.
• Protect cable from switching high voltage sources (AC motor control power).
• Ground cable correctly (avoid current ground loops).
4.5 Multi-Drop Configuration

Multi-drop, is a protocol for passing data between several daisy chained ICS 5000
units. Up to 10 units can be connected in a Multi-drop network (see Figure 4.5
which follows). ASCII, Modbus and DF1 communication protocols are supported
and configured in the same way as for stand alone ICS 5000 units.
Figure 4.5 Multi-Drop Communications Wiring Overview
C
Warning – All units must be powered up and contain valid parameters for the network to
function properly. If power is removed from any one unit, the remaining units “down
stream” from the Host or PLC will not be able to communicate.

4.5.1 Multi-Drop Connection Details

The first ICS 5000 is connected to the PLC or Host Controller using either RS-232
or RS-422. The serial data is then passed from the secondary RS-422 port on the
first unit to the primary RS-422 port on the second unit. This is then repeated until
all units are linked.
Serial Comm connector pins 1 through 5 support RS-422 port #2, pins 6 through 10
support RS-422 port #1 and pins 10 through 12 support the RS-232 port A complete
pin listing of the serial communications connections on the back of the ICS 5000 is
found in Table 4.4 that follows
Figure 4.6 Multi-Drop Communications Wiring Terminal Details.
Table 4.4 Multi-Drop Wiring Details

Pin # Function Description
1 RB (422 Port 2) RS-422 Receiver Negative
2 RA (422 Port 2) RS-422 Receiver Positive
3 TA ((422 Port 2) RS-422 Transmitter Positive
4 TB (422 Port 2) RS-422 Transmitter Negative
5 Com (422 Port 2) GND (tied to the ICS chassis)
6 RB (422 Port 1) RS-422 Receiver Negative
7 RA (422 Port 1) RS-422 Receiver Positive
8 TB (422 Port 1) RS-422 Transmitter Negative
9 TA (422 Port 1) RS-422 Transmitter Positive
10 Com (422 Port 1 & 232 Port) Isolated Signal Common
11 RXD RS-232 Received Data
12 TXD RS-232 Transmitted Data

4.5.2 Multi-Drop Software Configuration

Configuration of the ICS 5000 for a multidrop network is straight forward. The four
steps that must be followed are as follows:
1. Enable Multi-Drop operation - Either as Unit 1 Using RS-232 or as Any Unit
Using RS-422
2. Enable RS-422 communications
3. Configure Serial communications
4. Set the unique unit address.
Note – Do Not enable Multi-Drop on last unit on the network. Simply enable RS-422
communications and terminate the Multi-Drop chain at that unit.
Note – Multi-Drop communications is not supported in firmware revisions before
3.01. Before attempting to setup a multi-drop network, insure that all ICS units
contain firmware 3.01 or higher.
Enabling Multi-Drop
Configure the ICS 5000 to use Multi-Drop communications from the Protocols
screen ( [ALT] + [M] + [1] ) of the Communications tab which is shown in the figure
that follows. You simply select the configuration for the ICS 5000 you are working
with from the Other Protocols group.
• Select MULTI-DROP using RS232 to configure the ICS 5000 to act as the
first unit with communication to the host or PLC using RS-232.
• Select MULTI-DROP using RS422 to configure the ICS 5000 to act as any
unit, including the first, communicating solely with RS-422.
• Select None of the Above to configure the ICS 5000 to act as the last unit.
Note – Do Not enable Multi-Drop on last unit on “chain”.

Enabling RS-422 Communications

Every ICS 5000 unit on the Multi-Drop network (except for the first unit when
using a host supporting RS-232) must have it’s RS-422 port enabled. Configure the
ICS 5000 to use RS-422 communications from the Port Options screen of the
Communications tab ( [ALT] + [M] + [2] ), which is shown in the figure that follows.
You simply select 1 Use ASCII protocol from the RS422 Port Options group to
enable the port.
If you are using the MODBUS or DF1 protocol then option 1 from the RS422 Port
Options group will be worded as follows:
• Use ASCII protocol until host starts using MODBUS protocol
or
• Use ASCII protocol until host starts using DF1 protocol
Configuring Serial Communications

The configuration of the Multi-Drop network is the simplest when using the ICS
5000’s Default communications parameters of 9600 baud, No Parity, 8 Bits per
Word and 1 Stop Bit. This way the network can be configured without any
additional communications wiring. To leave the ICS 5000 configured with the
default parameters, simply skip to the Addressing section below.
Configure the serial communications parameters for both ports to match your setup
as described earlier in this chapter starting with Line Settings, page 4.9.
B
Tip – Because of the way the ICS 5000 is configured when in Default communications
mode, no additional wiring for setup is required. Details for configuring each ICS 5000 in
your Multi-Drop network are provided in the next section.

Addressing
As with any protocol that allows communication to multiple ICS 5000 units from a
single port, addressing is extremely important when using Multi-Drop. The Address
character(s) that proceed each message that is sent and received allow the program
or bus controller to route data correctly. Each ICS 5000 unit will only respond to
data that contains the address it uses, and all data transmitted from the ICS 5000
units will also contain their respective addresses. Please refer to Addressing,
page 4.10 for details on how to configure the ICS 5000 to use Addressing.
Configuring Remaining Units

As Multi-Drop support and addressing are enabled in each ICS 5000, using the
default parameters to establish communication will provide easy access to the next
unit for configuration. Once you have completed the setup of a unit, save the setup
using File / Save As then go OFF Line by clicking the button on the toolbar.
Insure power is on to the next unit in the chain, then continue as follows.
Use the Connection / Comm Port Settings menu item to display the PC
Communications Settings dialog box. Click Set PC to DEFAULT Settings: then
to reset the communications parameters to the default settings and attempt
to communicate with the Multi-Drop network. The unit(s) on the network that have
already been configured will not respond as they are using User communications
settings with an address character. If no response is received from the next unit to be
configured, cycle power when prompted. The software will automatically “attach”
to the unit and begin synchronizing data. Click the Write To ICS button to copy the
setup data to the new unit, then change the Address character before continuing on
to the next unit.
Once configuration of each unit is complete, the individual units can be accessed
directly loading the correct .i5k file then communicating to the Multi-Drop network
using the User communications parameters.
4.5.3 Multi-Drop Step By Step Setup

1. Connect laptop to RS-232 port (or RS-422 port via a converter) of ICS 5000
#1.
2. Start the ICS 5000 Support Software.
3. Open the .i5k file for ICS 5000 #1 or create a new one.
4. Using default settings establish communications with ICS 5000 #1. This will
require that you cycle power to the unit if you are using RS-422.
5. Enable RS-422 communications using the Port Options screen , choose 1 Use
ASCII protocol ...
6. Enable Multi-Drop from the Protocols screen, choose either MULTI-DROP
using RS-232 or MULTI-DROP using RS-422.
Note – Do Not enable Multi-Drop on last unit on “chain”.

7. Use the Line Settings screen to setup the “User” communications parameters
that you would like to use. Remember that the network setup will be easier if
you choose the default (and standard) parameters of 9600 baud, No parity, 8
Bits per Word and 1 Stop Bit.
8. Enable addressing from the Addressing screen and to specify a unique ASCII
Address.
9. If not done already, prepare ICS 5000 #2 for communications by connecting
the communications to the first unit and applying power.
10. Open the .i5k file for ICS 5000 #2 or create a new one.
11. Repeat the above procedure starting at Step 4 for as many ICS 5000 unit as
needed.
Note – Multi-Drop communications is not supported in firmware revisions before
3.01. Before attempting to setup a multi-drop network, insure that all ICS 5000 units
contain firmware 3.01 or greater.

CHAPTER
5
Advanced Communications
Configuration 5
In this chapter:
• Introduction
• Choosing A Communications Protocol
• Configuring DF1 Communication
• Modbus® Configuration
• DeviceNet Configuration
• PROFIBUS Configuration
• Interbus Communications Configuration
• Custom Read and Write Data Tables

5.1 Introduction
This chapter covers the configuration of the ICS 5000’s advanced communications
protocols. The advanced communications protocols are as follows:
• DF1
• MODBUS®
• DeviceNet
• PROFIBUS
• INTERBUS
Generally there are two steps required to configure the ICS 5000 to use any of these
protocols:
1. Enable and configure desired protocol
2. Develop custom Read and Write data tables to match the application
Once configured, it is up to the user to correctly wire the communications cabling
according to the guidelines specified by the selected protocol. Finally, the
configuration of the PLC or computer must be completed so that the same protocol
is use, and the communications settings match those configured in the ICS 5000.
The following image details the location of the communication ports available on
the ICS 5000.
Figure 5.1 ICS 5000 Communications Port Layout

Advanced Communications Configuration 5
5.2 Choosing A Communications Protocol

[Alt] + [M] + [1]
At boot up, both serial ports on the ICS 5000 use the ASCII protocol for five
seconds, after which any of the additional RS232/422 or Field bus protocols can be
used. The ICS 5000 supports ASCII, MODBUS and DF1 protocols for
communication via the serial ports. Any of which can be used in conjunction with
Multi-Drop for communicating with multiple units using a single host serial port.
The ICS 5000 also supports the Devicenet, PROFIBUS and INTERBUS field buses
for more advanced hardware networking. The figure below shows the Protocols
screen of the Communications tab which lists all protocols available with the ICS
5000.
5.2.1 Communication Protocol Switch-Over

For systems configured with the MODBUS protocol or the DF1 protocol, the
protocol switch-over is as follows:
Directly after boot-up the ICS 5000 is set to communicate in the ASCII mode. If no
ASCII message is received, then the ICS 5000 respond as configured in the Port
Options screen. The default method, however, reacts as follows:
When connected to the PLC the first message will cause the protocol to switch but it
will not be answered. The second and all other messages will be answered in the
new protocol. To go back to the ASCII protocol or to use the setup software again,
reset the unit. This arrangement makes it easy to shift back and forth between the
PLC and a PC running the setup software.

5.3 Configuring DF1 Communication
5.3.1 Overview
With the exception of the skew control mode, any of the control algorithms in the
ICS 5000 can be configured to use the DF1 protocol. The ICS 5000 supports DF1
via its RS-232 and RS-422 serial ports. Inside the ICS 5000, DF1 is supported by a
16 bit register and a 32 bit register. The 32 bit register are for PLC’s that supports
DINT files (AB’s ControlLogix PLC).
Note – As with the other optional communication protocols supported by the ICS
5000, DF1 must be enabled via the ICS 5000 Support Software (Beta Release)
before it can be used to communicate with the unit.
Configuration of the ICS 5000 for DF1 communications requires the following
steps:
1. Enable the alternate communications protocol (DF1)
2. Configure the serial communications parameters to match the PLC or SLC
3. Configure the node address to match that used by the PLC or SLC
4. Configure custom data registers (optional)
5. Correctly wire the serial communications
All steps must be configured correctly to enable communication between the ICS
5000 and the PLC or SLC. Once the ICS 5000 has been configured, it should be
reset to enable the new communications protocol. Once the unit is communicating
via DF1, it will need to be reset to communicate using ASCII. To reset the unit,
unplug the communications link from the PLC or SLC and cycle power to the ICS
5000.
5.3.2 Software Configuration

There are several steps that must be completed to allow the ICS 5000 to
communicate using DF1 protocol. Poor or no communication may result if any of
the steps are completed incorrectly or skipped. The following sections detail each of
these steps.

Enabling the DF1 Protocol

For ICS 5000 to use the DF1 protocol, it must first be enabled. You accomplish this
by selecting DF1 from the RS323/422 Protocols group of the Protocols screen ( [Alt]
+ [M] + [1] ) as shown in the figure that follows.
DF1 Serial Port Options

Now that the DF1 protocol has been enabled, you must select the serial port (RS-
232 or RS-422) which the ICS 5000 will use to communicate with the PLC or SLC.
Use the Port Options screen ( [Alt] + [M] + [2] ) of the Communications tab, shown
in the image that follows, to configure the operation of both ports. The port that is to
be used should be set to 1 Use ASCII protocol until host starts using DF1
protocol. This way the ICS will always initialize to ASCII for setup then
automatically switch to DF1 once the PCL or SLC starts communicating. Another
option is to use choice 3 Switch To DF1 Protocol Without Waiting For Host. This
option allows the port to switch automatically without the slight delay associated
with the first option. However, establishing communications with the ICS 5000

Support Software is more difficult with option 3 as power to the unit must be reset
any time ASCII communication is used. The Port Options screen of the
Communications tab is shown in the following image.
B
Tip – Shut down any communication port not being used to avoid accidental messages
from being received by the ICS 5000.
Line Settings
Use the Line Settings screen, shown in the figure that follows, to configure the basic
serial communications parameters. Five seconds after boot-up, both serial ports
(RS-232 & RS-422) have the option of switching to user-controlled line settings
(USER Settings - see DF1 Serial Port Options on page 5.5) you define. These
settings must match the serial port on the PLC or SLC that you are using.

DF1 Address
Each piece of hardware that resides on a DF1 network must have a “Node” Address
to uniquely identify the device. Use the Addressing screen ( [Alt] + [M] + [4] ) of
the Communications tab, shown in the image that follows, to set this address. If you
are also using an ASCII address, the DF1 address and the first character of the
ASCII address are the same. The DF1 address must be between 0 and 63 and unique
to the network.
Note – When multi-drop is used, all addresses on the network must be unique.
Custom Read and Write Data Table definition

While the DF1 protocol does not require the use of custom data tables, their use,
however, may be advantageous for you project. See A Word About Number
Conventions on page 5.66 for details on configuring this data.
C
Warning – Do not run the Setup software on one of the ports at the same time as
MODBUS or DF1 are running on the other port. If you do, there will be two masters (PC
and PLC) that are in control of the ICS 5000 unit (your vehicle).
5.3.3 Communications Cabling

The most common misunderstanding is that the ICS 5000 connects directly to the
DH+ cable (or BLUE HOSE as it is commonly referred). The ICS 5000 is an serial
device that supports DF1 protocol. There are three common hookup configurations:
1. Connect a serial cable from channel 0 of your PLC to the ICS 5000.
2. Connect a serial cable from a KE card to the ICS 5000 and plug the KE card
into the PLC.
3. Connect an RS-232 cable from a KF2 module to the ICS 5000 and connect
the DH+ cable (BLUE HOSE) to the KF2 module.

There are pros and cons to each communications configuration, so it is up to you to

choose the configuration most suitable to the application. The ICS 5000 supports
DF1 communications on either of it’s serial ports (RS-232 or RS-422). Therefore,
cabling depends upon which port you use and the port (or channel) on the processor
you use. The next two sections provide details on wiring your communications
connections.
Channel 0
Cabling between the ICS 5000 and the PLC or SLC to support communications on
CHANNEL 0 is relatively straightforward. The configuration used (a “null modem”
style) is the same as that used to communicate with the ICS 5000 from a PC or
Laptop computer. If you can establish communications from your computer to the
ICS 5000, then the PLC or SLC should be able to communicate using the same
cable, providing the appropriate connector is used. The PLC-5 series of controllers
utilizes a female DB-25 connector for CHANNEL 0 while the SLC controllers use a
male DB-9 (identical to most laptop). Gender changers and 9 to 25 pin converters
can be purchased at most electronic supply stores.
The Multi-Drop feature in the ICS 5000 has been developed to expand the
CHANNEL 0 connection by allowing multiple ICS 5000 units to communicate to
the PLC via that one port. Except for wiring between units, no additional
communications hardware is required. For more information on configuring the ICS
5000 to support Multi-Drop, consult Multi-Drop Configuration, page 4.19 or
contact Trimble Technical Support.
CHANNEL 1A
The cabling between the ICS 5000 and the PLC or SLC to support communications
on CHANNEL 1A is a bit more complicated due to the introduction of a DH+ to
Serial interface module. The ICS 5000 can not be connected directly to the DH+
port of the PLC This connection is accomplished by using a Rockwell Automation
KF-2 Module or equivalent. For wiring information, consult the User Manual of the
Interface Module used.
5.3.4 PLC/SLC Communications Configuration

The Rockwell Automation’s higher-level processors come equipped with a standard
communications port as CHANNEL 0 (DB-25 on PLC-5/XX and DB-9 on SLC-
5/0X) and a Data Highway Plus (DH+) port as CHANNEL 1 (typically a three pin
plug). Each of these ports must be configured by the user. Processors that support
DF1 communications with the Trimble ICS 5000 on either channel are shown in
Table 5.1 below.
Table 5.1 PLC/SLC Compatibility
PLC Processors SLC Processors
5/11 5/03 (no DH+ support on channel
1)
5/20 5/04
5/30 5/05

Table 5.1 PLC/SLC Compatibility

PLC Processors SLC Processors
5/40, 5/40L, 5/40V,
5/40VL
5/60, 5/60L
5/80, 5/80V, 5/80VL
5.3.5 PLC-5/XX Series Controllers

PLC-5 series controllers are “full size” rack mounted processors and I/O cards.
Virtually all processors in this family support communication to the Trimble ICS
5000 via both CHANNEL 0 and CHANNEL 1. Configuration of the
communications ports and the message instructions to enable communication
between the PLC and the ICS 5000 is described in the following sections.
CHANNEL 0 Configuration
Configuration of CANNEL 0 is shown in the figure below. The Communication
Mode should be set to System (Point-To-Point). The Diagnostic File - Specifies an
unused data file (9-999) to store channel data status information. The system
automatically creates an integer file. This is set to zero (the default) so it is disabled.
The PLC's Serial Port should be configured to match the ICS 5000's. In this
example we are using 9600 baud, 8 bits per character, 1 stop bit with no parity.
Error Detect(ion) is set to BCC and the Control Line configuration is set to Full
Duplex Modem.
This will fully configure the processor CHANNEL 0 communications port.

Communications via any of the other processor channel will be handled differently.
Note – If these changes are to be made “On-line” with the processor in “Run”, the
processor will have to be placed into “Program” and then returned to “Run” before
they can take effect.

CHANNEL 1A Configuration
Configuration of CANNEL 1A is shown in the figure below. Note that several of the
settings are fixed. The I/O Channel Mode is set to Data Highway Plus (DH+)
because this is the processor's default communications port. The Diagnostic File
specifies an unused data file (9-999) to store channel data status information. The
system automatically creates an integer file. This is set to zero (the default) so it is
disabled. Baud Rate must be 57.6 kBaud if CHANNEL 1A is configured for DH+.
The Node Address is set to the address number of the processor. If the Data
Highway Plus channel is CHANNEL 1A, the station (node) number is set with
switch SW1 on the processor. Link ID is used only if another communication
protocol (Data Highway or Data Highway II for example) is used. The Global
Status Flags File reduces DH+ traffic by allowing stations to share information
rather than send messages. It is not required to setup communications to a Trimble
ICS 5000.
This will fully configure the processor CHANNEL 1A communications port.

Communications via any of the other processor channel will be handled differently.

Message (MSG) Instruction Setup

The Message instruction for a PLC-5/XX controller is configured the same way
regardless of which channel is used to communicate to the ICS 5000. This
instruction can be found under the Input/Output instruction sub-group tab of the RS
Logic 5 Software. It can also be inserted by typing MSG on an empty rung. The
figure below shows a rung with an inserted message instruction.
When the message instruction is inserted into a rung of logic, the user is required to
enter a control block. The Control Block should be assigned according to Table 5.2
that follows. Failure to assign the correct control block will result in an error from
the message instruction. The message control block in the example ladder above is
N100:0. Control blocks from other message instructions (N100:28 and N100:42 in
this example) are used to sequence the operation of the message instruction on this
rung.
Table 5.2 Control Block Address Selection
If you have this processor: Use this Control Block address:
Original PLC-5 An integer (N) file address.
Example: N7:0
Enhanced PLC-5, Ethernet PLC- An integer (N) or message (MG)
5, or VME PLC-5 file address. Example:
MG10:0Using the MG control
block, the control block size is
fixed at 56 words.
Ethernet PLC-5, ConrolNet PLC- A message (MG) file type to
5, VME PLC-5 access the VMEbus, Ethernet, or
ControlNet network.
When using the message instruction, care should be taken to insure that all
communications attempts have been completed successfully. To assist with this, the
control block contains status bits that can be used to monitor the message
instruction. These bits include: EN - enabled bit; DN - done bit and ER - error bit.
Note – The processor will boot to run mode and begin executing the program before
the DH+ port is ready to communicate. This should be taken into consideration
when the code is being written, and the message commands should not be enabled
until the port is ready.
The status bits can be utilized to synchronize multiple message instructions, monitor
communications for timeouts and to perform retries in the event of an error or
communications time out. They are addressed as follows:

{Control Block}/15 - enabled bit

{Control Block}/13 - done bit
{Control Block}/12 - error bit
Where {Control Block} is the file for the message instruction to be monitored
(N100:0 in the previous example).
Once the Control Block is correctly defined, the setup screen (see the following
figure) will be displayed. This screen contains the remaining configuration that
needs to be done before the message instruction will pass data between the PLC and
the ICS 5000. From this screen the user may configure THIS PLC-5 and the
TARGET DEVICE (the ICS 5000).
For THIS PLC-5, the Communications Command specifies whether the instruction
performs a read (read data from the ICS 5000) or a write (write data to the ICS
5000) operation and the type of device that is being communicated with. The Data
Table Address specifies either the source (write) or destination (read) of the data
transferred using the instruction. Finally, the Size in Elements refers to the number
of data elements to be read from or written to the ICS 5000. See the section of this
document entitled “Interpreting Data in the PLC/SLC” for more information on the
data written to and read from the ICS 50000.
For the TARGET DEVICE (ICS 5000), the Data Table Address relates to the data
layout within the ICS 5000 (N7:0 in this example). The Data Table Address is
mostly symbolic. Only the portion of the address after the colon (:) is used by the
ICS 5000. The N# can be set to any value. The Local Station Address is the address
character setup in the ICS 5000 (33 in this example). The Local/Remote mode
should be set to Local.
5.3.6 SLC 5/0X Series Controllers

SLC 5/0X series controllers are “medium size” rack mounted processors and I/O
cards. Only the upper level (5/03, 5/04 and 5/05) processors in this family support
communication to the Trimble systems via CHANNEL 0, and only 5/04 and 5/05
processors support communication via DH+ on CHANNEL 1A. Lower level (5/03

and below) processors may support only DH-485 communication on CHANNEL

1A, but configuration of that protocol is not covered in this document.
Configuration of the communications port and the message instructions to enable
communication between the SLC and the ICS 5000 is described in the following
sections.
CHANNEL 0 Configuration
Configuration for CANNEL 0 is depicted in the figure below. Insure that the System
configuration and not the User configuration is active by checking the General tab
of the CHANNEL CONFIGURATION dialogue box. The Driver should be set to
DF1 Full Duplex. The serial port settings should be configured to match the
distance meter. In this example we are using 9600 baud, 8 bits per character, 1 stop
bit with no parity. The Source ID is not used in this application.
Protocol Control is setup as follows: Control Line is set to No Handshaking, Error

Detection utilizes BCC, and Embedded Responses are Enabled. The values for
ACK Timeout, NAK Retries and ENQ Retries can be left at the default values.
Checking the box enables Duplicate Packet Detect.

CHANNEL 1A Configuration
Configuration for CANNEL 1A is depicted in the figure below. The Driver should
be set to DH+ (the default). The Baud should be set to match the DH+ baud rate.
The Node Address should match the processors node address.
Message (MSG) Instruction Setup

The setup of the SLC 5/0X message instruction for communications over either of
the two channels is almost the same. By simply changing the Channel value
referenced in the MESSAGE SETUP dialogue box (picture follows),
communications can be directed to either channel. The Message instruction can be
found under the Input/Output instruction sub-group tab of the RS Logic 500
Software. It can also be inserted by typing MSG on an empty rung. The figure that
follows shows a rung with an inserted message instruction.
When the message instruction is inserted into a rung of logic, the user is required to
enter some brief information about the instruction. The Read/Write parameter
should be set to match the action the instruction is to perform (in this case it is set to
Read). The Target Device should be set to PLC5 because the ICS 5000 emulates a

PLC-5 series controller. Local/Remote should be set to Local. A Control Block

should be selected from your unused files (N100:0 is the control block file for this
example). Any unused integer file may be used for the control block. Control blocks
from other message instructions (N100:28 and N100:42 in this example) are used to
sequence the operation of the message instruction on this rung.
Care should be taken when using the message instruction to insure that all
communications have been completed successfully. To assist with this, the control
block contains status bits that can be used to monitor the message block. These bits
include: EN - enabled bit, DN - done bit and ER - error bit.
Note – The processor will boot to run mode and begin executing the program before
the DH+ port is ready to communicate. This should be taken into consideration
when the code is being written, and the message commands should not be enabled
until the port is available.
The status bits can be utilized to synchronize multiple message instructions, monitor
communications for timeouts and to perform retries in the event of an error or
communications timeout. They are addressed as follows:
{Control Block}/15 - enabled bit
{Control Block}/13 - done bit
{Control Block}/12 - error bit
Where {Control Block} is the file for the message instruction to be monitored
(N100:0 in the previous example).
Once the control block is correctly defined, the setup screen (see the figure that
follows) will be displayed. This screen contains the remaining configuration that
needs to be done before the message instruction will pass data between the SLC and
the ICS 5000.
The Channel value on the SLC is the set to 0 for communication via CHANNEL 0
and 1 for communication via CHANNEL 1A. The Target Node (ICS 5000) is set to
match the address setup in the ICS 5000 (33 in this example). The Local File
Address in the SLC is the source of data to be written or the destination of data to be
read. The Targets File Address relates to the data layout within the ICS 5000 (N7:0
in this example). The Targets File Address is mostly symbolic. Only the portion of
the address after the colon (:) is used by the ICS 5000. The N# can be set to any
value. The Message Length in Elements is the amount of data to be read from or

written to the ICS 5000. The Message Timeout is the length of the message timer in
seconds. A timeout of 0 seconds means that there is no timer and the message will
wait indefinitely for a reply.
5.3.7 Message Instruction Basics

This section is a primer for Message instruction usage. It is only intended as an
introduction, so please do not consider it to be a complete tutorial. For more
information on the subject, consult the programming reference that accompanies
your processor.
Figure 5.2 that follows depicts communication between a processor and two
Trimble ICS 5000 positioning systems.
Figure 5.2 PLC / ICS 5000 Data Flow
In this example, four message instructions are used to read and write to the two ICS
5000s. The message with control block that begins at N100:0 is writing two blocks
of data from processor file N200 beginning at word 3 to the first ICS 5000
beginning at register 3. This instruction could be used to write a value only to the
Distance Destination registers, which would initiate a move. The second message
command uses a control block beginning at N101:0. Here the first 7 registers are
read from the ICS 5000 and stored in processor data file N201 beginning at word 0.
This instruction could be used to the read status and the distance, while the
combination of the first two message commands would be an appropriate way to
read and write the minimal amount of data to the ICS 5000.
The next two message commands read and write all 16 words of status and control
information in the ICS 5000. The “read” data is stored in processor data file N201
beginning at word 16 while file N200 beginning at word 16 is source of the “write”

data. This combination is valid, but care must be taken to write the appropriate
values to control registers (distance and halt for example) to avoid unexpected
operation. Consult the command register listing in the Modbus/DF1 Set-up Manual
(Art. No. 571 701 291/3) for detailed information of control register actions.
Sequencing of the execution of multiple message commands and error monitoring is
critical to proper operation. Use the various status bits mentioned in the previous
section to perform the various “house keeping” tasks necessary.
5.4 Modbus® Configuration

This section of the ICS 5000 Support Software User Manual deals with the
operation of the ICS 5000 when using the ASCII/MODBUS® protocol. It discusses
the steps involved with preparing an ICS 5000 for MODBUS operation and the ICS
5000 register assignments. The ICS 5000 operates as an RTU SLAVE device,
therefore, a Master device (PLC or computer) must initiate communications.
With the exception of the skew control mode, any of the control algorithms in the
ICS 5000 can be configured to use the MODBUS protocol. The ICS 5000 supports
MODBUS via its RS-232 and RS-422 serial ports. MODBUS is supported by a 16
bit register.
5000, MODBUS must be enabled via the ICS 5000 Support Software before it can
be used to communicate with the unit.
Configuration of the ICS 5000 for MODBUS communications requires the
following steps:
1. Enable the alternate communications protocol (MODBUS)
2. Configure the serial communications parameters to match the PLC or SLC
4. Configure custom data registers (optional)
5. Correctly wire the serial communications
via MODBUS, it will need to be reset to communicate using ASCII. To reset the
unit, unplug the communications link from the PLC or SLC and cycle power to the
ICS 5000.
5.4.1 Software Configuration

communicate using MODBUS protocol. Poor or no communication may result if
any of the steps are completed incorrectly or skipped. The following sections detail
each of these steps.

Enabling the MODBUS Protocol

For ICS 5000 to use the MODBUS protocol, it must first be enabled. You
accomplish this by selecting MODBUS from the RS323/422 Protocols group of the
Protocols screen ( [Alt] + [M] + [1] ) as shown in the figure that follows.
MODBUS Serial Port Options

Now that the MODBUS protocol has been enabled, you must select the serial port
(RS-232 or RS-422) which the ICS 5000 will use to communicate with the PLC or
Host Computer. Use the Port Options screen ( [Alt] + [M] + [2] ) of the
Communications tab, shown in the image that follows, to configure the operation of
both ports. The port that is to be used should be set to 1 Use ASCII protocol until
host starts using MODBUS protocol. This way the ICS will always initialize to
ASCII for setup then automatically switch to MODBUS once the PCL or SLC starts
communicating. Another option is to use choice 3 Switch To MODBUS Protocol
Without Waiting For Host. This option allows the port to switch automatically

without the slight delay associated with the first option. However, establishing
communications with theICS 5000 Support Software is more difficult with option 3
as power to the unit must be reset any time ASCII communication is used.
B
Tip – Shut down any communication port not being used to avoid accidental messages
from being received by the ICS 5000.
Modbus Line Settings

Next you use the Line Settings screen shown in the figure that follows to configure
the basic serial communications parameters. Five seconds after boot-up, each serial
port (RS232/422) has the option of switching to user-controlled line settings (USER
Settings) you define (see MODBUS Serial Port Options on page 5.18). These
settings must match the serial port on the PLC or SLC that you are using.

MODBUS Address
Each piece of hardware that resides on a MODBUS network must have a “Node”
address to uniquely identify the device. Use the Addressing screen ( [Alt] + [M] + [4] )
of the Communications tab, shown in the image that follows, to set this address. If
you are also using an ASCII address, the MODBUS address and the first character
of the ASCII address are the same. The MODBUS address can be between 1 and
255 and must be unique on the network.
Note – When multi-drop is used, all addresses on the network must be unique.
Custom Read and Write Data Table Definition

While the MODBUS protocol does not require the use of custom data tables, their
use, however, may be advantageous for you project. See Custom Read and Write
Data Tables on page 5.62 for details on configuring this data.
C
Warning – Do not run the ICS 5000 Support Software on one of the ports at the same
time as MODBUS or DF1 are running on the other port. If you do, there will be two
masters (PC and PLC) that are in control of the ICS 5000 unit (your vehicle).
Communications Cabling
You will need to install a cable between one of the MODBUS compatible serial
ports on the PLC and the ICS 5000. See Serial Communications Port Information on
page 4.15 for details on wiring the RS-232 or RS-422 ports.
5.5 DeviceNet Configuration
5.5.1 Overview
Configuration of the ICS 5000 for DeviceNet communications requires the
following steps:

1. Enable the alternate communications protocol (DeviceNet)

2. Configure the DeviceNet communications parameters to match the PLC or
SLC
4. Configure custom data registers
5. Correctly wire the network communications
via DeviceNet, it will need to be reset to communicate using ASCII. To reset the
unit, unplug the communications link from the PLC or SLC and cycle power to the
ICS 5000.
5.5.2 ICS 5000 Software Configuration for DeviceNet

communicate using the DeviceNet protocol. Poor or no communication may result
if any of the steps are completed incorrectly or skipped. The following sections
detail each of these steps.
Enabling the DeviceNet Protocol

For ICS 5000 to use the DeviceNet protocol, it must first be enabled. You
accomplish this by selecting DeviceNet from the Other Protocols group of the
Protocols screen ( [Alt] + [M] + [1] ) as shown in the figure that follows.

DeviceNet Network Baud Rate

The only Line Settings parameter that is required by DeviceNet is the Baud Rate.
You configure the ICS 5000’s DeviceNet Baud Rate from the ICS 5000 Support
Software Line Settings screen ( [Alt] + [M] + [3] ) by using the drop down menu in the
DeviceNet group (shown below) to select either 125, 250 or 500. The values listed
are in kBaud (x1000).
C
Warning – DeviceNet requires that each device on the network use the same baud rate.
Introducing a device with a different baud rate will cause a network error.
DeviceNet Address
DeviceNet requires a unique Address be applied to each device on the network. The
ICS 5000’s address for the DeviceNet Network is configured from the ICS 5000
Support Software Addressing screen ( [Alt] + [M] + [4] ) by using the arrow buttons to
select a number between zero and 63.
C
Warning – DeviceNet requires that each device on the network use the same baud rate.
Introducing a device with a different baud rate will cause a network error.
B
Tip – Due to the way the DeviceNet scanner module locates nodes on the network, it is
desirable to have all node addresses as close to zero as possible.
Read and Write Table Creation

Read and Write data tables must be constructed in the ICS 5000 unit via the ICS
5000 Support Software before the DeviceNet Scanner can communicate with the
ICS 5000 unit. For details on configuring the Read and Write data tables, see
Custom Read and Write Data Tables on page 5.62.

ICS 5000 Status

The RS-232 port can be used for checking status of the ICS 5000 unit during setup
of the DeviceNet network. Connect the RS-232 port to a PC with a terminal
program (the HyperTerminal program provided with Windows works well). You can
check the status of the ICS 5000 unit by sending the “E” command to the unit.
C
Warning – Do not run the Setup software on one of the ports at the same time as
DeviceNet is running on the other port. If you do, there will be two masters (PC and PLC)
that are in control of the ICS 5000 unit (your vehicle).
C
Warning – Do not experiment by sending commands if it is not known which device (PC
or PLC) that is in control of the vehicle.
Note – The BT command resets the ICS 5000 and also the DeviceNet driver inside
the ICS unit.
5.5.3 DeviceNet Network Configuration
Network Registration
The following example screens are taken from Rockwell Automation’s RSNetWorx
for DeviceNet configuration software. The first step to adding a DeviceNet enabled
and configured ICS 5000 to a network is to run the Electronic Data Sheet or EDS
Registration Wizard by selecting Tools/EDS Wizard... as shown in the following
image.

Note – The EDS Wizard can also be initiated by going Online with the network and
using the mouse to right-click on an unregistered device (designated by a question
mark) then selecting Register Device from the popup menu.
This displays the EDS Wizard Options dialog box shown in the figure that follows.
Choose the first option, Register an EDS file(s), and click Next.
This displays the Register Device screen shown below. This screen allows you to
select the EDS file(s) for the device(s) you wish to register. When the ICS 5000 is
configured for DeviceNet operation (ICS 5000 Software Configuration for
DeviceNet on page 5.21), a custom EDS file is created. This file, called
ICS5000.eds, is stored in the working directory along with the .i5k file used to store
the configuration of the ICS 5000.
Click Browse to search for the EDS file that was generated for the ICS 5000 that
you are working with. The example path is C:\ICS\CRANE1\, you will need to
browse to the correct path for your EDS file for the configuration to be successful.

Once the correct file has been located, click Next to continue. At this point the
software will run a quick evaluation of the EDS file and display any errors detected
as shown in the following image.
Now that the ICS 5000 has been registered, you can pick an icon to use to depict the
unit on a graphical representation of the network. From the Change Graphic Image
screen shown below make sure that the ICS 5000 unit you are working with is
highlighted then click Change Icon.

This displays the default icon library (shown below), which, unfortunately does not
contain an icon for the ICS 5000. An icon in an alternate directory can be selected
by clicking Browse at the bottom of the dialog box.
Locate the ICS 5000 icon located in the ICS 5000 Support Software installation
directory. Upon opening this directory, the available icons will be displayed as
shown below. Select the ICS5K.ico file to choose the closest graphical
representation, then click Open.
This returns you to the Change Graphic Image screen, but this time the icon that
you choose will be used as shown below.

The Final Task Summary screen, shown in the image that follows, will now be
displayed, confirming all devices that you have chosen to register. Click Next to
execute the registration process and finish EDS file registration task.
The next step is to add the ICS 5000 to the DeviceNet Scanner’s Scanlist, and insure
that the device mapping on the scanlist is correct.
Scanner Configuration
Once the ICS 5000 unit has been successfully registered on the DeviceNet network,
it will be correctly displayed when the RSNetWorx software is Online. To go
Online, select Network / Online as shown below.

This will cause the software to attach to the DeviceNet network, and update the
graphical representation of the network as shown in the following image.
The graphical display of the network will contain some basic information about the
network’s population. Each device registered on the network is displayed in order of
it’s node address. The following figure shows that the ICS 5000 has been configured
as node 9, the 1747-SDN scanner module is node 0 and the PC interface through
which RSNetWorx is accessing the network is node 62.

Even though the ICS 5000 has been successful registered, and it appears on the
network graphical display, the system is not yet completely configured to exchange
data. The ICS 5000 must be added to the scanner’s Scanlist before useful data can
be exchanged over the DeviceNet network.
To configure the scanner’s Scanlist, click on the device on the network graphic
(shown in the previous image) then select Device / Properties or right-click on the
Scanner icon. This displays the Scanner Module Properties dialog box as shown
below.
Select the Scanlist tab to display the devices available for inclusion along with
devices already included in the Scanlist. To add the ICS 5000 to the Scanlist, insure
that the Automap on Add check box below the Available Devices window is
checked, then select the ICS 5000 that you configured and click the right arrow (>).
This will add the ICS 5000 to the Scanlist as shown below, and automap the data
registers needed as stated in the ICS 5000’s EDS file. Clicking the double right
arrow (>>) will add all devices.

Adding the ICS 5000 to the scanlist with the Automap on Add feature enabled, will
automatically configure the data registers specified within the EDS file. It is
important that the EDS file that was used to register the ICS 5000 (Network
Registration on page 5.23) contain the most current setup information. If you make
changes to the ICS 5000’s read or write registers after the unit has been registered
on the network, then the unit needs to be removed and then re-register using the new
EDS file.
Note – If changes are made to the read or write registers after it has been registered
on the DeviceNet network, then the unit must be removed and re-registered with the
new EDS file that was created by the Support Software.
The following figures present examples of the automapping results. Click Edit I/O
Parameters on the Scanlist tab of the Scanner Properties dialog box to display the
details of the ICS 5000 I/O mapping as shown below. This dialog box shows the
type of message (Polled) and the transmit (Tx) and receive (Rx) data sizes.
Scanner mapping details can be accessed from the tabs along the top of the Scanner
Module Properties dialog box. You use the Input tap to select the Scanner Input
mapping is shown in the following figure.

You select the Output tap to select the Scanner Output mapping is shown in the
following figure.
This completes the software configuration of both the ICS 5000 and the DeviceNet
scanner.
5.5.4 DeviceNet Cable Connections

The DeviceNet port (4 pole screw terminal) on the ICS 5000 is located on the rear
panel directly below the Power Connector. The pin configuration for the connector
is shown in Figure 5.3 and Table 5.3 that follow.
Figure 5.3 DeviceNet Wiring Overview
Table 5.3 DeviceNet Pinout

Terminal Function Wire color Description
1 CAN_High White Not inverted signal.
2 CAN_Low Blue Inverted signal.
3 V- Black DeviceNet networks power.
4 V+ Red DeviceNet networks power.

The shield or bare wire is connected to the chassis ground using the cable feed-
throughs on the rear cover of the unit as described in Grounding And Isolation,
page 5.34.
Cable
An ICS 5000 is connected to a DeviceNet network via a drop line. DeviceNet Thin
cable with an outside diameter of 6.9 mm (0.27 inch), commonly used for drops,
will fit the cable feed-through on the rear cover of the ICS 5000 unit. The cable
feed-through is designed to accept cables with a diameter between 5 to 12 mm (0.2
to 0.5 inch).
Note – DeviceNet Thick cable will not fit in to the ICS 5000 cable feed-through.
DeviceNet Wiring
The wires to be connected to the ICS 5000 unit are Can_H (White), Can_L (Blue),
V- (Black), V+ (Red) and the shield (Bare). The DeviceNet interface hardware
within the ICS 5000 (transceiver) is isolated from the rest of the unit.
Cable Connections
1. Turn off the power supplies for the ICS 5000 unit and the DeviceNet network
before beginning.
2. Remove the protective cover on the rear panel.
3. Remove the cable insulation so that the wires (item 1 in Figure 5.4) are
slightly longer than the shield (item 2 in Figure 5.4). The shield must come
into contact with the metal tongues (item 3 in Figure 5.4) in the hole. Cut the
Bare wire so it is as long as the shield.
Figure 5.4 Cable Preparations
4. Slide the strain relief cleat and insulator (stuffing tubes) onto the cable and
pass the cable through the hole (item 4 in Figure 5.5).

5. Connect the wires in the DeviceNet network cable to the 4 pole screw
terminal (item 5 in Figure 5.5) as listed in DeviceNet Cable Connections,
page 5.31. White wire (CAN_High) to terminal number 1. Blue wire
(CAN_Low) to terminal number 2. Black wire (V-) to terminal number 3.
Red wire (V+) to terminal number 4.
1 2 3 4
4.
5.
Figure 5.5 DeviceNet Cable Connection.
6. Connect the terminal strip to the block on the ICS rear panel.
7. Attach the strain relief collar (item 6 in Figure 5.6) and tighten the sealing nut
(item 7 in Figure 5.6) firmly with a 22 mm ring spanner to avoid leakage.
Tighten the sealing nut with 6.25 Nm.
Figure 5.6 Cable Feed-Through Sealing Nut Mounting
Power
It is recommended what the ICS 5000 be powered by a separate 24 VDC regulated
power supply and not the DeviceNet networks power supply. This is because the
voltage supplied by the DeviceNet network could drop to as low as 11 V DC and the
ICS 5000 unit requires at least 18 V DC (24 V DC nom) to operate. The supplied
power should be connected to the ICS 5000 power supply port, see Figure 5.2.

The DeviceNet networks power should be connected to the V+ and V- terminals on

the ICS 5000’s DeviceNet port. After the ICS 5000 has been configured for
DeviceNet, ICS 5000 Software Configuration for DeviceNet on page 5.21, the
DeviceNet task within the unit will continuously check the DeviceNet networks
voltage. If the voltage (V+) goes low, the DeviceNet task in the ICS 5000 shuts
down the unit.
B
Tip – If the DeviceNet network voltage goes low, the ICS 5000 unit will halt any started
motion in a controlled way and new commands will be ignored until the voltage is
restored.
Grounding And Isolation

The ICS 5000 grounding philosophy is to ground the unit in only one location. The
reason for this is to avoid ground loops. The ICS 5000 unit should only be grounded
via the DeviceNet network connection (Figure 5.6 that follows). The ICS 5000 unit
is isolated from the vehicle via it’s mounting bracket, and shields around the 24 V
cable and I/O cable should only be connected at the ICS 5000. Shields are
connected to the Chassis Ground using the specially designed cable feed-throughs
on the rear cover of the unit. When terminating the wiring to the ICS 5000 insure
that the shields are correctly attached. Consult the ICS 5000 Installation Manual
(571 701 451 or 571 701 453) for details on wiring.
Figure 5.7 ICS 5000 Interconnection and Grounding
Note – The ICS 5000 unit should only be grounded via the DeviceNet network, and
according to the DeviceNet specification, the DeviceNet network should be
grounded in only one location.

5.6 PROFIBUS Configuration
5.6.1 General Device description

PROFIBUS-DP is used for data exchange at the field level between industrial
controllers (PLC or PC) and distributed field devices such as I/O sensors-actuators,
motor starters and operator interfaces.
Regardless of the control algorithm being used, the ICS 5000 can be configured to
support the PROFIBUS protocol with the exception of the Advanced Skew Control
Version (TCS2). The ICS 5000 is implemented as a slave device on the PROFIBUS
network. The supported Profile is General. The unit must be configured correctly
before PROFIBUS communication will be possible.
Figure 5.8 Simplified overview of a PROFIBUS network
PNO identification number

The ICS 5000 unit has the PNO identification no. 068A.
PROFIBUS International Certificate

The ICS 5000 unit has the PROFIBUS Certificate No.: Z00791
Profile
The supported PROFIBUS profile in the ICS 5000 unit is of type General.
Station Address
The PROFIBUS Station Address of the ICS 5000 is configured via the ICS 5000
Support Software.

Bus Termination
A PROFIBUS network must be terminated at the ends of the bus segments. The ICS
5000 unit can be terminated by a built-in termination or by an external active
terminator (see PROFIBUS Connections with Internal Termination Jumpers,
page 5.50 for details).
Baud Rate
ICS 5000 supports Transmission rates for PROFIBUS between 9.6 kBaud to 12
Mbaud. The Baud rate is automatically detected by the ICS 5000 unit.
GSE File
The ICS 5000’s GSE file name is ICS_068A.gse. A bitmap file named
ICS5000n.bmp is also available for the PROFIBUS master configuration tool. The
GSE file and bitmap file are included in the ICS 5000 Support Software.
5.6.2 ICS 5000 Configuration

The ICS 5000 supports the PROFIBUS-DP profile General. Read and Write data
Modules are built from the various Command Modules available from the GSE file.
PROFIBUS-DP communication configuration for the ICS 5000 must be done using
the ICS 5000 Support Software provided with the unit.
Use the following steps to configure the ICS 5000 to use the PROFIBUS-DP
communication protocol.
1. Enable the PROFIBUS-DP communication protocol.
2. Set the Network address.
3. Build the read and write Modules.
4. Connect (internal or external) termination if required.
5. Print out the text file created from the ICS’s Support Software with the
settings and selected communication modules.
The PROFIBUS Master should be configured with the data from the settings in the
ICS. The data is available in a printable text file: “Profibus.txt” The text file is
stored in the same directory as the data files from the characterization.
Note – Network’s transmission rate is configured in the Master and auto detected by
the ICS 5000. Data format (Motorola or Intel) and extended diagnostic functions
are configured by the Master.
5000, PROFIBUS must be enabled via the Support Software before it can be used to
communicate with the unit.

Enabling PROFIBUS
PROFIBUS is enabled ICS 5000 Support Software Protocols screen ( [Alt] + [M] + [1]
) by selecting the PROFIBUS option.
PROFIBUS Network ID
PROFIBUS requires a unique Network ID be applied to each device on the network.
The ICS 5000’s address for the PROFIBUS Network is configured from the ICS
5000 Support Software Addressing screen ( [Alt] + [M] + [4] ) by using the arrow
buttons to select a number between zero and 128.
C
Warning – PROFIBUS requires that each device on the network have a unique Node
Address. Duplicate Node Addresses will cause a network error.
Read and Write Table Creation

Read and write data tables must be constructed in the ICS 5000 unit via the ICS
5000 Support Software before the PROFIBUS Master can communicate with the
ICS 5000 unit. See Custom Read and Write Data Tables on page 5.62.

ICS 5000 Status

of the PROFIBUS network. Connect the RS-232 port to a PC with a terminal
program. (For example the Hyperterminal program included with Windows can be
used.) Check the status of the ICS 5000 unit by sending the “E” command to the
unit.
C
Warning – Do not run the Support Software on the RS-232 port at the same time as
PROFIBUS is running on the other port. If this is done, there will be two masters (PC and
PLC) that are in control of the ICS 5000 unit (your vehicle).
C
Warning – Do not experiment by sending commands if it is not known which device (PC
or PLC) that is in control of the vehicle.
Note – The BT command resets the ICS 5000 and also the PROFIBUS driver inside
the ICS unit.
5.6.3 Communications Setup
C
Warning – The PROFIBUS-DP Master starts by automatically writing zeroes into all
configured Write Modules during the boot-up sequence. This must be anticipated in the
PLC program if you, for example, configure Modules like A for acceleration or V for
velocity. A wakeup value must be written into the specific registers after they have been
zeroed.
PROFIBUS Command Listing

Table 5.4 that follows contains the available command modules in the GSE file used
to construct the Read and Write tables in the ICS 5000 unit. The commands are
separated into 8, 16 and 32 Bits to allow you the flexibility to develop messages that
require shorter communication times on the network. In the table, the first and
second columns contain the Module function and the ASCII Command Equivalent.
The third column contains the Name in the GSE file and describes the Data Size (1
Byte, 1 Word or 2 Word - 8, 16 or 32 Bit). The Last column contains the ID number
of the modules in the ICS 5000.
Some of the commands use values that are small enough (< 128 for the 1 Byte (8
bit) and < 32,767 for the 1 Word (16 bit)) that a reduced word size will work. For
example: ID# 158 is declared as a 32 bit command, the value returned will never
exceed 128 and can thus be accessed as either an 8 or 16 bit value to reduce the
message size and conserve bandwidth on the network.
To use the Element ID #’s in the Read or Write Module configuration, simply enter
the number corresponding to the 1 Byte, 1 Word or 2 Word values (Right Hand
Columns) directly in to the Support Software’s element list. Care must be taken

when accessing data as smaller (8 or 16 bit) values. If the data value has the
possibility of exceeding the limit (128 or 32,767) then it must be treated as a larger
value. If not, then the value could be truncated by the PLC and errors could occur.
C
Warning – While accessing certain elements as smaller (8 or 16 bit) values will produce
correct results, this is not the case with every element. Take care when assigning
elements or data truncation may occur.
Table 5.4 PROFIBUS Command Module Listing

Module Function ASCII Name in GSE file and data size ICS
Char ID
Read Loop Status E R E Status 1 Byte 0
R E Status 1 Word 64
R E Status 2 Word 158
Read Station Destination S R S Station 1 Byte 11
R S Station 1 Word 65
R S Station 2 Word 159
Write Station Destination W S Station 1 Byte 11
W S Station 1 Word 65
W S Station 2 Word 159
Read Station Location Y R Y Station 1 Byte 22
R Y Station 1 Word 66
R Y Station 2 Word 160
Read Distance Destination D R D Distance Destination 1 Word 972
R S Distance Destination 2 Word 161
Write Distance Destination W D Distance Destination 1 Word 972
W D Distance Destination 2 Word 161
Read Current Distance X R X Current Distance 1 Word 982
R X Current Distance 2 Word 162
Read Return Signal Strength R R R Return Signal Str 1 Byte 7
R R Return Signal Str 1 Word 71
R R Return Signal Str 2 Word 163
Write Return Signal Strength W R Return Signal Str 1 Byte 7
W R Return Signal Str 1 Word 71
W R Return Signal Str 2 Word 163
Write Halt Acceleration H W H Halt Acc 1 Byte 81
W H Halt Acc 1 Word 72
W H Halt Acc 2 Word 164
Read Operating Acceleration A3 R A Op Acceleration 1 Word 73
R A Op Acceleration 2 Word 137
Write Operating Acceleration W A Op Acceleration 1 Word 73
W A Op Acceleration 2 Word 137


Char ID
Read Negative Operating A3 R A Neg Op Acceleration 1 Word 101
Acceleration R A Neg Op Acceleration 2 Word 165
Write Negative Operating W A Neg Op Acc 1 Word 101
Acceleration W A Neg Op Acc 2 Word 165
3
Read Positive Operating A R A Pos Op Acc 1 Word 102
Acceleration R A Pos Op Acc 2 Word 166
Write Positive Operating W A Pos Op Acc 1 Word 102
Acceleration W A Pos Op Acc 2 Word 166
Read Beam Breaks to Ignore I R I Beam Breaks to Ignore 1 Byte 101
R I Beam Breaks to Ignore 1 Word 74
R I Beam Breaks to Ignore 2 Word 167
Write Beam Breaks to Ignore W I Beam Breaks to Ignore 1 Byte 101
W I Beam Breaks to Ignore 1 Word 74
W I Beam Breaks to Ignore 2 Word 167
Read Operating Mode M R M Op Mode 1 Byte 11
R M Op Mode 1 Word 75
R M Op Mode 2 Word 168
Write Operating Mode W M Op Mode 1 Byte 11
W M Op Mode 1 Word 75
W M Op Mode 2 Word 168
Read Measurement Offset O R O Measurement Offset 1 Word 1052
R O Measurement Offset 2 Word 169
Write Measurement Offset W O Measurement Offset 1 Word 1052
W O Measurement Offset 2 Word 169
Read Positioning Tolerance T R T Positioning Tolerance 1 byte 14a
R T Positioning Tolerance 1 Word 78
R T Positioning Tolerance 2 Word 170
Write Positioning Tolerance W T Positioning Tolerance 1 byte 141
W T Positioning Tolerance 1 Word 78
W T Positioning Tolerance 2 Word 170
3
Read Operating Velocity V R V Op Velocity 1 Word 792
R V Op Velocity 2 Word 143
Write Operating Velocity W V Op Velocity1 Word 792
W V Op Velocity 2 Word 143
Read Negative Operating V3 R V Neg Op Velocity 1 Word 107
Velocity R V Neg Op Velocity 2 Word 171
Write Negative Operating W V Neg Op Velocity 1 Word 107
Velocity W V Neg Op Velocity 2Word 171
Read Positive Operating Velocity V3 R V Pos Op Velocity 1 Word 108
R V Pos Op Velocity 2 Word 172
Write Positive Operating Velocity W V Pos Op Velocity 1 Word 108
W V Pos Op Velocity 2 Word 172


Char ID
Read Beam Break Diagnostic U0; J R U0 Beam Break Diag Code 1 461
Code Byte
R U0 Beam Break Diag Code 1 110
Word
R U0 Beam Break Diag Code 2 174
Word
Write Beam Break Diagnostic W U0 Beam Break Diag Code 1 46
Code Byte
W U0 Beam Break Diag Code 1 110
Word
W U0 Beam Break Diag Code 2 174
Word
Read Motor Failure Diagnostic U1; J R U1 Motor Failure Diag 1 Word 1112
Code R U1 Motor Failure Diag 2 Word 175
Write Motor Failure Diagnostic W U1 Motor Failure Diag 1 Word 111
Code W U1 Motor Failure Diag 2 Word 175
Read Settling Time U2; J R U2 Settling Time 1 Byte 481
R U2 Settling Time 1 Word 112
R U2 Settling Time 2 Word 176
Read Pointing Laser U3; J R U3 PointingLaser Status 1 Byte 49
Status/Enable R U3 Pointing Laser Status 1 Word 113
R U3 Pointing Laser Status 2 Word 177
Write Pointing Laser W U3 Pointing Laser Status 1 Byte 49
Status/Enable W U3 Pointing Laser Status 1 Word 113
W U3 Pointing Laser Status 2 Word 177
Read Digital I/O Status Word U4; J R U4 Digital I/O Status 1 Byte 50
(Table “Digital I/O Status R U4 Digital I/O Status 1 Word 114
Word”Below)
R U4 Digital I/O Status 2 Word 178
Read DAC Voltage Digital Value U5; J4 R U5 DAC Voltage 1 Word 115
(4095 = 10 V) R U5 DAC Voltage 1 Word 179
Read System Self-test Z R Z System Self-test 1 Byte 26
R Z System Self-test 1 Word 90
R Z System Self-test 2 Word 183
Read General Purpose Module R General Purpose 1 Byte
R General Purpose 1 Word
R General Purpose 2 Word
Write General Purpose Module W General Purpose 1 Byte
W General Purpose 1 Word
W General Purpose 2 Word
1This value may exceed the limit for 8 bits (128) - If decided to use this element as an 8 bit value, ensure
that your application operates with values within the range of 0 to 128.
2
This value may exceed the limit for 16 bits (32,767) - If decided to use this element as an 16 bit value,
ensure that your application operates with values within the range of 0 to 32,767.

3This command only applies to the TCS control algorithm.

4
The DAC voltage value contained in this register is not appropriate for use in a control circuit. It is only
intended for use as an approximate reference of commanded velocity.
PROFIBUS Extended Diagnostic Bit

The ICS 5000 supports diagnostic functions for Beam Break and Motor failures.
This information can be utilized in two ways:
1. Use the specific modules for diagnostic (U0;J and U1;J) to be read in every
PLC cycle together with the other selected modules.
2. With the Extended Diagnostic Message in PROFIBUS-DP.
The PROFIBIUS-DP Extended Diagnostic Message is configured by the Master.
The ICS 5000 will send out a 10 byte diagnostic message. Byte 7, 8 and 9 contains
the specific diagnostic data for the ICS 5000 unit.
Note – Length of diagnostic message is always 10 whether extended diagnostic is
configured or not. If not the 3 last bytes will always be zero.
Table 5.5 Extended Diagnostic Register
Diagnostic Function Description
byte
0 Status 1 Standard PROFIBUS-DP diagnostics as
1 Status 2 specified in EN 50170
2 Status 3
3 Master address
4 Ident. no.
5 Ident. no.
6 Header Byte Length of diagnostic (including this byte) is
always 4.
7 Beam Break caused by 16-33 = Distance meter error
distance meter failure
8 Beam Break caused by 0-14 = Measuring problems, could be
measuring problem external or internal.1
20 = Beam break caused external
21 = Measuring range exceeded
9 Motor Failure 0 = OK
1 = Lagging1
2 = Leading1
3 = DAC failure1
4 = Profibus watchdog time out
1
See the chapters of this manual covering the different control algorithms for a complete list of diagnostic
codes.
The Extended Diagnostic Message is updated once the fault occur and the registers
are zeroed again after the ICS 5000 unit has been able to perform a complete
measurement. This will take about 3 seconds. When this is done the registers are
back to zero, except for the PROFIBUS watchdog time out message.

Note – If extended diagnostic registers are enabled, the read U0;J and U1;J
registers will also be zeroed after the unit has performed a complete measurement.
5.6.4 Parameterization Telegram

The Parameterization Telegram is, in most cases, built by a configuring program for
PROFIBUS, such as Siemens Step 7. The data for the Parameterization Telegram is
provided in Table 5.6 that follows if you would like to use another method.
Table 5.6 Parameterization Telegram
Byte Function Description
0 Station Status Standard PROFIBUS-DP Parameterization as
1 Watchdog control specification
2 Watchdog control
3 Min. Station Delay
4 Ident. number of slave
5 Ident. number of slave
6 Group ident.
7 SPC3 specific user Bit 0= Dis_Startbit, The receiver will not monitor
parameter byte the start bit when this bit is turned on (=1).
Bit 1= Dis_Stopbit, The Stop bit is not monitored
when this bit is turned on (=1)
Bit 2 = Wd_base, specifies which time base to
use for the watchdog.
0 means 10 msec timebase,
1 means 1 msec timebase.
8 ICS specific Bit 0 = ICS diagnostics (0 means active, 1 means
parametrization byte disabled)
Bit 1 = Motorola/Intel output (0 means Intel, 1
means Motorola)
5.6.5 Network Configuration

The descriptions contained in this chapter deal with the Siemens Step 7 software for
configuring a PROFIBUS-DP network.
GSE file Installation

The ICS 5000’s GSE (or GSD) file must be installed in the Master’s configuration
software. In Step 7 the GSE file is installed from the Hardware configuration screen.

From the Menu bar select Options/ Install New GSD as shown in the following
image.
This will display the Installing new GSE dialog box shown below. Navigate to the
folder where the ICS 5000’s GSE file (Ics_068A.gse) is stored. The bitmap file
(Ics5000n.bmp) will be located in the same directory.

Once installed, the ICS 5000 module’s folder created from the GSE file is located in
the Step 7’s Hardware Catalog under the following path: PROFIBUS-
DP/Additional Field Devices/General/ICS 5000.
The ICS 5000 module consist of 1 Byte, 1 Word, and 2 Word (8, 16, and 32 bits)
sub-modules with Read or Write functions.

Basic Rack Configuration

Before communication can be achieved, the Master must be configured for the
PROFIBUS network. The first step is to assign a Rack which contains the
CPU/PROFIBUS master. The Rack and Modules are selected from the Hardware
List as shown in the following image. Select Rail, Power supply (if applicable) and
the CPU.
Selecting CPU with PROFIBUS Master will open the window the Properties
window for network. Select the Parameters tab. Click New to create a new
PROFIBUS Network, then click Properties... to configure the network.

From the subnet Properties window now displaied (see figure that follows), select
the Network Settings tab. Use the Transmission Rate list, to select the transmission
rate for the network, then click OK to continue.
The selected transmission rate is now provided next to new network as shown in the
following figure.

The module for the configured CPU with the new PROFIBUS network is now
located in the rack as shown in the following figure. Open the folder in the
Hardware list on the right hand side of the screen that contains the ICS 5000 Module
(PROFIBUS-DP/Additional Field Devices/General/ICS 5000). Click on the ICS
5000 folder icon and drag it to the Network.
Inserting the ICS 5000 Module will open the Properties - PROFIBUS interface ICS
5000 window shown below. Use the Parameters tab to configure the ICS 5000’s
Address then Click OK.
Note – Make sure this Address matches the one configured with the ICS 5000
Support Software.
Once this has been completed, the ICS 5000 module appears as an icon on the
network. Selecting the ICS 5000 will open the configuration list table shown in the
following figure. The same modules as in the text file (Profibus.txt) created from the
ICS 5000 configuration must be selected. By selecting the sub modules from the
ICS 5000 folder on the Hardware list, the Communication Table for the ICS 5000 is
programmed in to the PROFIBUS Master.

Note – The selected modules shall be configured in the ICS 5000 using the ICS 5000
Support Software.
Selecting the ICS 5000 Modules Object Properties will open the Properties - DP
slave window shown below. Select the Parameter Assignment tab. The Device-
specific parameters folder allows you to disable/enable the Extended Diagnostic
functions (Ext.diagnostics). The default value is active. The INTEL or Motorola
(Swap) data format can also be configured from this window.
5.6.6 PROFIBUS Cable Connections
Cable
The cable fitting sealing on the rear panel is designed to accept cables with a
diameter between 5 to 12 mm (0.2 to 0.5 inch).

Port location
The PROFIBUS-DP, RS-232 and RS-422 ports on the ICS 5000 are located in a 16
pole screw terminal on the rear panel directly below the I/O Connector (see ICS
5000 Communications Port Layout on page 5.2).
PROFIBUS-DP Port Configuration

The pin configuration for the 16 pole screw terminal connector is as follows:
Table 5.7 PROFIBUS-DP port
13 +5 V FC Power supply voltage. (Should be wired to pin no. 14 if ICS’s
internal termination is used.)
14 B Receive/Transmit data - plus (RxD/TxD-P) pin 3 in D-Sub
15 A Receive/Transmit data - minus (RxD/TxD-N) pin 8 in D-Sub.
16 DGND Data reference potential. (Should be wired to pin no. 15 if ICS’s
internal termination is used.)
Note – Pin no. 16 (DGND) and 13 (+5V FC) are internally connected to the ICS
5000’s terminating resistors and should only be connected with jumpers to pin no.
14 and 15 if the ICS 5000 internal termination is used. They should not be used in
any other way.
Figure 5.9 PROFIBUS Connections with Internal Termination Jumpers
Termination
If the ICS 5000 is the last wired unit in the network, termination must be used.
Termination can be achieved with the built-in termination of the ICS 5000 or an
external active bus terminator, such as SIEMENS PROFIBUS Terminator (6ES7
972-0DA00-0AA0).
Implementation using the built-in termination on the ICS 5000 requires only the
addition of two jumpers on the 16 pin socket. The jumpers should be mounted
between pin no. 13 to 14 and 15 to 16. The terminating signals (+5V and DGND)
from the ICS on pin 13 and 16 are connected via a voltage divider and should not be
used for any other purpose than termination to pin 14 and 15.

PROFIBUS Grounding and Isolation

The ICS 5000 grounding philosophy is to ground the unit in only one location. The
reason for this is to avoid ground loops. The ICS 5000 unit should only be grounded
via the PROFIBUS network connection (Figure 5.10 that follows). The ICS 5000
unit is isolated from the vehicle via it’s mounting bracket, and shields around the 24
V cable and I/O cable should only be connected at the ICS 5000. Shields are
connected to the Chassis Ground using the specially designed cable feed-throughs
on the rear cover of the unit. When terminating the wiring to the ICS 5000 insure
that the shields are correctly attached. Consult the ICS 5000 Installation Manual
(571 701 451 or 571 701 453) for details on wiring
Figure 5.10 PROFIBUS Interconnection Overview
5.7 Interbus Communications Configuration
5.7.1 General Description

INTERBUS field bus is handling the data communication from a PLC or host
computer to one or several ICS 5000 units and other types of sensors or actuators
(such as I/O modules, encoders and robots).
INTERBUS field bus is designed as a data ring with a central master-slave access
method. The field bus works as a large shift register, where every unit connected to
the ring is a part of the shift register, through which the data is clocked. With this
ring structure it is possible to send and receive data synchronously (full duplex).
The ring system is implemented in one cable. The implemented INTERBUS field
bus in the ICS 5000 is of type remote bus supporting the PCP (Peripherals
Communication Protocol).

With the exception of the Skew control mode, all control algorithms in the ICS 5000
can be configured for the INTERBUS fieldbus communications protocol.
Figure 5.11 INTERBUS Interconnection Overview
INTERBUS Wiring
The ICS 5000 INTERBUS communication devices consist of two internal
interfaces. Both consisting of RS-485 circuits, one of the interfaces is galvanically
isolated from the rest of the unit. The galvanically isolated interface is called DI1
/DO1 and shall be connected to the Master (PLC) or a Slave device what is
connected before the ICS 5000 unit in the chain from the Master device.This is
shown in Figure 5.12 and Figure 5.13 that follow.
Figure 5.12 INTERBUS Interface Wiring

Figure 5.13 ICS 5000 Internal INTERBUS connections
ICS 5000 INTERBUS Port Pin Configuration

The INTERBUS port on the ICS 5000 is implemented using the two RS-422 ports
on the unit. These ports are accessed via the 16 pin Serial Com Ports screw terminal
on the back of the unit (see Table 5.1 on page 5.2). The following two tables
provide the pin outs for these connections (see Figure 5.14 for more details).
Table 5.8 ICS 5000 16 Pin Screw Terminal DI1 / DO1 Interface
PIN NO. FUNCTION DESCRIPTION
10 Isolated COM Tied to the opto-isolated ground of the interface circuit.
6 O (RA) Positive polarity of the DO1 interface.
7 /DO (RB) Negative polarity of the /DO1 interface.
8 DI (TA) Positive polarity of the DI1 interface.
9 /DI (TB) Negative polarity of the /DI1 interface.
Table 5.9 ICS 5000 16 Pin Screw Terminal DI2 / DO2 Interface
PIN NO. FUNCTION DESCRIPTION
5 GND Tied to the ground of the interface circuit.
4 DO (TA) Positive polarity of the DO2 interface.
3 /DO (TB) Negative polarity of the /DO2 interface.
2 /DI(RB) Negative polarity of the /DI2 interface.
1 DI(RA) Positive polarity of the DI2 interface.
Note – Older style ICS 5000 units may have a Serial Com Ports interface with only
12 terminals.
Note – The polarity on the ICS 5000 units RS-422 interface is switched on the
receiver and transmitter pins compared to the INTERBUS DO1 DI1 interface.

INTERBUS Cabling
Figure 5.14 below shows an example on how to connect an ICS 5000 to an
INTERBUS network.
Figure 5.14 Wiring diagram ICS 5000 to INTERBUS
5.7.2 ICS 5000 Configuration

The ICS 5000 is implemented as a slave device in the INTERBUS network. The bus
type is REMOTE.
The INTERBUS configuration of ICS 5000 is done with the ICS 5000 Support
Software. When the ICS 5000 unit is configured for INTERBUS communication,
both RS-422 ports are utilized by INTERBUS once the ICS 5000 has switched to
User parameters (five seconds after boot-up).

You configure the ICS 5000 for INTERBUS using the Protocols screen ( [Alt] + [M] +
[1] ) of the Communications tab as shown in the figure that follows.
Next you configure the RS-422 port options based upon the position of the ICS
5000 on the INTERBUS chain. Using the Port Options screen ( [Alt] + [M] + [2] ) of
the Communications tab select the appropriate setting from the RS422 Port Options
group as shown in the figure that follows.
Select option 3 INTERBUS device at END-OF-THE-CHAIN if the ICS 5000 unit is

the last device in the INTERBUS chain. Select option 1 INTERBUS device NOT at
end-of-the-chain if more devices follow after this unit.

of the INTERBUS network. Connect the RS-232 port to a PC with a terminal
program. (For example the Hyperterminal program included with Windows can be
used.). Check the status of the ICS 5000 unit by sending the E command to the unit.
C
Warning – Do not run the ICS 5000 Support Software on the RS-232 port at the same
time as INTERBUS is running on the other ports. (If you do, there will be two masters
(PC and PLC) that are in control of the ICS 5000 unit (your vehicle).
C
Warning – Do not experiment with sending commands if you do not know which device
(PC or PLC) that is in control of the ICS 5000 unit (your vehicle)
Note – The BT command resets ICS 5000 and also the INTERBUS circuit inside the
ICS 5000 unit.
5.7.3 INTERBUS Network Configuration

INTERBUS communication with ICS 5000 is performed using ASCII characters in
strings. End of transmission is indicated with a Carriage Return <CR>.
Note – The following descriptions cover configuring Phoenix Contact's IBS CMD
G4 Software to communicate with an ICS 5000 unit on INTERBUS.
Basic Configuration
Before communication can be achieved, the ICS 5000 must be registered on the
network. This can be done with the software online. Right Click on the
Configuration Frame icon located in the Project window (shown in the figure that
follows) and select Read Again. This will cause the ICS 5000 unit to appear as a
PCP icon below the Controller Board icon.

The example shows an INTERBUS network with an ICS 5000 unit connected as the
end unit. The Status bar in the bottom of the Project window indicates the Status:
Bus active and State: Online.
Note – Online configuration with IBS CMD G4 requires the network to be wired and
the connected units to be configured for INTERBUS communication.
Write Data to ICS 5000

Communication with the ICS 5000 is performed in the write service (Index 4002)
and the read service (Index 4003). The network Operating State must be changed to
Monitoring if you wish to use either the write service or read service via the IBS
CMD G4 software. Click the F3 State button. Select Monitoring from the Change o
... group of the Operating State window as shown in the figure that follows.
C
Warning – Care must be taken prior to switching to the Monitoring state to avoid conflict
with the control system.

As a safety precaution you must confirm that you want to change the operating state
to Monitoring. Do this by entering the word MONITOR in the Enable: field (as
shown in the image that follows), then Click OK.
The Monitoring State indicated on the Status bar will now be shown as Monitoring.
Right Click on the ICS 5000 unit’s PCP icon to display the menu shown in the
following figure. From this menu select Device Parametrization.

The Device Parameterization window with the description: Trimble, ICS 5000 as
shown below will be displayed. From the Menu Bar select Device/ Read Parameter
List. Four rows with index from 4000 to 40003 will be listed.
Select row 4002 and Click the Change Value button. In the displayed Change Text
window, enter the data to be sent to the ICS 5000 using the hex codes for all
characters. The first byte is reserved of the number of data bytes in the message. The
example in the following figure depicts sending: E;Y <carriage return> (see
Table 5.10 that follows for message details). Click OK to close the Change text
window.
Click F5 Write Value to send the data. Table 5.10 shows the hex codes for the
transmitted message.
Table 5.10 Example Write Data
Hex Code Commands Description
04 Number of data bytes
45 E Returns the current status of the ICS unit
3B ; Separates multiple commands transmitted with only one
carriage return

Table 5.10 Example Write Data

59 Y Reads the current station
0D <CR> Indicates end of transmission
B
Tip – Null characters (00) can be used in the transmit message if a fixed length of the
transmitted message is preferred.
Receive Data from ICS 5000

The ICS 5000 status bit changes to 1 if it has new data to be read. This can be
viewed from the IBS CMD G4 software using the Address Monitor (shown in the
figure that follows). The Address Monitor window is opened from the Controller
Board icon.
Note – The status bit is the second bit from the right in the highlighted row for
Address 1.

Select row 4003 and Click the F4 Read Value button to read the reply from the ICS
5000.
Click the Change Value button to view all 17 bytes in the reply.
Table 5.11 that follows shows the hex code for the received message. The first byte
(08) indicates it is 8 bytes in the received message.
Table 5.11 Example Read Data
08 Number of data bytes in received message.
45 E Returns the current status of the ICS unit.
20 Returned command and value are separated with a space
character.
31 1 Returned status on ICS.
3B ; Separates multiple commands.
59 Y Returns actual Station.
20 Returned command and value are separated with a space
character.
32 8 Returned station number.
0D <Carriage Indicates end of transmission.
Return>

If no more data exists to be read from the unit, the status bit changes from 1 to 0 as
shown in the following figure.
5.8 Custom Read and Write Data Tables

Located under the Communications Tab, the Read Table ( [Alt] + [M] + [5] ) and Write
Table ( [Alt] + [M] + [6] ) options allow the user to define the read and write data to be
exchanged with a PLC or computer. MODBUS, DFl, DeviceNet and PROFIBUS
represent data in integer arrays (e.g. 40001-40006 or N7:0-5 or Element0-
Element5). By default, the data in each array element is pre-defined (e.g. Element0
= Status Register) but you can create your own definitions by filling out the Read
(ICS 5000-to-host) and Write (host-to-ICS 5000) tables. This approach lets you
group important pieces of data together to simplify and speed up the reading/writing
process.
Note – You MUST must define Read and Write Tables when using DeviceNet and
PROFIBUS.
B
Tip – If Custom Register Definitions are not used, then the ICS 5000 uses the Default
Register Definitions described in Table 5.15 on page 5.69 making it backward
compatible with older DF1 and Modbus applications.

5.8.1 Default Register Definitions

When enabling the ICS 5000 with DF1 or MODBUS, the default register definition
are as shown in Table 5.12 that follows. This register layout matches the order used
in the older TCS 4000 units before custom register definition was available. It is
acceptable to skip the custom configuration process and use the default definitions
provided as long as the commands you need are contained in the default definitions.
Table 5.12 Default Command Listing
Element Name ASCII Char Read/Write DF1/MODBUS
Address
Status E R 40001/Nff:0
Station Destination S R/W 40002/Nff:1
Station Location Y R 40003/Nff:2
Distance Destination (MSW) D(MSW) R/W 40004/Nff:3
Distance Destination (LSW) D(LSW) R/W 40005/Nff:4
Current Distance (MSW) X(MSW) R 40006/Nff:5
Current Distance (LSW) X(LSW) R 40007/Nff:6
Return Signal Strength R R/W 40008/Nff:7
Halt Acceleration H W 40009/Nff:8
Operating Acceleration A R/W1 40010/Nff:9
Beam Breaks to Ignore I R/W 40011/Nff:10
Operating Mode M R/W 40012/Nff:11
Measurement Offset (MSW) O(MSW) R/W 40013/Nff:12
Measurement Offset (LSW) O(LSW) R/W 40014/Nff:13
Positioning Tolerance T R/W 40015/Nff:14
1
Operating Velocity V R/W 40016/Nff:15
Array Index Variable U R/W2 40017/Nff:16
Calibration Array C R/W 40018/Nff:17
Diagnostic Array J R/W 40019/Nff:18
Parameter Array (MSW) P(MSW) R/W 40020/Nff:19
Parameter Array (LSW) P(LSW) R/W 40021/Nff:20
Look-up Table Array (MSW) L(MSW) R/W 40022/Nff:21
Look-up Table Array (LSW) L(LSW) R/W 40023/Nff:22
1This
value is R/W for TCS and BCS control algorithms only. For the PDM algorithm it is R only.
2Care
must be taken when using this register as it can overwrite vital elements of the Calibration,
Parameter, or Lookup Table arrays.
5.8.2 Custom Register Definitions

There are five options to choose from when developing the data registers for an
application: 8 Bit, 16 Bit (two byte Integers), 32 Bit (four byte Integers), All Sizes (8
Bit, 16 Bit and 32 Bit) or All Registers. To assist with user selection of elements, a

Filter is provided to control the elements displayed (see figure below). Depending
upon the communication protocol selected, some or all of the options will be
avalible.
Note – Consult the manufacturer’s literature for the PLC or computer being use to
determine the maximum integer file size.
Based upon the filter selection of 8 Bit, 16 Bit, 32 Bit All Sizes, or All Registers, the
appropriate Read and Write element list will be displayed. The following sections
contain examples of typical 16 bit Read and Write Table screens.
Read Table Configuration

[Alt] + [M] + [5]
The Read Table configuration screen (see figure that follows) is comprised of an
element selection list on the left and a listing of the configured chosen elements on
the right. The 16 bit Status, for example, is the first element. The Read Table
depicted below is from an ICS 5000 configured to use the DF1 protocol.

To construct the message, you simply select the element(s) you would like to use
from the left hand column and click the button. You can select multiple
elements by holding down the [Cntl] key during the selection process. To remove an
element from the Table, simply select that element in the right hand column and
click the button. To remove all elements, select any element in the Table
(right hand column) and click the button.
To rearrange the order of the elements in the table, select the desired element and
click or . To move elements, they must be selected individually.
The PLC register address will be displayed on the right side of the configured data.
If you are using DF1 protocol, this address will begin with N7:0, when using
MODBUS the first register is 30001. The first register for both DeviceNet and
PROFIBUS is Element 0.
If DeviceNet or PROFIBUS are the selected protocols, then the button can
be used to view and save the scanner module configuration information. For
DeviceNet, the custom EDS file is displayed with the option to save it to disk. For
PROFIBUS, a list of the read and write modules use is provided for network
configuration.
When you have finished your configuration, proceed to the Write Table
configuration.
Write Table Configuration

[Alt] + [M] + [6]
The Write Table configuration screen (see figure that follows) is comprised of an
element selection list on the left and a listing of the configured chosen elements on
the right. The example shown reads the Destination (high and low words) along
with the current settings for Acceleration and Velocity. The Write Table depicted
below is from an ICS 5000 configured to use the MODBUS protocol. The Write
Table is constructed the same as the Read Table covered in the previous section.
The Write Table configuration screen also has a check box to Ignore Redundant
Data. When this is checked, the ICS 5000 will only respond to unique data values
sent from the PLC. For example if you command the ICS 5000 to move the vehicle

to Station 4, and there is a fault stopping the move, another value, such as Station 0,
will have to be sent to the unit before the move to Station 4 will be processed. This
is designed to reduce network traffic and can be very useful if network is highly
populated.
B
Tip – It can be very useful to utilize the Ignore Redundant Data enabled at the bottom of
the Write Table. This feature limits network traffic and can simplify PLC programming
code.
Finishing The Register Configuration

When the configuration of both the Read and the Write Tables is complete the data
must be sent to the ICS 5000 by pressing the image of the unit in the lower left
corner of the program window or by clicking the button on the Tool Bar.
5.8.3 A Word About Number Conventions

The MODBUS protocol is supported only by a 16 bit register. The DF1, DeviceNet
and PROFIBUS protocols are supported by a 16 bit register and a 32 bit register.
The 32 bit register is for PLC’s that supports DINT files (AB’s ControlLogix PLC).
In addition, the DeviceNet and PROFIBUS protocols also supported by an 8 bit
register. With the exception of the Least Significant Word or LSW registers, the ICS
5000 uses 16 bit two’s complement notation. E.g. 0xFFFFH=-1, 0x0001H=+1. The
normal range is therefore –32768 (0x8000) to +32767 (0x7FFF). Five of the
numbers in the ICS 5000 (D, X, and O commands along with the P and L arrays)
can be so large that this range is inadequate. To work around this limit, each of these
five numbers has been broken up into two numbers (MSW and LSW). In other
words, there are two registers assigned to each numbers instead of one register like
the other numbers. These registers are consecutive with the first (lower register
address) being the Most Significant Word or MSW. And the next register in the
sequence (higher register address) the LSW. The LSW registers are extensions of
the MSW registers which carry the sign and are therefore treated as unsigned
values. E.g. 0xFFFF=65535, 0x0001=1. The ICS 5000 then combines these two
numbers internally to form one 32 bit number according to the following equation:
“ICS 5000 number” = 65536*MSW + LSW
Table 5.13 that follows contains a few examples:
Table 5.13 Number Convention Examples
Test Value Method
Program destination to 65538 mm write 0x0001 (signed +1) to 40004/Nff:3 and
write 0x0001 (signed +1) to 40004/Nff:3 and
(65538 = +1 * 65536 + 2 = 0x00010002)
Program offset to -2 mm write 0xFFFF (signed –1) to 40013/Nff:12 and
write 0xFFFE (unsigned 65534) to 40014/Nff:13
(-2 = -1*65536 + 65534 = 0xFFFFFFFE)

Note – Writing a number to LSW of the Destination register causes the control loop
to activate and move the machine to a destination in millimeters specified by
combining 65536*MSW and LSW. To insure that the position is interpreted
correctly, write data to the MSW register first.
The following table contains some additional examples of 32 bit numbers supported
by the ICS 5000 as two 16 bit numbers.
Table 5.14 32 Bit Number Examples
Decimal Hex =MSW & LSW
0 (0x00000000) = 0 (0x0000) & 0 (0x0000)
-1 (0xFFFFFFFF) = -1 (0xFFFF) & -1 (0xFFFF)
-2 (0xFFFFFFFE) = -1 (0xFFFF) & -2 (0xFFFE)
32767 (0x00007FFF) = 0 (0x0000) & 32767 (0x7FFF)
65535 (0x0000FFFF) = 0 (0x0000) & -1 (0xFFFF)
65536 (0x00010000) = 1 (0x0001) & 0 (0x0000)
This complexity can be avoided in two possible ways:

1. Use stations instead of millimeter destinations.
2. If the near and far limits are less than 65.535 meters apart, the wake-up offset
can be adjusted so near travel limit is 0. Then only MSW register needs to be
used.
5.8.4 Advanced Communications Command Listing

The following tables contain all command elements available for use when building
Custom Read and Write Tables for the ICS 5000. Detailed descriptions of all
commands can be found in Appendix A, Commands and Diagnostics. The first
table, 16 Bit Commands, contains a listing of the 16 Bit command set. The second
table, 32 Bit Commands, contains information about the expanded 32 Bit command
set. The commands are separated into two groups to allow compatibility with a
wider range of PLC and computer hardware. In each table, the first and second
columns contain the elements name and the ASCII Command Equivalent, the third
column contains the Element type (Read or Write or Both) and the last columns
contain the various (16 and 32 Bit) ID #’s.
While the two tables contain 16 and 32 bit commands respectively, some of the
commands use values that are small enough (< 32,767) that a reduced word size will
work. For example: Element # 158 is declared as a 32 bit command, the value
returned will never exceed 128 and can thus be accessed as a 16 bit value to
conserve space. An ID # placed in the 16 ID column indicates that the value can be
safely treated as a 16 bit value
The 16 Bit compatible command listing contains 16 bit ID #’s while the 32 Bit
Command listing contains both 16 and 32 bit ID #’s. This is done to present the
option of accessing the smaller 16 bit values when using a PLC that supports 32 bit
registers. While this is a more efficient way to transfer data, care must be taken
when accessing data as smaller 16 bit values. If the value has the possibility of
exceeding the limit (32,767) then it must be treated as a larger value. If not, then the
value could be truncated by the PLC.

The ICS 5000 defaults to handling only 16 Bit integer values. 32 Bit values are only
enabled once a 32 Bit Write has been received from the PLC or SLC.
Note – The DF1 protocol selection in the ICS 5000 disables the use of 8 Bit integers.
16 Bit integers read with 32 Bit integer files will be padded with zeros once a 32 Bit
Write has been preformed to switch the ICS 5000 to 32 Bit Mode. 32 Bit integers
read with 16 Bit integer files will be truncated which may alter the data.

16 Bit Commands.
C
Warning – While accessing certain elements as smaller (16 bit) values will produce
correct results, this is not the case with every element. Take care when assigning
elements or data truncation may occur
Table 5.15 16 Bit Commands

Element Name ASCII Char Read/Write 16 ID
Status E R 64
Station Destination S R/W 65
Station Location Y R 66
Distance Destination (MSW) D(MSW) R/W 67
Distance Destination (LSW) D(LSW) R/W 68
Current Distance (MSW) X(MSW) R 69
Current Distance (LSW) X(LSW) R 70
Return Signal Strength R R/W 71
Halt Acceleration H W 72
1
Operating Acceleration A R/W 73
Beam Breaks to Ignore I R/W 74
Operating Mode M R/W 75
Measurement Offset (MSW) O(MSW) R/W 76
Measurement Offset (LSW) O(LSW) R/W 77
Positioning Tolerance T R/W 78
Operating Velocity V R/W1 79
Array Index Variable U R/W 80
Calibration Array C R/W 81
Diagnostic Array J R/W 82
Parameter Array (MSW) P(MSW) R/W 83
Parameter Array (LSW) P(LSW) R/W 84
Look-up Table Array (MSW) L(MSW) R/W 85
Look-up Table Array (LSW) L(LSW) R/W 86
Debug Array (MSW) B(MSW)2 R/W 87
Debug Array (LSW) B(LSW)2 R/W 88
Key to Activate Special Routine G2 R/W 89
System Self-test Z R 90
1This
value is R/W for TCS and BCS control algorithms only. For the PDM algorithm it is
R only.
2This command
should only be used by experienced personnel. If used incorrectly, it can
result in unexpected operation, vehicle damage and personnel injury.
32 Bit Commands
Note – When using 32 Bit Commands, a 32 Bit Write must be completed before a 32
Bit Read. The 32 Bit Write switches the ICS 5000 operating mode from the default of
16 Bits to 32 Bits. The switch is accomplished automatically when a Write from a

Dint file is received by the ICS 5000.

Table 5.16 32 Bit Commands
Element Name ASCII Char Read/Write 16 ID 32 ID
Status E R 94 158
Station Destination S R/W 95 159
Station Location Y R 96 160
Distance Destination D R/W 971 161
1
Current Distance X R 98 162
Return Signal Strength R R/W 99 163
Halt Acceleration H W 100 164
2
Negative Operating Acceleration A R/W 101 165
Positive Operating Acceleration A2 R/W 102 166
Beam Breaks to Ignore I R/W 102 167
Operating Mode M R/W 104 168
Measurement Offset O R/W 1052 169
Positioning Tolerance T R/W 106 170
Negative Operating Velocity V2 R/W 107 171
Positive Operating Velocity V2 R/W 108 172
Memory Protect Status U-1; J R 109 173
Beam Break Diagnostic Code U0; J R 110 174
Motor Failure Diagnostic Code U1; J R 1112 175
Settling Time U2; J R 112 176
Pointing Laser Status/Enable U3; J R/W 113 177
Digital I/O Status Word (See U4; J R 114 178
Table 5.17 that follows)
DAC Voltage Digital Value (4095 = U5; J3 R 115 179
10 V)
Spare 116 180
Spare 117 181
Array Index Variable U R/W 118 182
System Self-test Z R 119 183
Calibration Constant Array Value 0 U0; C4 R/W 120 184
Calibration Constant Array Value 1 U1; C4 R/W 121 185
4
Calibration Constant Array Value 2 U2; C R/W 122 186
Spare 123 187
1
This value may exceed the limit for 16 bits (32,767) - If you decide to use this element as an 16 bit
value, insure that your application operates with values within the range of 0 to 32,767.
2
This command only applies to the TCS control algorithm.
3
The DAC voltage value contained in this register is not appropriate for use in a control circuit. It is
only intended for use as an approximate reference of commanded velocity.
4
This command should only be used by experienced personnel. If used incorrectly, it can result in
unexpected operation, vehicle damage and personnel injury.

Digital I/O Status Word

The Digital I/O Status Word is shown in Table 5.17 below.
Table 5.17 Digital I/O Status Word
Bit I/O Element Value
0 Synchronization Output 1
1 Brake Output 2
2 Safety Output 4
3 FWD/REV Output 8
4 Spare Output 16
5 Synchronization Input 32
6 DAC Voltage is Positive 64
7 DAC Voltage is Negative 128
Combinations of multiple outputs or inputs will result in a sum of the values. For
example: When the Brake Output and the FWD/REV Output are both closed the
value of this element will be 10.
Note – For a detailed description or the function of the listed commands, status
codes and diagnostic codes, see Appendix A, Commands and Diagnostics.


CHAPTER
6
Station Configuration 6
In this chapter:
• Introduction
• Stations Configuration Tab

6.1 Introduction
This chapter covers the configuration of the Station Look-up Table stored in the ICS
5000. The use of the Stations varies between the different control algorithms, so be
sure you check you application before beginning. In general, Stations can be used
by the ICS 5000 to represent distances in millimeters. The ICS 5000 can hold up to
2000 stations, and they can be numbered in any order desired. Remember though
that skipped station numbers still count toward the total.
Note – Try not to skip stations or assign them out of order, this wastes stations as
even skipped ones count against the total number, and decreases the efficiency of the
Y command.
6.2 Stations Configuration Tab

There are only two different aspects to configure before using Stations - Station
Setup and Modify Stations.
6.2.1 Station Setup

[Alt] + [S] + [1]
Use the Station Setup screen picture below to configure the Station Location (Y
command) Format and the Starting Station Number.
Station Location (Y command) Format

You must select one of the two available formats for the Station Location (Y
command) Format. The Y command returns the station number that matches the
current position if in tolerance. When out of tolerance, there are two formatting
options for the response:

Station Configuration 6
Format 0
The station location will be negative when out-of-tolerance regardless of direction.
For example, Y -5 means the machine is close to Station 5 (Y 5 means it is at Station
5).
Format 1
10000 will be added to the station location when out-of-tolerance and the sign
implies the direction. For example, Y -10005 means the machine's distance is less
than Station 5, Y 10005 means it is greater than station 5 (Y 5 means it is at Station
5).
Starting Station Number

This is the first or lowest numbered station. For example, if there are 5 stations
numbered 10, 11, 12, 13, and 14 then 10 would be the Starting Station Number.
6.2.2 Modify Stations

[Alt] + [S] + [2]
Reached from the Stations tab, the Modify Stations screen allows you to
define/redefine station locations. This screen displays the length of travel as it is
defined by the Travel Limits using a scale in millimeters positioned above the
control buttons as shown in the following image. Stations are depicted as vertical
rectangles with the current active station shaded in green. If a station is defined
outside of the Travel Limits, then it will be shaded red when selected. The default
view is scaled such that each side of the display is a travel limit. Finally, when ON
Line with an ICS 5000 unit, the current position is indicated by the arrow ( ) and
the status is displayed in the center of the screen.
Making Modifications
To add or change stations, enter the number of the station in the Station field, then
position the axis at the desired location and click . Alternatively, you can
change the millimeter value for any station by dragging the icon (if Dragging has

first been enabled by checking the Enable Drawing option) to the desired location
or by entering a numeric value in the mm Value field. To remove a station, select the
station or enter the number in the Station field, then click . Deleting a
station will renumber any existing stations that were greater than the number of the
station deleted. For example if you delete station six out of ten consecutive stations
beginning with one, then everything above six will be shifted down (e.g. 7 to 6, 8 to
7, 9 to 8, and 10 to 9). To avoid this, you can delete the value in the mm Value field
to make the station undefined.
Click Undo to undo edits made to the Stations from this screen. Each time you
select Undo, the last change made (up to five) will be undone. The Undo button is
disabled if no edits exist. All edit Undo information is deleted once a Save has been
completed.
Enabling Motion
Checking the Go to Station option on the Modify Stations screen will enable you to
move the vehicle to any station simply by selecting that station. Before motion is
enabled however, the warning screen in the following image is displayed to confirm
your choice. Click Yes to continue and enable motion. If Enable Drawing is also
selected, then you will be able to move the vehicle by drawing the station. This can
be helpful for fine tuning a location.
Interpolate Feature
To assign a specific amount of evenly spaced stations to an axis use the Interpolate
feature. To use Interpolate you must define the first and last stations then click
to calculate millimeter values of undefined stations in between. For
example if you want to set up ten stations equidistant apart, setup the first station
then the tenth station leaving the middle eight undefined. Then click to
assign values to the eight undefined stations.
Note – When On Line with an ICS 5000 unit and a modification is preformed, the
ICS 5000 icon located at the bottom left of the screen will be displayed with a yellow
arrow indicating that the parameters need to be sent to the unit before any updates
will be applied. This is accomplished by clicking on the icon .

CHAPTER
7
Motion Control Overview 7
In this chapter:
• Introduction
• TCS Algorithm - Closed Loop Control
• BCS Algorithm - Open Loop Control
• PDM Algorithm - Feedback Only and Collision Avoidance
• ICS Integrated Approach

7.1 Introduction
This chapter provides a brief background on motion control as implemented in the
ICS 5000. The ICS 5000 is available with three different control algorithms:
• TCS Algorithm - Closed Loop Control
• BCS Algorithm - Open Loop Control
• PDM Algorithm - Feedback Only and Collision Avoidance
Before Selecting which method to implement, it is important that you understand
the benefits and limitations of each approach. The following sections give a detailed
description of each control approach along with some helpful integration advice.
7.2 TCS Algorithm - Closed Loop Control

The theory of operation behind the Total Control System (TCS) control algorithm
and the Self Learning part of the ICS 5000 Support Software is really quite simple.
In fact, anyone that has adjusted their driving style to that of an unfamiliar car has
performed many of the same tasks the software performs when “learning” the
characteristics of a vehicle.
• How hard do you press on the gas peddle to make the car go?
• How fast does the car accelerate?
• How fast does the car Brake?
• How does the car respond to changing speed – passing or slowing to exit a
highway?
Once all of these variables have been tested and you are comfortable with the
response of the car, tasks such as deciding when to begin braking at a traffic light or
accelerating to a specific velocity become quite easy. This same concept is applied
to allow the TCS to position vehicles. The key is to insure that the actual response of
the system does not change once the learned response is established. Minor loading
deviations such as changing from fully loaded to empty can be easily dealt with, but
drastic changes such as modifying the motor drives characteristics require that the
TCS control algorithm re-learn the response profile of the vehicle.
7.2.1 PID Closed Loop Control

The PID control loop that the ICS uses is a modified version of one of the most
popular industrial control algorithms. When it is desired to set an output to a
specific value, such as the temperature of a tank of water, a PID loop will improve
the controllers ability to accurately follow the set-point. The way a PID controller
works is that each gain acts upon any error present in the system differently. When
the error is zero the gains are effectively non-existent, but as the error becomes
larger the gains have more effect. The following is a listing of the individual gains,
and how they react with errors:
• Proportional Gain - Acts on errors based upon size.
• Integral Gain - Acts on errors based upon duration.

• Differential Gain - Acts on rate of change of the errors.

As the temperature in the tank just mentioned starts to cool and deviates from the
desired value or Set Point, the difference between the Set Point and the Temperature
feedback increases. The larger this value becomes, the greater the effect of the PID
loop on the output or in this case the heat supply. The goal being to drive the
temperature back to the desired level with a minimal amount of correcting or
settling at the end. This type of configuration should keep the temperature within a
reasonable tolerance.
Figure 7.1 PID Temperature Control Example
The same approach is used in motion control applications, except that the Set Point
is a desired destination; the Feedback is position; and the Output is power to the
motor. The way the Feedback and the Output are integrated with the PID loop is the
secret to successful control, and one of the things that sets the ICS 5000 using TCS
control apart from other controllers.
7.2.2 System Modeling

A PID control loop is only as good as it’s gains, and selecting the right gains is not
an easy task. That is why Trimble has developed the Self Learning feature of the
ICS 5000 Support Software. This feature allows the ICS 5000 to learn (or model)
the characteristics of the system it is controlling. This model is then used to choose
the optimal control loop gains for the system. Gains that will result in the shortest
move time independent of velocity, acceleration, length of move or starting point of
the move.
Using predictable, predetermined stimulus patterns, the ICS 5000 Support Software
instructs the ICS 5000 to output a voltage waveform to the axis motor controller.
While the axis is in motion, the Electronic Distance Meter (EDM) and the
Controller Interface accurately record the resulting response of the vehicle (see
Figure 7.2 that follows. By testing the vehicle with enough different sets of stimuli,

the ICS 5000 Support Software can accurately develop a mathematical model of the
system’s response. In addition to being used to develop the loop gains, the model is
also used by the TCS control algorithm to calculate move profiles and monitor
system performance problems.
Figure 7.2 “Black Box” Modeling Example
Figure 7.3 that follows depicts a TCS algorithm controlled system. As the analog
output (velocity reference) is increased from zero, the velocity of the vehicle
(velocity feedback) follows. The amount of “lag” that the system demonstrates is
depended upon the responsiveness of the system and will vary. The system model is
formed to exactly profile the response of the vehicle thus minimizing lag errors and
over corrections. Errors between the analogue control set-point and the velocity
feedback still do exist but are quickly dealt with by the TCS algorithm’s PID loop. If
the velocity feedback falls below the theoretical response then the error causes the
control signal to oppose or correct the error by increasing the voltage above the
theoretical set-point.
Figure 7.3 Typical TCS Algorithm Response Curves
The amount of undershoot and overshoot present during a move factors into the
systems settling time. A correctly matched TCS algorithm will minimize a systems
settling time resulting in moves that appear to ramp directly down to the final
position. Changes in the system’s theoretical response by increasing/decreasing the
rolling resistance or changing the drive to motor horsepower ratio, can cause an
increase in settling time. Correcting these problems could require a re-modeling or
re-characterization of the system.
Note – Remember that if the systems response changes drastically the TCS’
theoretical profile of the system will require updating

7.3 BCS Algorithm - Open Loop Control

The Brake Controlled System (BCS) algorithm developed by Trimble utilizes a
simple open loop positioning algorithm coupled with a state of the art Electronic
Distance Meter to close the positioning loop around even the poorest responding
mechanical systems. The BCS algorithm allows the user to configure from a two to
a seven speed positioning algorithm. The algorithm uses the distance feedback to
implement a set of velocities and minimum distances. As the distance measured
approaches the distance commanded to travel to, the BCS causes the motor drive to
change speed.
For example: At 5 meters from the final distance, the speed will be reduced from
speed 4 to speed 3 causing the vehicle to slow. At 3 meters, the velocity is again
reduced to that relating to speed 2. The final speed is used to jog the vehicle for a
short distance prior to using the mechanical brake for final positioning. The
resulting move profile, if tuned correctly, can be very effective at positioning all
sizes of vehicles.
Figure 7.4 BCS Algorithm Positioning Overview
The BCS algorithm is used when the TCS algorithm is unable to the control the
axis. This is typically caused by the control configuration (two speed contactor for
example), or poor mechanical performance. Because the BCS algorithm does not
model the performance of the system, it is much more flexible when it comes to
poor performance. The trade off is that the BCS algorithm can not compete with the
TCS algorithm with respect to settling time or quality of control.
7.4 PDM Algorithm - Feedback Only and Collision Avoidance

The Programmable Distance Meter (PDM) algorithm developed by Trimble - is a
fast monitoring device for Distance, Velocity and Acceleration. with a state of the
art Industrial Distance Meter. The PDM can also be configured for an Advanced
Collision Avoidance function. While the PDM is equipped with the analog and
digital controls as the TCS and BCS, the PDM is configured to use this I/O for

control. The PDM is strictly for position monitoring and collision avoidance
applications were an external control loop will be developed in the PCL or host
controller.
Figure 7.5 Collision Avoidance Overview
7.5 ICS Integrated Approach

Unlike traditional positioning solutions, where the feedback device is monitored by
the main vehicle controller, the ICS 5000 combines an infrared distance meter whit
a dedicated positioning microprocessor. In essence, the ICS 5000 acts as a
positioning co-processor to the vehicle controller. This approach frees up the
vehicle controller for supervisory tasks and insures that optimal control is always
achieved independent of vehicle controller make or model. This distributed
approach also greatly reduces the complexity of the overall system design while
implementing a vastly superior control algorithm.
7.5.1 Advanced Position Control - In Search of the Trapezoidal Response

In theory, a trapezoidal response is the perfect move profile. After taking into
account the mechanical and electrical limitations of a vehicle, the tightest profile
one can achieve resembles a trapezoidal pattern. There will be a slight amount of
rounding at the corners, depending upon the responsiveness of the system, but
basically it is still a trapezoid. Over time, various control methods have been
developed to approach this level of performance, but rarely, if ever, do they achieve
their goal - Trapezoidal Control.
More often than not, the performance of a controller falls prey to the limitations of
it’s integration without even approaching the engineered design limits of the system.
This is understandable, because without the right tools (an advanced PID loop with
a Model Predictor for example) approaching the optimal Trapezoidal Control level
is not possible. Factors such as creep speed at the end of the move or speed changes

during deceleration eat away at the efficiency of a control system. Trimble’s ICS
5000 distance meter based positioning system successfully overcomes the
limitations of common controllers by integrating the hardware in a rather
uncommon manner.
By moving the control loop out of the PLC and into the position feedback device
were modeling and other advanced control approaches can be utilized enabling
vehicle control to approach the elusive Trapezoidal level. This configuration also
allows the control loop to function independent of PLC scan time limitations. The
result is a control system that gives the designer the flexibility to modify
performance characteristics for the vehicle such as velocity and acceleration without
“tweaking” the control loop gains each time. Performance gains from the
implementation of the ICS 5000 positioning system are realized in two ways:
Short term - The drastically reduced move times (typically 25% and as much as
50% for some moves) result in improved cycle times and more throughput.
Long term - The smooth transitions between velocity extremes places less stress on
the vehicle potentially reducing maintenance worries and extending the operational
life of the vehicle.
7.5.2 System Integration with the ICS 5000

Integration of an ICS 5000 to an industrial vehicle control scheme is simple once it’s
operation is understood. Unlike every other feedback device, the ICS 5000 is also a
motion controller. It interfaces directly with the PLC and the Motor Drive acting as
a “Positioning Co-Processor”. All motion control tasks must be directed by the ICS
5000 including fault handling (with the exception of emergency stops of course).
The ICS 5000 has been designed to function as a distributed controller that will
respond to move requests from the PLC, but require no other interaction to complete
the positioning of the vehicle.
The ICS 5000 has digital I/O designed to sequence the vehicle’s mechanical brake
and drive enable. These are typically passed through the PLC so that it can monitor
the status of these signals and take control during manual operation when the ICS
5000 is “out of the loop”. In addition to the digital I/O, the ICS 5000 uses an analog
signal (-10 to +10VDC or 0 to +10VDC) to direct the motor drives operation. The
Speed Reference is used by the motor drive to turn the motor at the desired RPM’s
which moves and eventually positions the vehicle. It is imperative that this signal be
routed directly to the motor drive using shielded cable to reduce electrical
interference.
7.5.3 Motor Drives

Motor Drives (or Motor Controllers) come in two basic types - AC or DC. DC
motor drives convert the AC supply voltage to a DC supply that drives a DC motor.
DC drives and motors typically cost less than AC, but require substantial
maintenance to insure proper operation. AC motor drives also convert the AC
supply voltage to a DC supply, but then recreate an AC waveform that powers an
AC motor. This extra voltage conversion, along with new technology to improve
performance, is what elevates the price of AC drives with respect to DC. The trade-
off comes with the virtually maintenance free operation of the system.

Since we deal primarily with AC motors and drives, that is all that will be covered
here. Just remember that in general, DC is the standard of operation that AC tries to
emulate. Therefore, as we discuss the operation of AC drives, it is assumed that the
performance of a DC drive meets or exceeds AC in every way.
Different Types of AC Drives

There are basically three different types of AC drives:
• Open Loop Volts/Hertz
• Open Loop Vector
• Closed Loop Vector
Open Loop indicates that there is no encoder feedback from the motor to the drive to
indicate the position of the rotor. Closed Loop utilizes encoder feedback to greatly
improve speed regulation by closely monitoring rotor movement.
Volts/Hertz or constant volts per hertz Mode describes the basic method of control
used by an AC drive. It is the simplest drive configuration that changes the voltage
and frequency of the AC supplied to the motor to achieve a desired speed. While
this is an efficient way to control speed, there is no way to control torque and thus,
precise control is not possible.
Vector or Field-Oriented Control uses a complex series of control algorithms to
manipulate the torque in addition the speed. Closed Loop Vector drives come
extremely close to DC drive performance and are a suitable substitution in almost
every application including vertical applications.
The ICS 5000 will work very well with either Volts/Hertz or Open Loop Vector
drives. On a few instances, a Closed Loop Vector drive should be used to improve
torque control at zero speed (vertical applications for example), but in general
Closed Loop Vector is “over kill” as the ICS 5000 already provides position
feedback for the drive.
7.5.4 PLC or Host Controllers

The PLC or PC Controllers that reside in almost every vehicle are the heart and soul
of the system. They contain the control logic which enables the vehicle to do
whatever it is supposed to do. The PLC or PC may also be the link between the
vehicle and an upper level controller (PLC or PC) responsible for synchronizing
multiple vehicles or operations.
What is a PLC
A PLC or Programmable Logic Controller consists of a Processor, a Rack and
multiple I/O Cards. The processor executes a program that coordinates all activities
of the vehicle.
How do PLCs Differ from PCs

PLCs user proprietary hardware and are specifically designed for industrial
applications. The operating systems are real-time and rarely fail.



CHAPTER
8
Tools & Utilities 8
In this chapter:
• Introduction
• Tools Tab
• Utilities Menu

8 Tools & Utilities
8.1 Introduction
This chapter covers the various tools and utilities provided with the ICS 5000
Support Software. You may find these helpful for setting up and troubleshooting an
ICS 5000 installation.
8.2 Tools Tab

The Tools tab of the ICS 5000 Support Software contains the following six screens:
• Terminal
• Over-/Undershoot
• Motor Tuning Aid
• Random Moves
• Output Test
• Chart Recorder
Depending upon the control algorithm you are using, some of the options will be
made unavailable (see figure that follows). The PDM algorithm, for example, does
not utilize the Over-/Undershoot, Motor Tuning Aid, Random Moves, or Output Test
screens. As a result, these options are greyed out to indicate inactivity.
8.2.1 Terminal
[Alt] + [T] + [1]
Use the Terminal screen to communicate directly to an ICS 5000 using ASCII
commands. A list of these commands along with a brief description of each is
located in Appendix A, Commands and Diagnostics. You type the command in the

Tools & Utilities 8
field below the Message to ICS label and press Enter to send a command to the ICS
5000. The response will appear in the terminal window as shown in the following
figure.
Click Settings to display the PC Communications Settings dialog box which allows
you to reconfigure the communications parameters as described in User
Communication Parameters on page 4.2. If your configuration’s communications
parameters use an address character, then the Other Devices button will also be
available. Click Other Devices to launch a second Terminal screen, as shown
below, which uses a separate set of communication parameters. Use this window to
communicate to a second addressed ICS 5000 without having to re-load parameters.
B
Tip – The second Terminal screen is very helpful when communicating with the two units
while setting up or troubleshooting an ASC system.
Once the second Terminal screen is open, click Settings to display the PC
Communications Settings dialog box. The communications parameters configured
from this Terminal screen are only active until the screen is closed. The ICS 5000

8 Tools & Utilities
Support Software stores the original set of communication parameters, allowing you
to switch communications between two ICS 5000 with little effort. This is
especially useful when working with skew control systems or multi-drop. Use the X
in the upper right hand corner to close the window when finished.
B
Tip – Remember that the ICS 5000 only responds to CAPITAL letters. Also, you can
string multiple commands together by using a semicolon (;) between each command
(e.g. X;D).
8.2.2 Over-/Undershoot
[Alt] + [T] + [2]
Use the Over-/Undershoot Control screen, shown below, to make minor
adjustments to the position control loop gains. Clicking the Start button on this
screen causes the axis being controlled to cycle back and forth (current position is
indicated by the top arrow icon ) between the left and right turn around points
( ). Use your mouse to drag the turn around points to any location or enter new
values in the Left Point and Right Point fields. The goal of this screen is to make it
easier for you to observe the over/undershoot of the system. The Pause Time,
Velocity and Acceleration can all be changed to see how the axis reacts under
different conditions.
Once the axis is in motion, monitor the screen at the turn around points. If
necessary, click Zoom In to increase the magnification of the display. Undo
magnification by clicking Zoom Out or Normalize. As the axis approaches on of
the turn around points, it should decelerate directly to that arrow (keep in mind the
working tolerance), stop and accelerate in the opposite direction. If overshooting or
undershooting is observed, insure that it is occurring the same at both turn around
points. Overshooting at one point and undershooting at the other is the symptom of
an other problem and can not be corrected with this screen.
Once you have determined that the over/undershooting is symmetrical, us either the
Overshoot or Undershoot buttons to begin correcting the problem. Click
Overshoot to add more overshoot to an undershooting condition, or click

Tools & Utilities 8
Undershoot to add more undershoot to an overshooting condition. Remember that

the Overshoot and Undershoot buttons slightly change the way the axis stops and
should be used sparingly. The percentage of Gain Change is displayed above the
move axis along with the current status of the control loop in the ICS 5000. As you
make changes to the Under/Overshoot, the percentage will change. After five
consecutive button clicks, the field changes to yellow, and after ten it changes to
red. The colors are used to inform you of excessive changes to the control loop
gains.
If you are having trouble detecting if the axis is undershooting or overshooting,
click Graph to display a Position vs. Time Graph (shown below) of the motion. This
free running plot of the motion contains a set of target lines that are switched from
top to bottom depending upon the turn around point destination. These lines indicate
the destination of the move +/- the Positioning Tolerance. Each move should
complete the turn around between the lines. Add a second or two of Pause Time to
separate the moves and help clarify the positioning.
Alternatively, you can move the axis by dragging the top arrow ( ) to any point
between the systems End of Travel Limits. All motion can be stopped by clicking
either Halt or . Turn the Pointing Laser on to check system alignment.
8.2.3 Motor Tuning Aid

[Alt] + [T] + [3]
The Motor Tuning Aid screen is provided to assist you with the proper configuration
of you motor controller. This screen turns the ICS 5000 into a signal generator. It
will generate the waveform selected (Square, Triangle, or Trapezoid) once you click
Start. Use the Settings group to adjust the properties of each waveform. Use Voltage
#1 and Voltage #2 to adjust the maximum output voltages for each direction for the
Square and Triangle waveforms, and use Time Interval to adjust the duration which

8 Tools & Utilities
the Square Wave is applied. Finally, use the Ramp Rate to control the ramping of the
Triangle and Trapezoid waveforms. All motion can be stopped by clicking either
Halt or .
C
Warning – Items in this menu can cause vehicle motion and possible damage!!! It is
important that you consult a Trimble representative prior to using the Motor Tuning Aid
so that you can fully understand what will happen with each test.
B
Tip – Spend as much time as needed to insure that the motor drive is tuned correctly.
This can save hours in lost time and may be the only way to successfully complete a
Characterization with usable data.
Note – The final test that should be completed with this screen is to determine the
maximum Ramp Rate your system can handle. Using the Trapezoid Wave, click Start
to begin motion. After the axis has begun moving back and forth, gradually adjust
the Ramp Rate until the acceleration and deceleration is acceptable. Remember that
the ICS 5000 uses a 10 VDC control signal. Therefore, the acceleration time will
equal 10 v / Ramp Rate v/s.
Square Wave
Use the Square Wave selection for tuning over/under-shoot and current limit if the
motor rotor is locked down. Because no ramping is used, you must select a low
enough values for Voltage #1 and Voltage #2 to prevent slippage or over current.
Start with a value of one volt for each. When you click Start, the axis will start
moving back and forth following the square wave output to the analog reference.
Watch the motion of the axis to insure that it follows the signal as closely as possible
with limited under and overshoot. Tune the motor drive, if possible, to get the
correct response before continuing to the next waveform.

Tools & Utilities 8
Triangle Wave
Use the Triangle Wave selection for tuning current stability (if locked rotor) and
linearity around zero speed. Select a median setting for Voltage #1 and Voltage #2,
such as three volts, and use a reduced Ramp Rate so you may more easily observe
the performance around zero speed. Watch for a smooth transition around each turn
around point with minimal deadband. Proceed to the next waveform when satisfied.
Trapezoid Wave
Finally, use the Trapezoid Wave for determining maximum velocity and current
limit (acceleration) if motor rotor is NOT locked. Begin by entering an estimated
Speed Goal in mm/sec. If you do not know what your top speed will be guess and
adjust it as the readings begin appearing (see image that follows). Use the Ramp
Rate field to adjust the acceleration/deceleration of the system. Increase this value
until you reach a maximum value with which you are satisfied. Record the value
and enter this as the Ramp Rate during the Characterization (see Ramp Rate on
page 9.34).
8.2.4 Random Moves

[Alt] + [T] + [4]
Use Random Moves screen which follows to test the machine for marginal operation
and to measure the settling time. Destinations (either millimeters or stations) are
chosen at random so a variety of move lengths are tested automatically. The status
of the control loop is monitored continuously, with any warnings (such as Beam
Break or Motor Warning) displayed in the field in the center of the screen. Marginal
control settings (gains) are reported as Motor Warning or are implied if the Average

8 Tools & Utilities
Settling Time is much larger than the Typical Settling Time. The Random Moves
screen is particularly useful during setup or when trying to verify the operation of
the ICS 5000’s control loop.
In the Number of Moves field enter the number of moves you want the vehicle to
complete. A minimum of 20 moves is recommended. Use the Start Delay and Pause
Time fields to enter a delay time in seconds before motion begins and to enter a
pause time in seconds between each move. The Minimum Distance field is used to
enter a minimum distance to insure per move, and the Ending Position option
allows you to select the final positioning of the vehicle. Selecting the Stations
option will cause the routine to select random station locations instead of distances
in millimeters. If no stations are defined, then this option is not available.
8.2.5 Output Test

[Alt] + [T] + [5]
Use the Output Test screen to directly control the ICS 5000’s digital and analog
outputs. This is useful when testing the ICS 5000 and the wiring to other devices. A
voltmeter may also be useful. It is important to note that when the outputs are
manipulated using this screen they ignore the selected output format and always use

Tools & Utilities 8
format A (see Control Options on page 3.3). Also, when the Analog Output is
selected all the Relay Outputs will be open and when the Relay Outputs are selected,
the Analog Output will be set to zero.
C
Warning – Disconnect the ICS 5000 from the motor drive or disable the motor drive.
Failure to do so can result in uncontrolled high speed motion of the machine
C
Warning – Items in this menu can cause vehicle motion and possible damage!!! It is
important that you consult a Trimble representative prior to using the Output Test screen
so that you can fully understand what will happen with each test.
8.2.6 Chart Recorder

[Alt] + [T] + [6]
Use the Chart Recorder Screen to graphically display the output of the ICS 5000 vs.
time. When you enter this screen, the chart recorder is already capturing data at the
rate dictated by the Seconds of Data setting at the bottom of the screen. Seconds of
Data also represents the horizontal display scaling in seconds.

8 Tools & Utilities
If you are using an ICS 5000 with the TCS or BCS control algorithms, then the
Message to ICS field can be used to issue move (S or D) commands. Once the
message is received, the move will commence.
This screen is particularly useful when setting up an axis that is difficult to see or
configuring an ICS 5000 using the BCS algorithm. Because of the configuration
process required with setting up the BCS algorithm, the Strip Chart Recorder offers
a detailed look at the profile of a move as shown in the image that follows.
Right clicking on the graph gives you the option to Save, Copy or Print a bitmap
image file of the data displayed.
8.3 Utilities Menu
8.3.1 Flash Loader

Use the Flash Loader screen to download a new firmware revision to an ICS 5000
when an upgrade is needed. Firmware files can be obtained at the Trimble web site
or can be e-mailed to you by a Trimble representative. Firmware in the ICS is like
the operating system and application program in a computer.
Downloading firmware does NOT affect parameters, stations and other settings that
customize the ICS 5000 to match your application. A new firmware should only be
downloaded with a short, direct cable using the RS-232 port (do NOT download

Tools & Utilities 8
through an ASC system, MODEM, multi-drop network or wires over 50 meters).

Do not disturb a download in progress. If a download is interrupted, first cycle
power on the ICS 5000 and try to start the download again without going on-line. If
that doesn't work, the ICS 5000 will need to be sent in for service.
C
Warning – Contact Trimble support personnel prior to performing a firmware upgrade.
Downloading an incorrect firmware revision to your ICS 5000 could result in undesired
operation, and may even require that the unit be returned for service.
C
Warning – Do NOT download through an ASC system, MODEM, multi-drop network or
wires over 50 meters.

8 Tools & Utilities
8.3.2 Hardware Configuration

Use the Hardware Configuration screen shown below to determine which features
your ICS 5000 can support. If you are trying to use a feature that is unavailable on
this ICS 5000, it will be marked in RED. Features may be added via hardware
upgrades or possibly by entering a new configuration number. Please contact
Trimble support personnel before attempting to modify this screen.
Note – The New Serial Number field is inactive unless you have entered the master
password for the software.

Tools & Utilities 8
8.3.3 Analog Output Calibration

Use the Analog Output Calibration screen to calibrate the zero point of the ICS
5000’s analog output. The analog output is calibrated in production to perfectly
match each ICS 5000. If this setting is changed, any different ICS 5000 unit used in
place of the original will not be an exact match. This procedure should only be
attempted by experienced Trimble service personnel.
C
Warning – Disconnect the ICS 5000 from the motor drive or disable the motor drive.
Failure to do so can result in uncontrolled high speed motion of the machine
Note – The Analog Output Calibration screen is inactive unless you have entered
the master password for the software.

8 Tools & Utilities

CHAPTER
9
TCS Control Algorithm
Configuration 9
In this chapter:
• Introduction
• System Integration Principles
• System Configurations
• Hardware Output Status
• TCS Parameters Tab
• Characterize Tab
• Software Error Messages

9.1 Introduction
This chapter covers the configuration of the TCS (closed loop) control algorithm for
the ICS 5000. See Chapter 7.2, TCS Algorithm - Closed Loop Control on page 7.2
for information on the theory of operation of this algorithm.
9.2 System Integration Principles

The integration of the ICS 5000 as a motion controller should be approached with a
modular state of mind. Think of the ICS 5000 as a positioning co-processor that is
wholly responsible for motion related tasks including error detection and reaction.
The ICS 5000 works together with the PLC to control motion instead of simply
providing a position feedback signal. No attempt should be made to anticipate the
safe shut down of the control loop during an error by removing control from the ICS
5000. Instead, the PLC should take advantage of the resources that this distributed
control approach frees up by enhancing the communication driver used with the ICS
5000. Thorough support of the status codes and some choice diagnostic registers
could save hours of down time spent troubleshooting problems. The exception is
when a motor drive faults or safety condition is not satisfied. In this case, the PLC
should assume immediate control and stop the machine.
Figure 9.1 TCS Algorithm Integration Overview
9.2.1 Safe Shutdown of System Operations

The fail-safe design of the ICS 5000 requires little PLC interaction. Once a move
command has been initiated the ICS 5000 is capable of controlling every aspect of
the move. While the move is in progress, the control loop is constantly monitoring
the relationship between the system model and the position feedback. This allows

TCS Control Algorithm Configuration 9
the ICS 5000 to react to performance related deviations before problems develop.
When the ICS 5000 determines that action is necessary, the response is generated
automatically without assistance from the PLC.
Below is a brief summary of the ICS 5000 TCS Algorithm error handling responses.
Also included in this listing is a suggestion as to how the PLC should react once the
system has been shut down and an error reported. For more detailed information on
error generation see Hardware Output Status, page 9.12 and Commands and
Diagnostics, page A.I.
Table 9.1 TCS Algorithm Error Handling Responses
FAULT ICS 5000 ACTIONS PLC RESPONSE
Loss of Data • Ramps vehicle down to zero speed Retry move. If data
(Beam Break and then opens Safety contact and loss continues then
declared). Automatic Brake contact. check alignment of
Retries not enabled. • Reports status of E 2 when polled by unit.
(RETRY = 0) PLC.
Loss of Data • Ramps vehicle down to zero speed No action necessary
(Beam Break but keeps the Safety contact and if ICS 5000 succeeds
declared). Automatic Brake contact closed while to complete the
Retries enabled. redetermining absolute position. move. Otherwise
(RETRY > 0) Then resumes the move. If Beam same as above.
Break is permanent, same action as
above.
• Reports status of E 2 during the stop
when polled by PLC.
Faster than • Immediately opens Safety contact PLC should not retry
theoretical model and Brake contact. This is a the move because
(Motor Failure) “runaway” situation. error could be
• Reports status of E 4 when polled by mechanically related.
PLC.
Slower than • Ramps vehicle down to zero speed The PLC should not
theoretical model and then opens Safety contact and retry the move
(Motor Failure) Brake contact. because error could
• Reports status of E 4 when polled by be mechanically
PLC related.
Warming Up • Will not initiate any motion. Both Retry command for
Safety relay and Brake relay are up to 10 seconds
open. upon first power up.
Selftest Failure • Reports status of E 128 when polled Reboot unit using BT
by he PLC. command then check
for status to change.
9.2.2 Status Interrogation and Response

Every move initiated by the ICS 5000 will result in a change in status. The PLC
must query the ICS 5000 at the completion of each move to determine if the move
was a success or failure. The transmission of this query at the end of a move can be
triggered by monitoring the ICS 5000’s Brake output. This relay will open to set the
mechanical brake when motion has ceased or a fault has occurred. The following
text details basic logic that the PLC should possess to deal with possible fault
situations reported by the TCS algorithm:

Send move command (D or S) to ICS 5000

If ACK received from ICS 5000 then
Data received successfully, move in progress.
If NAK is received from ICS 5000 then
Data needs to be re-transmitted.
Wait for Brake Relay to open
Send E command to ICS 5000
Read Status response E ###
If ### = 2 then retry move command 2 times before reporting Beam Break
Fault.
If ### = 4 then report Motor Failure Fault.
If ### = 8 then retry E command, still positioning.
If ### = 16 then Move Complete in Position.
If ### = 32 then retry E command for 30 seconds before reporting Warming
Up.
If ### = 128 then send BT command to reboot ICS 5000 and retry E
command.
9.3 System Configurations

The ICS 5000 system can be configured for three main algorithm versions.
Available algorithms are:
• TCS (Total Control System)
• BCS (Brake Control System)
• PDM (Programmable Distance Meter)

Each of these can be set to different sub versions, with different I/O formats, aimed
at their specific applications. These various I/O formats are selected from the
Control Options screen ( [Alt] + [G] + [2] ) shown in the figure that follows.
To configure the ICS 5000 to use the TCS algorithm, select TCS from the Algorithm
section of the Control Options screen. The Output Format section allows you to
configure the ICS 5000’s I/O to match the requirements of your system. The
following sections provide information on the I/O configurations available with the
TCS algorithm.
C
If you attempt to change the Algorithm type of a configured ICS 5000 unit the
following warning will be displayed.
For information on the different control algorithms, see Chapter 7, Motion Control
Overview on page 7.1.
9.3.1 Configuration Overview

The TCS algorithm has two main sub versions TCS1 and TCS2. TCS1 is a closed
loop single axis control with internal ramp generation. It can be hardware
synchronized to other ICS 5000 units for collision avoidance. Two ICS 5000 units

using the TCS2 algorithm together with the Advanced Skew Controller form a
closed loop Advanced Skew Control system. The different sub versions for the TCS
algorithm, are shown in Table 9.2 which follows.
Table 9.2 TCS System Configuration Overview
Sub Version Control Format I/O Functions
TCS1 A Bi-Polar Output version (-10 to +10 VDC)
B Uni-Polar Output version (0 to +10 VDC with one
direction contact)
C Uni-Polar Output version (0 to +10 VDC with two
direction contacts)
TCS2 A Bi-Polar Output version (-10 to +10 VDC)
direction contact)
direction contacts)
Note – All relay outputs on the ICS 5000 are 24 Volt DC/AC reed style contacts. The
relay input used for system synchronization is a 12 - 24 Volt DC/AC coil. See the
ICS 5000 Installation Manual for more information on output specifications.
Despite minor output differences, the units function identically. The various
configurations are explained in detail in the following paragraphs.
Note – The TCS1 sub-versions support all communication protocols. TCS2 sub-
versions are only available with the ASCII protocol.
9.3.2 Format “A” Configuration - Bi-Polar Output versions (–10 to + 10 VDC)

The bi-polar output configuration of the TCS algorithm is the most commonly used.
The analog control signal, used by the motor controller for speed reference, varies
from 0 VDC to -10 VDC for one direction and from 0 VDC to +10 VDC for the other.
The control I/O perform the following functions:
Table 9.3 TCS Format “A” I/O Configuration
I/O NAME DESCRIPTION
13 & 14 Analog Output – 10 (pin 14) to +10 (pin 13) V DC speed
reference to the motor drive.
7&8 Safety Contact Normally open contact (OUT 3) that opens to
indicate a fault. OUT 3 also interrupts the
Analog Output signal.
5&6 Brake Contact Normally open contact (OUT 2) that closes to
release the mechanical Brake on the motor.
3&4 TCS Status Output for Normally open contact (OUT 1) used to
Synchronization indicated when the TCS has begun to ramp
to a stop after a fault.
1&2 TCS Status Input for Coil for a normally open contact (IN) used to
Synchronization indicated when another TCS in the system
has begun to ramp to a stop after a fault.

TCS configuration codes for control Format “A”

The listed configuration codes below are retrieved by sending the Self Test (Z)
command to the unit. The configuration codes only show the communication
protocols using the RS-232 and RS-422 ports. PROFIBUS-DP and DeviceNet
communication protocols use their own communication port and are not included in
the configuration code.
50001 – Configured for the basic serial communications protocol with ASCII
character set.
50101 – Configured for the basic serial communications protocol (default settings)
with ASCII character set and the Gould Modicon Modbus® protocol in RTU mode.
with ASCII character set and the Rockwell Automation DF1 protocol used in Allen
Bradley PLC-5 series and SLC 500 series PLC’s.
50301 – Configured for INTERBUS with the PCP protocol.
50008 – Advanced Skew Control version. Supports the basic serial communications
protocol with ASCII character set. Two units are used to control the skew of a
bridge or gantry crane. This version is covered in depth in the Advanced Skew
Controller Installation Manual.
For information on product code and the Self test message, see Commands and
9.3.3 Format “B” Configuration - Uni-Polar Output versions (0 to +10 VDC)

only from 0 VDC to +10 VDC. Direction is indicated by the state of one relay
contact, OPEN for one direction CLOSED for the opposite.
Table 9.4 TCS Format “B” I/O Configuration
13 & 14 Analog Output 0 (pin 14) to +10 (pin 13) V DC speed
9 & 10 Direction Contact Normally open contact (OUT4) that indicates
direction. Open for one direction, closed for
the other.

TCS configuration codes for control Format “B”

character set.
Bradley PLC-5 series and SCL 500 series PLC’s.
9.3.4 Format C Configuration - Uni-Polar Output versions (0 to +10 VDC)

only from 0 VDC to +10 VDC. Direction is indicated by the state of two relays, one
for reverse direction and one for forward direction. A CLOSED relay indicates the
direction. If both reverse and forward direction contacts are opened, then the
mechanical brake on your system should be set (de-energized).
Table 9.5 TCS Format “C” I/O Configuration
9 & 10 Reverse Direction Normally open contact (OUT4) that indicates
Contact direction. Closed to run in the reversed
direction.
5&6 Forward Direction Normally open contact (OUT 2) that indicates
Contact direction. Closed to run in the forward
direction.

Table 9.5 TCS Format “C” I/O Configuration

Note – Forward and reverse are arbitrary, no physical direction is implied. The ICS
will determine polarity during the characterization process.
TCS configuration codes for control Format “C”

character set.
9.3.5 Sampling Frequency Configuration

The sampling frequency (samples/sec. or Hz) used in the IDM (Industrial Distance
Meter) inside the ICS 5000 can be configured during the set up. The available
sampling frequencies are: 19.35, 30.58, 49.32 and 69.50 Hz with the default being
30.58 Hz (the TCS/BCS/PDM system 4000 uses 30 Hz). If ICS 5000 is used as a
replacement unit for an old system, 30.58 Hz should be used to avoid having to re-
characterize.
For information on configuring sampling frequency in the ICS 5000 Support
Software, see Chapter 3.4, Sample Rate on page 3.5.

9.3.6 Continuously Self Adaptive Function (Auto Gain Limit)

During setup, you can fine tune the control loop from the Over-/Undershoot screen
by typing the ‘O’ and ‘U’ keys. Once the setup is finalized, changes in temperature,
load, friction and line voltage may de-optimize this tuning. This either slows down
positioning or requires the operator to re-tune. Alternatively, the TCS algorithm can
be configured to automatically and continuously adapt to these changes within user
defined limits. With this continuously self adaptive function (Self tuning) the TCS
algorithm will be able to handle most normal changes in the response of the vehicle
by itself. A Characterization would still needed to do the initial tuning required to
adapt to large changes. For information on configuring the Auto Gain Limit in the
ICS 5000 Support Software, see Auto Gain Limit on page 9.17.
9.3.7 Operational Modes

The TCS algorithm supports the Modes listed in Table 9.6 and Table 9.7. The Mode
codes are bit mapped. This means that each unique mode has it’s own bit. If two or
more different modes are desired, send the summation of the individual modes. For
information on configuring the modes in the ICS 5000 Support Software, see Wake
Up Mode, page 9.22.
Holding Modes
The TCS algorithm can be configured for four different types of holding modes.
Table 9.6 TCS Algorithm Holding Modes
M Number Mode
0 Full servo without Integration during beam breaks.
The control loop is always trying to make the position error equal to zero. If,
however, the ICS 5000 is performing an internal auto-calibration or a Beam
Break occurs, then the integrator is zeroed and a new DC bias must be re-
established once the measurement is restored. Halt commands also remove
the integrator. This has the advantage of being as close to the desired
position as possible even with disturbances.
The disadvantage are that phase meter noise may cause the load to flinch
and twitch. Also, if the motor is lifting something it will falter during a beam
breaks and auto-calibrations. This mode is recommended on horizontal
applications without a brake.
4 Zero DAC (reference) voltage when within tolerance at destination.
Once the control loop gets the load within tolerance it turns the integrator and
control loop off. In this mode the brake can be configured to be released if the
position is out of tolerance.
This mode is recommended on horizontal applications with or without a
brake.

Table 9.6 TCS Algorithm Holding Modes
M Number Mode
8 Full servo.
The integrator is always on for bias, even during data loss where it remains
“frozen” at the last value. The integrator is zeroed after a Beam Break fault,
Motor Failure fault or a return signal strength measurement (R) command.
This mode is recommended for vertical applications without a brake.
12 Zero DAC (reference) voltage and integrator.
This mode is like mode 4 but the integrator is always on except after a Beam
Break fault, Motor Failure fault or a return signal strength measurement (R)
command. In this mode the load will remain levitated once the brake is
released since the DAC is outputting a voltage.
This mode is recommended for vertical applications with a brake.
Other Modes are:

Table 9.7 TCS Algorithm Modes
M Number Mode
1 Enable warning code to be sent with the status information “E”.
The TCS algorithm can send a warning for motor failure when motor warning
level is exceeded. The warning code for beam breaks will be sent when half
the I value is exceeded.
• With ASCII protocol, the warning (E 8, #) where #=2 mean almost beam
break. #=4 mean almost motor failure, # =0 mean no warning.
• With PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocols the
warning code is multiplied by 256 and added to the status. For example:
The total status on a travelling vehicle (status 8) with a motor failure
warning will be: 4 * 256 + 8 = 1032
The total status on a positioned on destination vehicle (status 16) with a
beam break warning will be: 2 * 256 + 16 = 528
2 Enable reporting status on auto-calibration (E 64) to be sent with the
status information.
If mode two is enabled and not mode one the E status will be 64 when an
auto-calibration is performed. If mode one and mode two are enabled a
warning will be send when half the time to the next auto-calibration has
passed.
• With ASCII protocol, the warning (E 16, #) where # = 64 means half the
time to next auto-calibration has passed.
warning is multiplied by 256 and added to the status. For example if the
status is 16 and the time is less than half to next auto-calibration, the
status will be: 64 * 256 + 16 = 16400.
16 Hold the response of position readings and station locations (X & Y).
If beam is broken position data (X & Y) responses will be withheld until the
beam is re-established or the I-number is exceeded.
• With ASCII protocol, the reply on X and Y commands is delayed for as
long as the beam break ignore time.
• With PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocols, the last
known position is returned during the beam break.

Table 9.7 TCS Algorithm Modes
M Number Mode
32 Disable the Ramp Retardation feature.
Ramp Retardation limits the acceleration ramp output to the system in an
effort to zero position error, thereby also avoiding the drive to enter current
limit condition.
64 Disable reverse directions.
Some applications, like elevators, require the TCS to ignore destinations that
would cause the machine to stop and reverse directions.
128 Simple Halt
The response on the Halt command can be slow if high noise filter values and
or low P and D gains are used. With Mode 128 enabled a simple ramp down
will be used instead.
For information on ASCII protocol status, see Commands and Diagnostics,

page A.I. For PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocol information, see
Chapter 5, Advanced Communications Configuration on page 5.1.
9.4 Hardware Output Status

The table below shows how the different output relay contacts act during different
situations. The functions are the same for all TCS algorithm versions except for the
following:
• TCS2 is the Advanced Skew Control version. Therefore the SYNC. Output is
directly connected to the dedicated input on the Advanced Skew Control unit
and it’s function adapted for this purpose.
• TCS Format C uses the forward relay and reverse relay as a brake function.
The brake should be set when both relays are open and released when either
is closed.
Table 9.8 TCS Algorithm Output Status

Status Code Safety Brake Sync
Warming up E32 Open Open Open
Just out of warm-up or halted with H- E1 Closed Open Open

command.
Moving to a destination or station. (D# or S# E8 Closed Closed Closed

command sent to TCS.)
At Destination or Station. (Will not change E16 Closed Open Closed

during auto-calibration unless a new D# or S#
command is sent.)
After a prolonged Beam Break (I-number E2 Open Open Closed
exceeded) at Destination or Station.

Table 9.8 TCS Algorithm Output Status

Status Code Safety Brake Sync
After a prolonged Beam Break during a move E2 Closed Closed Open
and while decelerating.
When stopped after a prolonged Beam Break E2 Open Open Open

during a move. No RETRYs enabled.
When stopped after a prolonged Beam Break E2 Closed Closed Open

during a move. With RETRYs enabled.
After a lagging motor failure and while E4 Closed Closed Open

decelerating.
After a leading motor failure warning and while E4 Open Closed Open
decelerating with RAMP RETARDATION
active.
After a leading motor failure and while E4 Open Closed Open
decelerating with RAMP RETARDATION
disabled (M32).
When stopped after a motor failure. E4 Open Open Open
Sync input configured as normal and stopped E8 Closed Closed Closed

after the sync. input been opened.
Sync input configured as halt and stopped after E1 Closed Open Open
the sync. input been opened.
During auto-calibration and when a D# or S# is E16 or Closed Open Open

sent to the TCS. (Before the move starts.) E64 if
in M2
During auto-calibration just before final E8 or Closed Closed Open
positioning. (Will happen if calibration time E64 if
interval has run out during the move.) in M2
For information on status and diagnostic codes, see Commands and Diagnostics,
page A.I.

9.5 TCS Parameters Tab

[Alt] + [P]
When the TCS control algorithm has been selected, the TCS Parameters and
Characterize tabs are shown. The TCS Parameters tab (shown below) displays all
the values for the control loop with the exception of the tolerance. Use this tab to
view the wake-up values for the TCS algorithm and to make changes to meet the
specific needs of the vehicle being controlled.
Note – If this is a new installation the table and fields in the TCS Parameters tab
will be empty and a characterization of the vehicle must be performed before
control is possible.
B
Tip – Wake-up values are the values the ICS 5000 starts with after a boot up. For
example: Once Characterized, the ICS 5000 unit has a maximum value for Velocity. A
lower Wake-up value for velocity can be configured so the ICS 5000 uses this value as
default.
The TCS Parameters tab contains links to the following screens:

• Common Control Parameters
• Acceleration and Velocity
• Noise and Filter
• Beam Breaks
• Wake Up Mode
• Sync Input Definition

sections. The shortcut key combinations for reach each screen are also provided in
each section.
For information on how to perform a characterization on a ICS 5000 unit, see
Characterize Tab, page 9.27.
9.5.1 Common Control Parameters

[Alt] + [P] + [1]
Use the Control Parameters screen to configure the Common TCS algorithm
control parameters. These parameters modify certain aspects of how the TCS
control algorithm will react. An Advanced column displays the control loop gains
and model information. Values in the Advanced column are accessible only with the
Master password active.
Restore the old settings from when the file was last saved by clicking
.
In the Common parameters column the following parameters can be configured.
Warning Level
Motor Warning means deviations in your machines performance have exceeded the
Warning limit entered. If you have the warning byte enabled (see Operational
Modes on page 9.10), the ICS 5000 will send E #, 4 or W #, 4 when this occurs. It is
also the point at which Ramp Retardation is activated. Enter a percentage of
deviation at which the Motor Warning should occur in the field.
Failure Level
Motor Failure means deviations in performance have exceeded the Failure limit
entered. The TCS algorithm shuts down the machine and reports E 4 or W 4. Setting
this value too small leads to nuisance shutdowns; setting it too high will cover up a
real problem. Normally the default setting of 40% is adequate for most situations.
Enter a percentage of deviation at which the Motor Failure should occur in the field.

Windup Limit
The Windup Limit limits the PID loop’s integrator action. A good rule-of-thumb is
to make it double that of the worst non-linearity in the drive (reported during the
Characterization). For example, if the drive slows down 3% when fully loaded, set
the windup limit to 6%. This number affects the disturbance response.
Start Delay
Start Delay controls the time between closing the Brake contact and ramping up the
Analog output. It gives the mechanical brake time to release before the drive is
asked to accelerate. If the ICS 5000’s Brake output is used to enable the motor drive,
set this value to the time it takes for the drive to enable.
Stop Delay
The Stop Delay is the time between opening the ICS 5000’s Brake contact and
indicating On Station is controlled by this number. It gives the load time to stop
swinging or it helps when the mechanical brake sets slowly. Also, if the brake sets
slowly, the re-release time will probably need to be non-zero.
Re-release Delay
A non-zero value in the Re-release Delay parameter permits the ICS 5000’s Brake
contact to re-release if the machine gets out of tolerance while the brake is setting.
The larger the value, the longer the machine must be out of tolerance before the
brakes will release again. A recommended starting value is 0.15 seconds.
Creep Distance
Creep Distance tells the TCS algorithm how much of the remaining distance to
travel at a creep speed. One use for this is to give the payload some extra time to
stop swinging before being delivered. Another use is to guarantee there will never
be any overshoot by slowing down prematurely then creeping to the final
destination. A value of zero disables this feature.
Creep Speed
Creep Speed tells the TCS algorithm how fast to travel the defined Creep Distance.
Creep time will be approximately equal to Creep Distance/Creep Speed. Because
this normally increases the travel time, it should only be used when benefit is
greater than the time penalty. A value of zero disables this feature.
Braking Distance
Braking Distance tells the TCS algorithm how far from the destination to open the
Brake contact, thus using the mechanical brake for final positioning. This can
improve the positioning time if the following are true:
a. The brake reacts quickly and stops the machine quickly
b. The positioning tolerance is more than 4 mm or counts

c. The drive is not very responsive
Auto Gain Limit

Auto Gain Limit is used to control how much the feed forward gain can adapt. A
non-zero value lets the feed forward gain try to adjust itself in response to changes
in temperature, load, friction and line-voltage. A value of zero disables it. 5% is
normally adequate. At times, this feature may need to be disabled. For more
information, see Continuously Self Adaptive Function (Auto Gain Limit) on
page 9.10.
Velocity Flat Time

The Velocity Flat Time is the minimum time between acceleration and deceleration
phases of any move. This option inserts a consistent top velocity in an otherwise
triangular shaped velocity profile. This feature helps avoid the whiplash effect
common on short moves by giving the vehicle time to stabilize at a constant speed
before starting to decelerate.
9.5.2 Advanced Control Parameters

The Advanced parameters column contains parameters such as the PID gains, these
parameters are automatically tuned from the Characterization and it is not
recommend that they be changed.
C
Warning – The values contained in the Advanced parameters column are very sensitive.
Changing any of these values could cause the crane to become un-controllable. Do not
modify these values unless you know exactly what the response will be. Trimble
relinquishes all responsibility for system damage if these values have been changed.
Disturbance P Gain
This number tunes the proportional response to disturbances. It changes the way the
machine returns to a set point after being pushed away. The easiest way to create
disturbances is to add a voltage source (e.g. 1.5 v battery) in series with the TCS
analog output and remove it.
Disturbance I Gain
This number tunes the integral response to disturbances. Increasing can very easily
lead to oscillations, especially when there is backlash in the drive. This gain will
have little or no effect if the windup limit is small. Like the P gain above, it will
normally only change the disturbance response.
Disturbance D Gain
This number tunes the derivative response to disturbances. Increasing tends to
dampen or stabilize the system but amplify feedback noise.

Transient P Gain
This number tunes the proportional response to transients. It affects the
over/undershoot. Increasing it too much will cause instability. It is easier to
experiment with this gain if the disturbance PID gains are reduced e.g. P=D=0,
I=original value/4.
Transient D Gain
This number tunes the derivative response to transients. It affects damping, stability,
and over/undershoot. Too much will cause instability. Like the transient P gain, it is
easier to tune if the disturbance gains have been reduced. There is much less noise
penalty if this gain is high.
Negative Deadband
Negative Deadband is the largest negative voltage that will NOT move the machine.
It helps save time when trying to move the machine small distances. Sometimes,
additional time can be saved by making it slightly bigger. Sometimes, smoother low
speed operation can be achieved by reducing it.
Positive Deadband
Positive Deadband is the largest positive voltage that will NOT move the machine.
It helps save time when trying to move the machine small distances. Sometimes,
additional time can be saved by making it slightly bigger. Sometimes, smoother low
speed operation can be achieved by reducing it.

9.5.3 Acceleration and Velocity

[Alt] +[P] + [2]
The Acceleration and Velocity screen allows you to modify the Acceleration and
Velocity values which the TCS will “wake up” with upon power up or reset. These
values can also be referred to as the default values. Even if a value has been changed
using the “A” or “V” command, the unit will reset to the “wake up” value if the unit
is reset. A value entered cannot exceed the maximum value listed.
Click to restore your settings to its original values. The result of a

change of values for acceleration and velocity is depicted on the graph shown on the
figure above. Changes in the positive and negative direction are also indicated.
Acceleration
The maximum value for the Acceleration is determined from the “Slew rate”
entered during the Characterization or the current limit of the motor drive. The
wake-up value for Acceleration can be configured for positive direction and
negative direction.
Velocity
The maximum value for the Velocity is determined by the setup of the motor drive.
Remember that a closed loop positioning algorithm reduces the top speed by 5% to
allow for positioning adjustments during moves (also called “head room”). The
wake-up value for the Velocity can be configured for positive and negative direction.
B
Tip – Positive and negative values for acceleration can be used to maximize the
performance of a stacker crane.

9.5.4 Noise and Filter

[Alt] + [P] + [3]
Use the Noise and Filter screen to re-configure the values for Noise Limit and Low
Pass Filter settings after a Characterization.
B
Tip – Before you start experimenting with different settings of Noise and Filter values
make a back-up of your parameter file.
Noise Limit
This choice allows you to limit the Noise Limit which will make the load position
smoother but slower. The noise limit is expressed in volts and limits the peak
voltage noise from the D/A converter output. Range is from 1/32 to four Volts. Enter
a value of four to disable the noise limitation.
For information on tuning the Noise Limit, see Manual Controls on page 9.47.
Low Pass Filter

This choice also allows you to gradually add a Low Pass Filter into the control loop
which has the same affect as adding mass to your load. This will cause the load to
position smoother but slower. The filter is expressed in terms of a number where
one, for example, adds a small filter, while ten adds a much larger one (note that
adding filters can also increase the velocity limit). Most situations that add filters
use about five. Sometimes, with loads (such as hoists and elevators) driven by
wires, the spring action causes the control loop to create a response where the load
backs up before it takes off. By selecting an appropriate filter value this “back-up”

can be minimized or eliminated. Optimum filter values are mostly between four and
eight. The filter calculation routine will help you pick the best value in case there is
a back-up problem.
Click for a calculation of the new parameters. A graphical presentation

of the result from the changes are shown in the Characterization Program window.
If you are satisfied with the result click the Done button, if not satisfied with the
result, change the values and watch the result on the graphs. For information on
tuning the Low Pass Filter, see Manual Controls on page 9.47.
Click for a graphical view on the existing parameters Transient and
Disturbance Response. Click Done to get back to the Noise and Filter screen.
9.5.5 Beam Breaks

[Alt] + [P] + [4]
The Beam Break Parameters screen (image that follows) allows you to modify the
methods which the TCS algorithm uses to deal with Beam Breaks (data losses). The
first parameter is the wake up or default number of Beam Breaks to ignore which
controls the fault tolerance. The next parameter Number of Automatic Retries allows
you to enable automatic recovery from a Beam Break fault. Finally, the Number of
Beam Breaks to Skip allows the TCS algorithm to delay ramping down the velocity
when data is first lost. More details on these parameters are provided in the
following sections.
For information on Beam Break diagnostics, see Commands and Diagnostics,

page A.I.

Number of Beam Breaks to Ignore

The I number for maximum consecutive bad data samples to Ignore is determined
during the characterization by the time it takes the vehicle to travel 2.4 meters at full
speed. When this number is exceeded, the TCS algorithm will perform a controlled
stop and issue a Beam Break error message. Even if the value has been changed
using the I command, the ICS 5000 unit will return to the wake up value declared
here once reset. The value entered cannot exceed the maximum value listed. During
normal operation there is no benefit to lowering this value from the maximum.
Number of Automatic Retries

Use this field to enable one or more Automatic Retries after a Beam Break fault has
occurred. The automatic retry feature is useful in situations where Beam Breaks
occur frequently due to environment or system mechanical problems. The retries are
preformed independent of the PLC code, and without issuing the Beam Break fault
status.
Number of Beam Breaks to Skip

During a move, a Beam Break normally causes the vehicle to immediately begin
ramping down. If the Beam Break goes away before the Ignore level is exceeded,
the machine speeds back up and finishes the move. The slight loss of time caused by
this slow down and recovery can be avoided by setting the number of Beam Breaks
to Skip to a value greater than zero. With Skip enabled, the vehicle will only begin
slowing down after the Beam Breaks to Skip value of bad samples has been
exceeded.
9.5.6 Wake Up Mode

[Alt] + [P] + [5]
The Wake-up Mode screen allows the user to modify the basic operational modes of
the TCS algorithm including: Holding Modes, Enable Warning Codes, report Auto-
Calibration, Wait for Good Data, Disable Ramp Retardation and Disable Reverse

Direction on an ongoing move. For information on the different holding modes and
algorithm modes, see Table 9.6 on page 9.10 and Table 9.7 on page 9.11. The
following screen descriptions.
B
Tip – By default after a characterization Mode 4 is used. (Deadband when positioned on
destination.) Mode 4 is the most common used mode and will fit to the most of the
installations.
Mode 1 Warnings
Enables a Warning code that is sent with the status information. This lets the host
controller know when a Beam Break and/or a Motor Failure warning has occurred
(this is a rarely used feature). Adds 1 to the Mode sum. For protocol information,
see Table 9.7 on page 9.11.
Mode 2 Calibration
Enables reporting of the Auto-Calibration within the status so the host controller
can know when an Auto-Calibration is occurring (this is a rarely used feature). Adds
2 to the Mode sum. For protocol information, see Table 9.7 on page 9.11.
Mode 4 Deadband
Enables Deadband Holding mode where the speed reference signal is set to zero
when on station. Highly desirable in most applications and is required if a parking
brake is used. Adds 4 to the Mode sum. For information, see Table 9.6 on page 9.10.

Mode 8 Integrator
Prevents the integrator from being zeroed at the beginning and end of a move and
when a beam break occurs. This characteristic may be desirable for vertical
applications but is usually turned off for horizontal applications. Adds 8 to the
Mode sum. For information, see Table 9.6 on page 9.10.
Mode 16 Wait
Delays the response of the On Position and Station Location readings if the
measurement beam is broken. Adds 16 to the Mode sum. For protocol information,
Mode 32 Retardation
Ramp Retardation limits the acceleration ramp output to the system if the machine
is unable to accelerate quickly enough. If the machine is lagging because it cannot
match the commanded acceleration then the TCS reduces the ramp to 1/3 of the
Wake-up value until the error has dropped back below the Warning Limit. Nuisance
motor failure reports are eliminated but vector accuracy for X-Y coordinated moves
is degraded. Adds 32 to the Mode sum. For information, see Table 9.6 on page 9.10.
Mode 64 Reversals
Some applications, like elevators, require the TCS algorithm to ignore destinations
that would cause the machine to stop and reverse directions. This selection adds 64
to the Mode sum. For information, see Table 9.6 on page 9.10.
Mode 128 Halt

The response on the Halt command can be slow if high noise filter values and or low
P and D gains are used. With the Simple Halt mode enabled a simple ramp down
will be used instead. For information, see Table 9.6 on page 9.10.
9.5.7 Sync Input Definition

[Alt] + [P] + [6]

The Sync (roniztion) Input relay is typically used in coordination with Sync Output
relay. The function of the Sync Input relay can be configured in three different
options:
• Normal - De-energizing the SYNC input programs the velocity to zero while
keeping the control loop active. This is good when there are multiple
machines on the same runway that need to avoid collisions but is basically an
unused input for all other applications.
• Halt - The SYNC input can be programmed to perform a HALT when de-
energized. This adds a redundant shutdown path when safety is important.
• Ignore - The SYNC input is ignored. This is the default choice after a
Characterization.
B
Tip – Sync input is by default configured to Ignore. If no Synchronization wiring between
several ICS 5000 units exists, this section can be ignored.
For information on Synchronization wiring, see the ICS 5000 Installation Manual.

9.5.8 ASC Parameters

[Alt] + [P] + [7]
The ASC Parameters screen is only available for the Skew Control TCS format. It
allows the user to configure the Skew Limit and the Skew Distance for the Advanced
Skew Controller.
For information on how to setup and configure ICS 5000 in the Skew Control
format, see the Advanced Skew Controller Installation Manual.
Note – Using the ICS 5000 Support Software with the Advanced Skew Controller
requires the set of the Connection/Direct Connection item on the Menu bar to be
unselected.
Skew Limit
This choice allows you to limit the maximum Skew between the two ends in an
Advanced Skew Control System. The default wakeup value is 400 mm. When the
skew limit is exceeded, the ASC performs a controlled halt and the Skew Limit
exceeded status is reported. This error must be corrected before the ASC will be
allowed to move the vehicle. The Skew Limit can also temporary be changed using
the N command.
C
Warning – Do not set the Skew Limit to a higher value than mechanically allowable. Make
sure there is mechanical skew limits on the vehicle before starting to configure this value.

Skew Distance
In some situations it can be beneficial to have an intentionally skew on the vehicle.
The Skew Distance option allows you to configure the distance from which the
vehicle shall start to square before it is finally postponed on the destination. The
Skew between the axis can be controlled in two ways:
• By using stations in both TCS units with different values for position.
• By sending the O command to the Advanced Skew Controller with a squaring
value in mm and use the go to a destination in mm command for positioning.
Note – A non-zero Skew Distance also disables the collision avoidance outputs.
9.6 Characterize Tab

[Alt] + [Z]
The Characterization is the method that the ICS 5000 Support Software uses to
learn the characteristics of the system that it is going to control. By executing a
series of movements and recording the change in position feedback, the ICS 5000
Support Software is able to develop an accurate model of the vehicle’s performance.
It then uses this model to determine the optimal control loop gains.
The Characterization process is broken down into two phases. First comes the data
gathering phase. This phase involves the Support Software exciting the system with
known waveforms and recording the response. Much like a person who is driving an
unfamiliar car for the first time, the Support Software begins with slow predictable
movements and builds to full speed, full acceleration moves as the program
becomes more comfortable with the vehicle’s performance.
Once the data has been collected the Support Software finishes the Characterization
by reducing the collected data into a theoretical system model. This model is used
by one of the tuning procedures (Brown or ITAE) to select the optimal control loop
gains for the system. The model is also used to develop the move profiles used

during positioning, to compensate for data loss, and to monitor for possible
performance deviations. If performance deviations are too great, the ICS 5000 will
alert the PLC of possible mechanical problems in the form of a Motor Failure status.
Navigation through the settings screens for the Characterization is achieved by

using the and buttons. Once all settings are correct, click the
button to begin the process.

9.6.1 Preparation
[Alt] + [Z]
The first screen in the Characterization is the Preparation screen. This screen
briefly explains what is necessary to begin a characterization. In some cases it is not
necessary to use a load when Characterizing, but this is something that will have to
be determined on a case-by-case basis. As a rule of thumb, if the load is small with
respect to the total weight of the vehicle it is not necessary during Characterization.
If this is the first characterization, it is recommend that you spend some time
adjusting the motor drive settings and determining the maximum slew rate usable
with the crane. The final outcome of the characterization depends greatly on the
proper tuning of the motor drive. To perform the drive tuning tests click the
button. For Motor Tuning information, see Motor Tuning Aid,
page 8.5.
Click to continue to the next screen.
B
Tip – After finalizing the Motor Drive Tuning, make sure the vehicle is positioned in the
middle of the track before the characterization starts.
9.6.2 Characterization Menu

If a prior Characterization has been successfully completed using this software, then
the Characterization Menu screen will be displayed. This is dependent upon data
saved in the .i5k file in the working directory. The .i5k file contains the results of the
various tests performed during the last Characterization so that they do not need to
be performed every time. For example, the results of the Deadband test will not
change just because the top speed of the motor controller has been reduced.
Therefore there is no reason to perform that test again.

The Characterization Menu, shown in the screen that follows, allows you to
complete only the steps of the Characterization that are necessary.
Select the desired test from the menu and click the button to go to the first
screen in the selected test. If the selected test is not number 5 or 6, the program will
return to this menu after completion of the test.
More information on the different choices can be found at:
• 1. Define Characterization Parameters - Settling Time on page 9.30.
• 2. Polarity, Deadband and Sticky Test - Deadband and Polarity Test,
page 9.40 and Speed Regulation or Bias Test on page 9.41.
• 3. Acceleration and Velocity Test - Acceleration and Velocity Test on
page 9.41.
• 4. Pink Noise Test - Pink Noise Test on page 9.43.
• 5. Calculate the model parameters and tuning constants - Transient
Response on page 9.46 and Manual Controls on page 9.47.
9.6.3 Settling Time

The Settling Time screen asks you to provide some basic information about the
performance of the vehicle. If final positioning takes a long time, as with some
stacker cranes and vertical applications, then the excitation ramps used during the
Pink Noise test are modified to take this into account. The alternate set of Pink
Noise ramps are extended to allow any unwanted response characteristics to decay
before beginning the next ramp. The default set of ramps is a series of quick steps

suitable for short settling times. Choose from the settling time options provided, see
following figure, to more closely match the Characterization routine to your
application.
B
Tip – Normal vehicles with short settling times can use the set of quick “steps”.
Click to go to the next screen.
9.6.4 Gear Box

The measurements for modeling during the Pink Noise test can be configured to be
performed in one of two ways:
1. Only measure the acceleration mass
2. Measure both acceleration mass and deceleration mass.
Normally, to avoid back-lash induced errors, only the acceleration mass is measured
(acceleration and deceleration mass are assumed to be the same) during the
Characterization. A minority of drive systems decelerate much differently than they
accelerate. Certain gear boxes, older worm-gears in particular, have much different
characteristics for acceleration and deceleration. This is because power flow
efficiency through the gear box is so different in the two directions. It has the effect
of making the mass appear to decrease during deceleration and increase during
acceleration. If not taken into account, this characteristic could cause severe
undershoot in a tuned system.

Use the Gear Box Considerations screen to tell the Characterization what type of
system you are using by selecting one of the options from the screen that follows.
B
Tip – Try with the NORMAL/SYMETRICAL choice if its the first time or if you don’t know
which to choose.
Click the button to go to the next screen.
9.6.5 Accuracy/Time Trade -off

The type of motor drive that you select is really not related to the quality of the drive
itself. It has been found that non-ideal machine characteristics are usually second
order effects and can be handled better by hiding them in the measurement noise.
The simplest way to get more noise is to reduce the number of samples averaged. So

in effect this question controls the number of samples taken during the Pink Noise
test. If you choose SHORT model, the samples are reduced and it takes less time. If
you choose LONG, the samples are increased and it takes more time.
B
Tip – AVERAGE choice will work for most applications.
9.6.6 Horizontal vs. Vertical

If the axis of a vehicle or the vehicle itself moves vertically or carries loads in
excess of it’s own weigh then the Horizontal vs. Vertical screen selection, shown
below, should be answered Vertical Application. By selecting Vertical Application
an alternate setup is used during the Acceleration and Velocity Test. Before the
Acceleration and Velocity test is begun, you will be prompted to put a full load on
the machine. This way the Acceleration and Velocity test will be conducted under

the worst case scenario, and determine a more accurate top acceleration. At the
conclusion of this test you will be prompted to remove the full load from the
machine.
9.6.7 Ramp Rate

The Ramp Rate screen is necessary to establish the appropriate ramps for the
vehicle. If torque produced by your vehicle can overcome the friction of the wheel,
(spinning or skidding) then it is important to use a low enough ramp rate to avoid
this. The ramp rate is setup in volts/seconds using the following screen. This will
determine the maximum working acceleration of the vehicle.
The Ramp Rate value is configured by clicking on the to increase or decrees the
volts/sec. value or click on the button to use the value observed
during the Motor Drive tuning. For Motor Drive Tuning information, see Motor
Tuning Aid on page 8.5.

The ICS 5000 unit’s ramp generator can be bypassed by clicking on the
button. This will cause the unit to use a step function when
accelerating or decelerating. On most vehicles this is unacceptable, so select this
option with care.
Alternatively, the Ramp Rate value can also be configured by entering the
Acceleration Time of the vehicle in the Acceleration Time field.
B
Tip – The common way configuring the Ramp Rate is to use the results from the
Trapezoid test in the Motor drive tuning and with the calculated Acceleration Time in mind.
Note – If the option is selected the following Warning will POP up.
9.6.8 Ending Position

The Ending Position screen allows you to specify where the vehicle should be
positioned at the end of the gathering data portion of the Characterization. Once the
vehicle is positioned at the selected position, all motion is complete.
Three Ending Position choices are available:

• Near the middle
• Near Limit - Shortest distance between reflector and ICS 5000
• Far Limit - Farthest distance between reflector and ICS 5000

9.6.9 Automatic Pause

The Automatic Pause option instructs the Support Software to pause the
Characterization periodically and prompt for the user to press a key when the
Characterization should resume. The Support Software will pause before each
move, and can be suspended as long as required. This choice is primarily intended
for Characterizing bridge cranes with the Advanced Skew Control System. You then
have the possibility to square up the bridge between moves
Note – The characterization can also be temporary paused by clicking on a pause

button.
9.6.10 Delayed Start

If it is necessary to start the Characterization and move away from the vehicle
before motion begins, a Start Delay can be configured.
Configure a Start Delay by enter a time in sec. in the Start Delay field or use the
to configure the delay time.

Note – If a Start Delay is used and the prior screen has been used to insert a pause
prior to the move, the start delay will be incorporated each time before motion
resumed.
C
Warning – The next action will initiate vehicle motion over the entire area to travel. Be
sure that you anticipate this by taking any precautionary measures necessary. If you are
unsure of what will happen, stop and contact a Trimble engineer before proceeding.
Click the button to start the data gathering portion of the Characterization.
The vehicle will begin travelling back and forth within the configured Travel
Limits.
If a Start Delay is configured the following screen appears before the tests starts as
the delay is counted down.
9.6.11 Characterization Program

After the initial configuration process, the Characterization moves to the data
gathering phase and the following screen id displayed. It will automatically perform
the tests required of the vehicle without switching from the Static Data tab.
At any time during the Characterization, motion can be paused by using the
button.

Click OK to get back to the tests, click cancel to abort the characterization.
C
Warning – Clicking on the Pause button will stop the tests first after it has finished the
ongoing test. For Emergency STOP use the Vehicles Emergency STOP function.
The characterization can also be aborted by clicking the button.

Click Yes to abort the Characterization procedure, click No to return to the tests.
The following Status appears if the Characterization routine is aborted.
To exit the Characterization, click the button. This will restore the original
parameters to the ICS 5000 if the Characterization was not completed successfully.
Positioned Near the End Limits

If the characterization is started with the vehicle too close to one of the end limits
then the following message appears. Reposition the vehicle to the middle of the
track and click OK to continue,

Show Log
Create a log on the Characterization by clicking the button. If a log is
created the following window opens.
Save the log file as a text file by clicking the button, exit the Log window
by clicking .
Note – The Log file data must be saved before exiting the characterization program,
else the log data will be lost.
B
Tip – Creating a log file can help troubleshoot a failed Characterization.
9.6.12 Offset Test

When the Characterization Program first starts to determine the polarity and
deadband, it first checks to make sure that there is no position drift. If a drift is
present, the program automatically determines what offset will compensate for the
drift. This offset will become a permanent part of the TCS algorithm output until the
next time polarity and dead-band are determined. As with all ICS 5000 output
signals, the offset will only be delivered to the motor drive when the Safety output is
closed. Therefore, the offset is not in effect during warm-up, Beam Breaks, Motor
Failures or Signal Strength readings.
The offset is also used to compensate for a non-symmetrical deadband. This has the
negative effect of causing a small non-zero output when you would normally expect
a zero output but greatly improves the symmetry of the Over/Undershoot
characteristics
The first test of the gathering data tests is the Offset test

The Offset test begins by checking if there is any drift in the system. The Support
Software starts by outputting a zero VDC signal and measuring any position drift. If
there is no drift in the system, then the Deadband and Polarity test starts.
If drift is detected, the Support Software tries to compensate for the drift by
changing the Output voltage offset and re-measuring the response of the vehicle.
This test continues until an acceptable voltage is found that stops the drift in the
system, or if the value is to high to compensate for using the TCS algorithm.
B
Tip – If the drift is to high for the TCS algorithm to compensate, adjust the drift on the
Motor drive.
9.6.13 Deadband and Polarity Test

The next test that the Characterization performs determines the Deadband and
direction of motion (Polarity) of the system. This test starts by exciting the motor
drive with 1 VDC.
If motion is recorded then the voltage is decreased by half. This process continues
until no motion is observed. At this point the test increases the voltage and watches
for motion.
A series of eight tests are conducted to determine the deadband in both directions.
The result of the Offset, Polarity and Deadband tests are shown in the Upper part of
the Static Data screen.
If the vehicle can’t be moved on the track in a predictable manner during these tests,
error or warning messages will be displayed. For information, see Not Moving,
page 9.51, High Deadband, page 9.52 or Change Direction Error, page 9.52.

9.6.14 Speed Regulation or Bias Test

If the deadband voltage level is above 0.078 volts or below -0.078 then the Speed
Regulation test is automatically initiated.
The Speed Regulation or Sticky test moves the vehicle up and down half the length
of travel using a 5% reference signal (0.5 volts). Once this test has been performed it
is not required again and can be skipped by click on the button.
If the vehicle cannot be moved on the track with 0.5volt then a message is
displayed. For information, see Bad Track, page 9.52.
B
Tip – If its not possible to control the vehicle with 0.5 Volt reference over the whole track
its strongly recommended to stop the characterization and fix the problem causing this
error.
9.6.15 Acceleration and Velocity Test

The Acceleration and Velocity test executes a series of step outputs using the pre-
defined ramp rate. The steps are conducted in each direction followed by a display
of the results of the test. This test will determine the maximum working velocity and
acceleration for the vehicle. The velocity that the vehicle reaches during the 10 volt
step should match the top speed for which the drive and motor have been
configured. To allow for regulation margins, the actual closed loop top speed will be
95% of this speed. Therefore it is important to set up the drive so the final top speed
matches the performance specification of the vehicle.
C
Warning – During the next series of tests the vehicle will be moving very fast and using all
of the area of travel. Notify individuals working near the vehicle that it could approach
them very quickly. At no time however will the area of travel exceeded the end of travel
limits.
Steps Outputs
The Acceleration and Velocity test starts by positioning the vehicle at one of the end
of travel limits.

The TCS puts out 2.5 volt to the vehicle and measures the response.
The measured response is uploaded to the Support Software.
This test is performed using 2.5 Volt, 5 Volt and 10 Volt steps in both directions. The
results are then shown in the Static Data field (shown in the figure that follows).
The corrected velocity and acceleration values have been recalculated to correct for
the dynamics of the machine. The more non-linear the acceleration profile, the more
of a change will be made by this correction. For motors that work against current
limit this change should be minimal.
B
Tip – During this test its a good idea to check the relationship between acceleration and
velocity data for each step by using the Log file.
Vertical Application
If the choice Vertical Application was selected in the Horizontal vs. Vertical,
page 9.33 screen, you will be prompted to put a full load on the vehicle before the
Acceleration and Velocity test starts.
After the Acceleration and Velocity test is finalized you will be prompted to the load
to half back on the vehicle.
Note – Changing load is only required if its a varietal installation or if using loads
exceeding the weight of the vehicle.

Troubleshooting with the Characterization Log

Possible system problems can be observed during this test. The best way to monitor
the Characterization for problems is to use the Characterization Log. Look for a
linear relationship between the velocities printed for each step. The value should
double from step to step. The acceleration values should remain somewhat constant,
look for drastic changes from step to step to indicate problems.
For information on error message and solutions go to the section: Not Moving,
page 9.51 or Track or Acceleration, page 9.53.
9.6.16 Pink Noise Test

The Pink Noise ramps are a series of 3 or 9 step ramps (depending on the answer to
the Settling Time question - see Settling Time on page 9.30) used to gather the
response data required to model the system. The previous tests were required only
to collect the maximum and minimum performance data.
B
Tip – This test can take a long time so be prepared. Selection of a high sampling
frequency results in a large amount of passes while a low sampling frequency results in
less passes.
This test is used to develop the actual model of the system.

The ramps that are executed are very slow and deliberate with the vehicle appearing
to just “wander” back and forth on the track.
The Static Data field above the Status field shows the settings used in this test.
B
Tip – If the number of passes appears to be excessive the Skip button can be used to exit
the program early. While this is not always recommended, it can be required if many
Characterizations need to be run to optimize the systems settings. It is always
recommended that at least half of the required passes be completed before exiting.
9.6.17 Pink Noise Data

The program reduces the data collected during the Pink Noise ramps to a workable
system model. This process also, referred to as the Curve Fitting routine, is
graphical displayed in the Pink Noise Data tab shown below. The red line is the
theoretical model being “fitted” to the data which is the green line. As the process
proceeds the model will gradually conform to the data.

This process can also be displayed numerically by viewing the Log file.
The Curve Fitting is done in the sampled data or Z domain. As with all sampled
systems, it is difficult to predict what goes on in between samples. In the screen
below, where the proportional and derivative gains are chosen, it becomes possible
to accidentally find gains that look good at the sampled times but bad in between.
To avoid this problem, the sampled data is converted to the continuous data or
Laplace domain. This not only keeps the behavior between samples under control, it
also acts like an additional filter to improve the noise rejecting capabilities of the
Support Software.
For information on error, warning messages and solutions, go to the section: Non-
Linearity, page 9.53 or Speed Overshoot, page 9.54.
9.6.18 Step Response

The graph viewed on the Step Response tab shows how the machine, which is
everything except the ICS 5000, responds to a small change in the velocity set point.
The more square-like or sharp it is, the better. Some motor drives can be tuned so as

to affect this curve; if the curve is very, rounded indicative of a slow or sluggish
response, or if the curve overshoots, then re-tuning the drive to sharpen the step
response would be wise.
9.6.19 Transient Response

The graph viewed using the Transient Response tab shows how the system, which
does include the ICS 5000, responds to a small change in the position set point. Like
the velocity step response, the more square-like or sharp it is, the faster the system
will position or get on-station. However, faster is not always better. Stress on the
vehicle and load sway can be reduced by rounding the curve.
The tuning program handles two calculations, one for Transient Response and one
for Disturbance Response. The Transient Response mainly affects the
Over/Undershoot, while the Disturbance Response affects stability and how the

vehicle returns to set point after being pushed away. The red line in the graph is the
calculated Transient Response. (How the system responds to a change of setpoint).
The green line is the calculated Disturbance Response.
B
Tip – Manual tuning to reduce stress on the machine and load sway (rounding the curve)
after a Characterization can be accomplished in several ways:
1. Increase the Low Pass Filter.

2. Decrease the Noise Limit. This de-tunes or reduces the system loop gain
which will also cause the curve to be more rounded.
3. Manipulate the Transient Response PD gain manually. This is not a common
solution and should not be necessary in the most cases therefore access to this
requires a password.
Note – Test the performance of the system before starting with manual tuning.
Manual Controls
Manual Controls group contains the selection of the Tuning Algorithm and Tuning
Strength. It also contains the functions for tuning the Low Pass Filter and Noise
Limit values.
Two tuning algorithms for the gain parameters are supported:

• Brown tuning will select gains that provide a smoother “machine friendly”
final positioning result in gain parameters
• ITAE tuning is designed to provide a “hotter” final positioning profile.
The Tuning Strength for Brown and ITAE tuning can be set to: Gentle, 2..8 and
Aggressive.
Note – The default configuration after a new characterization is Brown tuning and
Gentle strength.
B
Tip – The Default choice of Tuning Algorithm (Brown) and Tuning Strength (Gentle) will
suit the most of the applications. For a normal installation it is no need to experiment with
these settings. Testing with different settings for the Noise Limit and Low Past Filter can
however be necessary for optimal performance.
Tuning Noise Limit allows you to limit the noise gain which will make the load
position smoother but slower. The noise limit is expressed in volts and limits the
peak voltage noise from the D/A converter output. Range is from 1/32 to 4 Volts.
Enter 4 to disconnect the noise limitation.
Tune the Noise limit by select Noise Limit in the Manual Controls group and enter a
value in the Control Value field or move the slider to the left. The result of changing
Noise Limit is showed directly on screen as a change in the graph for Transient and
Disturbance response.

Tune the Low Pass Filter by select Low Pass Filter in the Manual Controls group
and enter a value in the Control Value field or move the slider to the left. The result
of changing the Low Pass Filter is showed directly on screen as a change in the
graph for Transient and Disturbance response.
9.6.20 Disturbance Response

This graph shows how the Disturbance gains are tuned to response on a force
function. Tuning the Disturbance Response is performed in the Transient Response
tab. See Manual Controls, page 9.47 for tuning information.

9.6.21 Finalizing the Characterization
B
Tip – The Log file data must be saved before exiting the characterization program, else
the log data will be lost.
Exit the Characterization part of the Support Software with the button. The
new settings of parameters are written to the ICS 5000 unit.
Finishing a Characterization will return you back to the Characterization Menu.

From the Characterization Menu its possible to re-do the entire Characterization or
portions of the Characterization.
For information on using the Characterization Menu, see Characterization Menu on

page 9.29.
From the Characterization tab go to the Tools tab [Alt] + [T] + [1] and test the result of
the Characterization in the Terminal.
For more information on using the Terminal, see Terminal on page 8.2.
For information on commands, see Commands and Diagnostics, page A.I
Start with a short moves and then increase the distance if the results seams ok.
C
Warning – Be prepared with the Emergency STOP on this tests. Bad gain-parameters if
tuned wrong can cause a dangerous behavior of the vehicle.

After making sure the vehicle can travel in both directions without any strange
behaviors. Save the new parameters to file and use the Over/Undershoot test to
observe how well the vehicle is stopped at destination (see Over-/Undershoot on
page 8.4). Finally, use the Random Moves test to measure the settling time and move
times and the Chart Recorder to watch the behavior of the analog output. For
information, see Random Moves on page 8.7 and Chart Recorder on page 8.9.
Note – Make sure a back-up of the original parameters from the Characterization
has been saved prior to fine tuning or experimenting with different settings.
9.7 Software Error Messages

The following is a list of warning and disaster messages that can be issued by the
ICS 5000 Support Software during the Characterization. A warning is triggered by
less than optimal performance and allows the user to continue if no changes to the
system are possible. A warning will give several suggestions on how to improve the
problem, but sometimes it is just not possible to improve the situation.
Disaster messages indicate that fatal error has occurred and completion of the
Characterization is not possible at this point. The problem must be rectified before
the Characterization can be completed successfully.
9.7.1 Not Moving

This problem can be detected during the different tests with the exception of the
Pink Noise test, but it will of course be detected on the first test, the Deadband and
Polarity test. It means the ICS is trying to move the vehicle but can not see any
response in motion on the output signal to the drive.
Suggestions are for the deadband and Polarity test if its during:
• Check if the drive is enabled.
• Check the wirings from the ICS to the drive. (Deadband and Polarity test)
• The ICS puts out 1 volt to the drive in the deadband test. Click Retry and
check the voltage.
• Check so the drive did not get into its current limit. (Acceleration and
Velocity test)
Note – No Motion during the Pink Noise test is detected as a Beam Break. This is
due to the fact that the software is now measuring the response on the vehicle of
different test signals.

9.7.2 High Deadband

This problem can be detected during the Deadband and Polarity test. It means what
the deadband is very high.
Suggestions are:
• The IR-compensation is turned down to low or there is too much resistance in
the wires between the motor and drive.
• The track has a detente or bump which should be smoothed out.
• The motor may be undersized for the application.
9.7.3 Change Direction Error

This problem can be detected during the Deadband and Polarity test. It means what
the vehicle can only travel in one direction.
Suggestions are:
• The direction control of the drive may not match the selected ICS Output
format in the Control Options screen.
• The wirings can be wrong if the direction is controlled with relays (format B
and C).
• The drive is not a 4 quadrant or regenerative drive. In this case must the drive
be replaced.
9.7.4 Bad Track

This problem can be detected during the Speed Regulation or Bias test. It means
what it was not possible to move the vehicle with 0.5V on this position.
Suggestions are:
• Check the track for mechanical damage.

9.7.5 Track or Acceleration

This problem can be detected during the Acceleration and Velocity test. It means
what the near and far limits are too close or the acceleration is not high enough to
get the vehicle up to speed within the defined position limits.
Suggestions are:
• Modify the near limit and far limit to give the vehicle more room.
• Turn up the current limit or get a larger motor.
• Lower the top speed somehow.
• The acceleration test was interrupted somehow (motor drive stopped) and
restarted with to short track left to travel. Retry the test.
9.7.6 Non-Linearity
This problem can be detected during the curve fitting process. It means what the
drive using to control the vehicle is not very linear. Overshoot and undershoot will
vary depending on the velocity, acceleration and direction.
Suggestions are:
• Use tach feedback instead of EMF.
• Use Pulse Width Modulated instead of SCR drives.
• Reduce the friction

Velocity
Voltage
Figure 9.2 Linearity
9.7.7 Speed Overshoot

This problem can be detected during the curve fit process. It means that the drive
has more than 20% speed overshoot. This increases the positioning time.
Common sources are:

• Undersized VF drive and AC motor combinations.
• Too much integral gain in tunable drives.
• Poorly tuned DC drives
• Any spring-like thing in the drive train (drive shaft, rubber coupling, wire
rope, pulley/timing belt)
• Even mounting the sensor far from the drive wheel in large structures can
cause it

Note – If you can make the system look more like the ideal velocity step response
below, you should abort, fix and re-characterize.
Velocity
Time
Figure 9.3 Velocity step response


CHAPTER
10
BCS Control Algorithm
Configuration 10
In this chapter:
• Introduction
• Hardware Output Status
• BCS Parameters Tab
• Control Parameters Setup

10.1 Introduction
This chapter covers the configuration of the BCS (open loop) control algorithm in
the ICS 5000. See Chapter 7.3, BCS Algorithm - Open Loop Control on page 7.5
for information on the theory of operation of this algorithm.

The integration of the ICS 5000 as a motion controller should be approached with a
modular state of mind. Think of the ICS 5000 as a positioning co-processor that is
wholly responsible for motion related tasks including error detection and reaction.
The ICS 5000 works together with the PLC to control motion instead of simply
providing a position feedback signal. No attempt should be made to anticipate the
safe shut down of the control loop during an error by removing control from the ICS
5000. Instead, the PLC should take advantage of the resources that this distributed
control approach frees up by enhancing the communication driver used with the ICS
5000. Thorough support of the status codes and some choice diagnostic registers
could save hours of down time spent troubleshooting problems. The exception is
when a motor drive faults or safety condition is not satisfied. In this case, the PLC
should assume immediate control and stop the machine.
10.2.1 Safe Shutdown of System Operations

The fail-safe design of the ICS 5000 requires little PLC interaction. Once a move
command has been initiated the ICS 5000 is capable of controlling every aspect of
the move. While the move is in progress, the system controller is constantly
monitoring the relationship between the distance to the target and the speed levels.
When the ICS 5000 determines that action is necessary, the response is generated
automatically without assistance from the PLC.
Following is a brief summary of the ICS 5000 BCS algorithm error handling
responses. Also included in this listing is a suggestion as to how the PLC should
react once the system has been shut down and the error reported. For more detailed
information on error generation please see Hardware Output Status, page 10.11 and
Commands and Diagnostics, page A.I.
Table 10.1 BCS Algorithm Error Handling Responses
Fault BCS Algorithm Action PLC Response
Loss of Data • Ramps vehicle down to zero speed Retry move. If data
(Beam Break and then opens Brake contact. loss continues
declared). Automatic • Reports status of E 2 when polled by then check alignment
Retries not enabled. PLC. of unit.
(RETRY = 0)
Loss of Data (Beam • Ramps vehicle down to zero speed No action necessary
Break declared). but keeps the Brake contact closed if ICS 5000 succeeds
Automatic Retries while re-determining absolute to complete the
enabled. (RETRY > position. Then resumes the move. If move. Otherwise
0) Beam Break is permanent, same same as above.
action as above.
• Reports status of E 2 during the stop
when polled by PLC.

BCS Control Algorithm Configuration 10
Table 10.1 BCS Algorithm Error Handling Responses

Fault BCS Algorithm Action PLC Response
Slower than • Ramps vehicle down to zero speed PLC should not retry
theoretical model and then opens Brake contact. the move
(Motor Failure) • Reports status of E 4 when polled by because error could
PLC. be mechanically
related.
Faster than • Ramps vehicle down to zero speed The PLC should not
theoretical model and then opens Brake contact. retry the move
(Motor Failure) • Reports status of E 4 when polled by because error could
PLC. be mechanically
related.
Warming Up • Will not initiate any motion. Brake Retry command for
relay are open. up to 10 seconds
• Reports status of E 32 when polled upon first power up.
by the PLC.
by he PLC. command then
check for status to
change.
10.2.2 Status Interrogation and Response

Every move initiated by the ICS 5000 will result in a change in status. The PLC
must query the ICS 5000 at the completion of each move to determine if the move
was a success or failure. The transmission of this query at the end of a move can be
triggered by monitoring the ICS 5000’s Brake output. This relay will open to set the
mechanical brake when motion has ceased or a fault has occurred. The following
text details basic logic that the PLC should possess to deal with possible fault
situations reported by the BCS algorithm:
Send move command (D or S) to ICS 5000
If ACK (ª) received from ICS 5000 then
Data received successfully move in progress.
If NAK (§) is received from ICS 5000 then
Data needs to be resent.
Wait for Brake Relay to open
Send E command to ICS 5000
Read Status response E ###
If ### = 2 then retry move command 2 times before reporting Beam Break
Fault
If ### = 4 then report Motor Failure Fault
If ### = 8 then retry E command - still positioning
If ### = 16 then Move Complete In Position
If ### = 32 then retry E command for 10 minutes before reporting Warming
Up

If ### = 128 then send BT command to reboot BCS and retry E command

To configure the ICS 5000 to use the BCS algorithm, select BCS from the
Algorithm section of the Control Options screen. The Output Format section allows
you to configure the ICS 5000’s I/O to match the requirements of your system. The
following sections provide information on the I/O configurations available with the
BCS algorithm.
C


The BCS algorithm has two main sub versions BCS1 and BCS2. BCS1 is an open
loop single axis control with programmable speed plateaus. BCS2 is an open loop
single axis control system with a two speed function (digital output for speed
changes). The different sub versions for the BCS, are shown in Table 10.2 which
follows.
Table 10.2 BCS System Configuration Overview
Sub Version Control Format I/O Functions
BCS1 A Bi-Polar Output version
( -10 to +10 VDC)
direction contact).
direction contacts).
BCS2 D Two speed Output version (Fast / slow speed
indicated with relay contact).
relay input used for system synchronization is a 12 - 24 Volt DC/AC coil. See the
ICS 5000 Installation Manual for more information on output specifications.
configurations are explained in detail in the following paragraphs.
10.3.2 Format A Configuration: Bi-Polar Output versions (-10 to +10VDC)

from 0 VDC to -10 VDC for one direction and from 0 VDC to +10 VDC for the other.
Figure 10.1 System integration BCS format A

The control I/O performs the following functions:

Table 10.3 BCS Format “A” I/O Configuration
13 & 14 Analog Output – 10 (pin 14) to +10 (pin 13) VDC speed
3&4 BCS Status Output for Normally open contact (OUT 1) used to
1&2 BCS Status Input for Coil for a normally open contact (IN) used to
Synchronization indicated when another BCS in the system
10.3.3 BCS1 Configuration Codes for Control Format A

command to the unit. The configuration codes only shows the communication
character set.
10.3.4 Format B Configuration: Uni-Polar Output Version (0 to +10 VDC)

The analog control signal used as a speed reference by the motor drive varies only
from 0 VDC to +10 VDC. Direction is indicated by the state of one relay contact,
OPEN for one direction CLOSED for the opposite.


Table 10.4 TCS Format “B” I/O Configuration
9 & 10 Direction Contact Normally open contact (OUT4) that indicates
the other.
Synchronization indicated when the BCS has begun to ramp
10.3.5 BCS1 Configuration Codes for Control Format B

character set.

10.3.6 Format C Configuration: Uni-Polar Output Version (0 to +10 VDC)

The analog control signal used as a speed reference by the motor drive varies only
from 0 VDC to +10 VDC. Direction is indicated by the state of two relays, one for
reverse direction and one for forward direction. A closed relay indicates the
direction. If both reverse and forward direction contacts are opened the brake on
your drive should be enabled.
Figure 10.2 System integration BCS format C

Table 10.5 BCS Format “C” I/O Configuration
9 & 10 Reverse Direction Normally open contact (OUT4) that indicates
Contact reverse direction. Closed for reversed
direction. Open for forward direction or
applying the brake.
5&6 Forward Direction Normally open contact (OUT 2) that indicates
Contact forward direction. Closed for forward
direction. Open for reverse direction or
applying the brake.
Synchronization indicated when the BCS has begun to ramp

10.3.7 BCS1 Configuration Codes for Control Format C

character set.
10.3.8 Format D Configuration: Two Speed Output Version

Speed is indicated by the state of a relay contact, OPEN for low speed and CLOSED
for the high speed. Direction is indicated by the state of one relay contact, OPEN for
one direction CLOSED for the opposite.
Figure 10.3 System integration BCS format D


Table 10.6 BCS Format “D” I/O Configuration
9 & 10 Direction Contact Normally open contact (OUT 4) that indicates
the other.
indicate a fault.
3&4 High / Low speed Normally open contact (OUT 1) indicated low
contact speed and closed contact indicate high
speed.
10.3.9 BCS2 Configuration Codes for Control Format D

character set.

The sampling frequency (samples/sec. or Hz) used in the IDM (Industrial Distance
Meter) inside the ICS 5000 can be configured during the set up. The available
sampling frequencies are: 19.35, 30.58, 49.32 and 69.50 Hz with the default being
30.58 Hz (the TCS/BCS/PDM system 4000 uses 30 Hz). If ICS 5000 is used as a
characterize.
For information on configuring sampling frequency in Support Software, see
Chapter 3.4, Sample Rate on page 3.5.


The BCS algorithm supports the modes listed in Table 10.7. The Mode codes are bit
mapped. This means that each unique mode has it’s own bit. If two or more different
modes are desired, send the summation of the individual modes. For information on
configuring the modes using the ICS 5000 Support Software, see Wakeup Mode,
page 10.20.
Table 10.7 BCS Algorithm Modes
M Number Mode
The BCS can send a warning for motor failure when motor warning level is
exceeded. The warning code for beam breaks will be sent when half the I
value is exceeded.
break. #=4 mean almost motor failure, # =0 mean no warning.
The total status on a travelling vehicle (status 8) with a motor failure
warning will be: 4 * 256 + 8 = 1032
2 Enable reporting status on auto-calibration (E 64) to be sent with the status
information.
passed.
status is 16 and the time is less than half to next auto-calibration, the
status will be: 64 * 256 + 16 = 16400.
If beam is broken position data (X & Y) responses will be withheld until the

page A.I. For PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocol information, see
10.4 Hardware Output Status

The table below shows how the different output relay contacts act at different
situations. The functions are the same for all BCS versions except for the following:
ICS 5000 Support Software User Manual 1 0 . 11

• BCS algorithm format D (Two speed version) does not support the Sync
output.
Table 10.8 BCS Algorithm Output Status

Status Code Brake Sync BCS1 Only
Warming up E 32 Open Open
Just out of warm-up or halted with H- E1 Open Open

command.
Moving to a destination or station. (D# or S# E8 Closed Closed
command sent to BCS.)
At Destination or Station. (Will not change E16 Open Closed
during auto-calibration unless a new D# or S#
command is sent.)
After a prolonged Beam Break (I-number E2 Open Closed
exceeded) at Destination or Station.
After a prolonged Beam Break during a move E2 Closed Open
and while decelerating.
When stopped after a prolonged Beam Break E2 Open Open
during a move. No Retries enabled.
When stopped after a prolonged Beam Break E2 Open Open
during a move. With Retries enabled.
After a lagging motor failure and while E4 Closed Open
decelerating.
After a leading motor failure and while E4 Closed Open
decelerating.
When stopped after a motor failure. E4 Open Open
Sync input configured as normal and stopped E8 Open Closed
after the sync. input been opened.
Sync input configured as halt and stopped after E1 Open Open
the sync. input been opened.
During auto-calibration and when a D# or S# is E16 or Open Closed
sent to the BCS. (Before the move starts.) E64 if
in M2
During auto-calibration just before final E8 or Closed Closed
positioning. (Will happen if calibration time E64 if
interval has run out during the move.) in M2
For information on status and diagnostic codes, see Commands and Diagnostics,
page A.I.

10.5 BCS Parameters Tab

[Alt] +[P]
When the BCS control algorithm has been selected, the BCS Parameters tab is
shown. The BCS Parameters tab (shown below) displays all the values for the
control loop with the exception of the tolerance. Use this tab to view the wake-up
values for the BCS algorithm and to make changes to meet the specific needs of the
vehicle being controlled.
Note – If this is a new installation, the table and fields in the BCS Parameters tab
will be empty and a configuration of the vehicle to control shall first be performed.
The BCS Parameters tab contains links to the following screens:
• Control Parameters
• Top Speed
• Beam Breaks
• Wakeup Mode
• Sync Input Definition
sections. The shortcut key combinations for reach each screen are also provided in
each section.
For information on how to perform a configuration on a BCS algorithm, see Control
Parameters Setup, page 10.22.

10.5.1 Control Parameters

[Alt] + [P] + [1]
The Speed and Distance parameters that enable the BCS to control a vehicle are
entered using the fields of the Control Parameters screen shown below.
For information on how to configure this screen, see Control Parameters Setup,
page 10.22. The following is a short description on each field, this descriptions are
also shown in the Support Software by selecting the fields. For a detailed
information, see the link in the end of each field’s description.
Number of Speeds
This field controls the number of speeds. If set for two, the analog output goes to
10v for high and 0v for low speed. If 3-7, the analog output ramps up and down to
the values determined by the various Speed # Voltage fields. See also: Selecting the
Number of Speeds, page 10.23
Failure Level
If the measured velocity differs from theoretical speed by this percentage or more, a
Motor Failure fault will be declared. See also: Optimizing Velocity Failure Level,
page 10.33
Top Speed
The velocity in millimeters the vehicle will reach with 10 V reference. This is used
to calculate a Theoretical Speed which is compared with the Actual Speed for Motor
Failure detection. See also: Multi-Speed Algorithm, page 10.24
Brake/Start Delay
The time between closing the Brake relay and ramping up the analog output. It gives
the mechanical brake time to release before the drive is asked to accelerate. If the
ICS 5000’s Brake output is used to enable the motor drive, set this value to the time
it takes for the drive to enable. See also: Brake/Start Delay, page 10.33

Speed 1 min. Distance

This is the distance at which the Brake is applied. This number controls whether the
load stops short of or beyond the target destination. See also: Speed 1 Setup,
page 10.28
Speed 1 Voltage
The voltage reference supplied to the motor drive for Speed 1. Too high of a value
causes violent stops when the brake is applied and makes positioning inconsistent.
Too low of a value can cause the machine to stall or get stuck. This value is also
used for the Jog pulses. See also: Multi-Speed Algorithm, page 10.24
Speed 2 min. Distance

The distance to transition from Speed 2 to Speed 1. If this is too large, you will
waste time at low speed. If this is too small, you will overshoot the target
destination. See also: Adding Multiple Speeds, page 10.30
Speed 2 Voltage
The voltage reference supplied to the motor drive for Speed 2. See also: Multi-
Speed Algorithm, page 10.24
Speed 3 - 7 min. Distance

The distance to transition to the next lower SPEED #. If too large, you will waste
time at the current speed. If too small, you will not see a clean transition to the next
speed. See also: Adding Multiple Speeds, page 10.30
Speed 3 - 7 Voltage
The voltage reference supplied to the motor drive for the corresponding Speed #.
See also: Multi-Speed Algorithm, page 10.24
Fine Pos. Jog Time

Some Fine Positioning parameters are available to configure how the BCS
algorithm corrects small position errors. The first one, Fine Pos. Jog Time,
determines the time period to apply the Speed 1 reference to the motor drive. If this
is too large the machine may cycle back and forth without finding final position. If
this is too small, too many tries will be required resulting in a fault. See also: Fine
Pos. Jog Time, page 10.26
Fine Pos. Wait Time

The next Fine Positioning parameter is the Fine Pos. Wait Time. This is the time to
wait after applying the Speed 1 reference to the motor drive. Start with twice the
time required to stop after pulsing. See also: Fine Pos. Wait Time, page 10.27

Fine Pos. Fail Limit

The final Fine Positioning parameter is Fine Pos. Fail Limit. This determines the
maximum number of times the Speed 1 reference will be applied to the motor drive
before declaring a Motor Failure fault. See also: Fine Pos. Fail Limit, page 10.27
Normal Accel Time

For 2 speed AC motors, enter your estimate of the time to reach top speed. For
variable speed drives, enter the desired time to reach top speed. See also: Normal
Accel Time, page 10.27
Normal Decel Time

For 2 speed AC motors, enter your estimate of the stopping time from top speed. For
variable speed drives, enter the desired stopping time from top speed. See also:
Normal Decel Time, page 10.27
Emergency Decel Time

For emergencies like Beam Breaks, Motor Failures and halts enter the time you
would like to see the machine stop within. See also: Emergency Decel Time,
page 10.27
Reversed Polarity
This check box lets you reverse the polarity of the BCS algorithm’s reference
voltage output. If the machine goes in the wrong direction, select or unselect this
box to reverse the polarity. See also: Reversed Polarity, page 10.28

10.5.2 Top Speed

[Alt] + [P] + [2]
The Top Speed Determination screen displays a filtered velocity feedback that
should be used to complete the Top Speed field of the Control Parameters screen.
Once the estimated top velocity has been selected and tuned to work with the
system, the actual top velocity should be recorded using this step.
The Speed # field’s default value is the configured number of speeds and the Top
Speed field’s default value is the entered Top Speed from the Control Parameters
screen. Click the button to initiate movement of the vehicle. The vehicle
will travel back and forth approaching the two endpoints. If desired, you can
configure a Pause Time in seconds between each move by entering a value in the
Pause Time field or using the arrow keys. The slider can be used for adjusting the
estimated top speed. Try to adjust the Top Speed to the average of the actual
measured top speed. The adjusted value for Top Speed is automatically recorded in
the Top Speed field on the Control Parameters screen.
All motion can be stopped by clicking either Halt or .
C
Warning – The velocity verification section of the Support Software will cause the vehicle
to move. Be sure that you anticipate this by taking any precautionary measures necessary.
If you are unsure of what will happen, stop and contact a Trimble engineer before
proceeding.
Note – It is important that this step be completed to enable the BCS algorithm to
more accurately detect performance related error (Motor Failures) via the Failure
Level parameter.
For information on how to use the Top Speed Determination when implementing the
speed steps, see also: Testing Top Speed, page 10.32.

10.5.3 Beam Breaks

[Alt] + [P] + [3]
The Beam Break Parameters screen (image that follows) allows you to modify the
methods which the BCS algorithm uses to deal with Beam Breaks (data losses). The
first parameter is the wake up or default number of Beam Breaks to Ignore which
controls the fault tolerance. The next parameter, Number of Automatic Retries,
allows you to enable automatic recovery from a Beam Break fault. Finally, the
Number of Beam Breaks to Skip allows the TCS algorithm to delay ramping down
the velocity when data is first lost. More details on these parameters are provided in
the following sections.

page A.I.

The I number for maximum consecutive bad data samples to Ignore is determined
during the characterization by the time it takes the vehicle to travel 2.4 meters at full
speed. When this number is exceeded, the BCS algorithm will perform a controlled
stop and issue a Beam Break error message. Even if the value has been changed
using the I command, the ICS 5000 unit will return to the wake up value declared
here once reset. The value entered cannot exceed the maximum value listed. During
normal operation there is no benefit to lowering this value from the maximum.

Number of Automatic Retries

Use this field to enable one or more Automatic Retries after a Beam Break fault has
occurred. The automatic retry feature is useful in situations where Beam Breaks
occur frequently due to environment or system mechanical problems. The retries are
preformed independent of the PLC code, and without issuing the Beam Break fault
status.
Number of Beam Breaks to Skip

During a move, a Beam Break normally causes the vehicle to immediately begin
ramping down. If the Beam Break goes away before the Ignore level is exceeded,
the machine speeds back up and finishes the move. The slight loss of time caused by
this slow down and recovery can be avoided by setting the number of Beam Breaks
to Skip to a value greater than zero. With Skip enabled, the vehicle will only begin
slowing down after the Beam Breaks to Skip value of bad samples has been
exceeded.
C
Warning – Using the Skip function with the BCS control algorithm can cause the vehicle to
exceed its end of travel limits, if a Beam Break occurs during slow down to final position.

10.5.4 Wakeup Mode

[Alt] + [P] + [4]
The Wake-up Mode screen allows you to modify the basic operational modes of the
BCS algorithm including: enable Warning Codes, report Auto-Calibration and Wait
for Good Data. For information on the different algorithm modes, see Table 10.7 on
page 10.11 or the following screen descriptions.
B
Tip – By default, Mode 0 is used after the initial configuration. Mode 0 is the most common
mode used with the BCS algorithm and will fit to the most of the installations.
Mode 1 Warnings
controller know when a Beam Break and/or a Motor Failure warning has occurred
(this is a rarely used feature). Adds 1 to the Mode sum. For protocol information,
Mode 2 Calibration
2 to the MODE sum. For protocol information, see Table 10.7 on page 10.11.

Mode 16 Wait
measurement beam is broken. Adds 16 to the Mode sum. For protocol information,
see Table 10.7 on page 10.11
10.5.5 Sync Input Definition

[Alt] + [P] + [5]
The Sync (roniztion) Input relay is typically used in coordination with Sync Output
relay. The function of the Sync Input relay can be configured in three different
options:
• Normal - De-energizing the SYNC input programs the velocity to zero while
keeping the control loop active. This is good when there are multiple
machines on the same runway that need to avoid collisions but is basically an
unused input for all other applications.
• Halt - The SYNC input can be programmed to perform a HALT when de-
energized. This adds a redundant shutdown path when safety is important.
• Ignore - The SYNC input is ignored. This is the default choice after a
Characterization.
B
Tip – Sync input is by default configured to Ignore. If no Synchronization wiring between
several ICS 5000 units exists, this section can be ignored.
For information on Synchronization wiring, see ICS 5000 Installation Manual.

10.6 Control Parameters Setup

The Speed and Distance parameters that enable the BCS algorithm to control a
vehicle are entered via the Control Parameters screen selected from BCS
Parameters tab of the ICS 5000 Support Software (shown below).
10.6.1 Choosing Control Parameter Values

The fields in the Control Parameters screen must be completed correctly before the
BCS algorithm can be used to control a vehicle. Filling out the table is a three step
process:
1. Estimate the correct values for the speeds and distances.
2. Tune the performance of the vehicle so that the control is acceptable.
3. Use the Support Software to determine the actual value for the Top Speed.
The table is filled out with Speeds (voltages), Distances and various control
parameters. Isolate the lowest speed first and tune the distance until the vehicle
positions repeatability without under or overshooting. Then gradually add the
remaining speeds one at a time, tuning each to provide only the slightest hesitation
when the unit shifts from one speed down to another. Once a comfort level is
developed with the performance of the control algorithm, the actual speed should be
determined using the Top Speed Determination, see Top Speed, page 10.17.
B
Tip – Because the BCS algorithm is “open loop” it can not compensate for load and
performance changes. Therefore, it is best to preform the Control Parameter tuning with
a maximum load on the vehicle.

The software performs some basic validity checks to insure the accuracy of the data
entered. Incorrect data is identified as a red field as shown in the following image.
The following sections describe the setup process in greater detail and give some
suggestions to guide you to a successful setup.
Selecting the Number of Speeds

Enter the Number of Speeds that the BCS algorithm will be using for the positioning
algorithm. This is dependent upon how fast the vehicle moves at full speed and how
smooth you need the deceleration portion of the move to be. Multi-speed algorithms
use the analog output to ramp the motor drive down from one speed to the next. The
reaction time of this ramp is determined by the Normal Decel. Time parameter
entered on the Control Parameters screen.
The BCS algorithm can also implement a simple two speed algorithm using only
high speed and creep speed. Depending upon the type of interface used by the motor
controller to which you are integrating the ICS 5000 there are two ways of
developing the two speed profile:
• The BCS algorithm format D uses a digital output.
• The BCS algorithm format A, B or C uses an analog output.
The first option uses contacts to interface with a High Speed/Low Speed contactor,
while the second configuration uses the analog reference signal to drive the motor at
either full speed or creep speed.
For information on Pin configuration, see:
• Format D Configuration: Two Speed Output Version, page 10.9.
• Format A Configuration: Bi-Polar Output versions (-10 to +10VDC),
page 10.5
• Format B Configuration: Uni-Polar Output Version (0 to +10 VDC),
page 10.6
• Format C Configuration: Uni-Polar Output Version (0 to +10 VDC),
page 10.8.

Analog Voltage Levels

The relationship between the entered voltages and the velocity setpoint is really
quite simple. The entered voltages for the different speeds are supplied to the motor
drive as the velocity signal from the ICS 5000. The highest entered voltage will be
supplied to the motor drive as the highest velocity signal. Even though the
maximum output from the ICS 5000 is 10VDC, there is no problem with configuring
a lower voltage for the maximum velocity.
Note – The vehicle’s final velocity depends on the motor drive’s velocity related
settings.
In the example presented in Table 10.9 that follows, Speed 3 in is one half of speed
4 (the highest speed). Therefore the voltage output when speed 3 is active will be
one half the maximum or 5VDC.
Table 10.9 Velocity/Analog Output
Speed Number Velocity (mm/sec.) Analog Output (VDC)

1 50 0.5
2 200 2.0
3 500 5.0
4 1000 10.0
Using this information, a two speed algorithm using the analog output could be
setup with the following parameters:.
Multi-Speed Algorithm
The same approach used to setup the two speed algorithm can be carried over to a
multi-speed system. Enter the Speed 1 Voltage to Speed n Voltage in the table where
N is the highest number of speeds to incorporate into the system. The selected
voltages are the voltage the ICS 5000 supplies to the motor drive at each speed.
This data relates to how fast (in millimeters per second) the load will be traveling at
different speeds. The Speed 1 Voltage should be slow enough to insure that the
positioning tolerance of your system is satisfied while preventing the vehicle from
stalling under full load. This voltage may have to be found by trial and error if this
data is not readily available.

The illustration in Figure 10.4 depicts the layout of a four speed algorithm. The
graph of Velocity vs. Distance in the top half of the figure shows the relationship
between Speed Voltage and Distance settings and the final positioning point. The
bottom half of the figure shows the theoretical response of a vehicle when it is
exposed to this positioning algorithm.
Figure 10.4 BCS Positioning theory
If the various Speed Voltages are not known, Trimble suggests a formula that uses
Speed 1 and the maximum velocity of your system to calculate the remaining Speed
variables. For example, for a 7 Speed algorithm, we may know that the Speed 1
Voltage (LO SPEED) should be 0.30 volts to insure positioning accuracy and that
the Speed 7 Voltage is 10.00 volts. For a geometric progression from Speed 1 to
Speed 7, we can assume the following:
Speed 1 Velocity = 0.30 volts
Speed 2 Velocity = 0.30 * N volts
Speed 3 Velocity = 0.30 * N^2 volts
Speed 7 Velocity = 0.30 * N^6 = 10.00 volts

Solving for n gives:

0.30* N^6 = 10.00
N^6 = 10.00/0.30
N^6 = 33
N = 33^(1/6)
N = 1.79
Therefore, substituting 1.79 for n in our original formula results in the following
reference voltages:
Trimble only suggests this solution and the design engineer for your application
may have his or her own speed algorithm implementation. Trimble recommends
designing the speed profile base upon the particular performance attributes of your
application.
10.6.2 Selecting Other Parameters

Once the Speeds and Distances have been correctly tuned and recorded it is time to
finish setting up the remaining control parameters. These values are responsible for
everything from detecting performance related errors to adjusting the fine
positioning attributes.
Fine Pos. Jog Time

The Fine Pos. Jog Time (in seconds) determines the number of seconds that the
motor will be energized too get back into position if the load ever misses (under or
over-shoots) its destination. A correctly functioning positioning system should not
encounter this problem, but this is an added feature to insure that positioning is
successful on every move sequence. Try setting this value to around 1 second. The
key with this setting is not to have the value too large. If the value will move the
vehicle more that the length of the positioning tolerance then it is too big.

Fine Pos. Wait Time

The Fine Pos.Wait Time determines the amount of time to wait after pulsing the
motor to see if the load is on position. Typically this should be twice the Fine Pos.
Jog Time. This value is required to let the vehicle settle after jog pulses so that the
location may be determined accurately. If this value is too small then the vehicle
could never actually come to a complete stop before trying to jog again.
Fine Pos. Fail Limit

The Fine Pos. Fail Limit determines the number of times the BCS algorithm will
attempt to jog your load before it shuts down operation. During the set-up stage for
the BCS algorithm, this figure should probably be quite high (> 10 tries). During
normal operation this number should be quite low (< 5 tries).
Ramp Parameters
The Acceleration Time parameters (Normal Accel Time, Normal Decel Time and
Emergency Decel Time) are vital in instructing the BCS algorithm which ramp rates
to use while accelerating up to speed or decelerating from Speed to Speed. The time
is roughly converted into a slew rate which limits changes in the analog signal.
Without this feature, some vehicles would spin there wheels during acceleration and
deceleration. It is important that these values be determined prior to setting up the
Speed and Distance relationship table as the ramp rate will effect the time it takes
the vehicle to change speeds. Thus, changes made to the normal deceleration value
after setup has been completed, could result in changes to the various Speed
Distance values.
Normal Accel Time

Set the Normal Accel Time to the time it should take the load to get from a dead stop
to high speed. The acceleration rate that the vehicle can safely withstand
mechanically should determine this parameter. This acceleration time will control
how quickly the D/A CONVERTER ramps up to 10 VDC.
Normal Decel Time

Set the Normal Decel Time to the time it takes the load to stop from Top Speed. This
Decel Time controls the ramp rate of the D/A Converter output as the analog control
signal changes from Speed to Speed. Once this time is set and experimentation
begins on the Speed Distances, the Normal Decel Time should not be adjusted.
Modifying this value will cause the Speed Distance relationships to change.
Emergency Decel Time

Emergency Decel Time is the time it will take the load to come to a stop in the event
of a beam obstruction (Beam Break) or Motor Failure in the ICS 5000. The H or halt
command also uses this time to decelerate. An Emergency Deceleration is done in
an open loop fashion and does not use the various Speed Distances to shift speeds,
but simply ramps down to 0 V when the Emergency Decel Time is implemented.
Typically setting this time to your Normal Decel Time is satisfactory.

Reversed Polarity
If your are using format B or C, ignore this check box, because it pertains only to the
bi-polar analog signal in format A. Select or clear this to change the polarity of the
analog signal reversing the direction of the drive.
10.6.3 Tuning The Speed Profile

Begin setting up the Control Parameter table with Speed 1 Distance. Once Speed 1
has been successfully setup, the other Speeds will be added one by one and meshed
with the previously setup Speeds to insure that there ability to position is not altered.
Note – While Setting up speed 1, there is no need for setting Speed2 to Speed7 to a
default value. Just select the speed to be tested from the Over/Undershoot screen.
Speed 1 Setup
Set Speed 1 Distance to the distance from the final destination that the brake will be
set and make a mental note of this distance for future use.
Figure 10.5 Speed 1 Setup
B Tip – If one of the fields in the table is red, a value was not entered correctly.
Testing Speed 1
Testing of various Speed Distances requires movement of the vehicle. Because the
control loop has not yet been verified, it is imperative that someone be prepared to
press an Emergency Stop button if something unexpected should happen.
C
Warning – Next action will initate motion of the vehicle and using all of the area to travel.
Be sure that you anticipate this by taking any precautionary measures necessary. If you
are unsure of what will happen, stop and contact a Trimble engineer before proceeding.
Manually position the vehicle to the center of the length of travel and enable it for
automatic control.

Speed 1 Undershoot/Overshoot Adjustment

Go to the Over/Undershoot test. [Alt] + [T] + [2]
For information on using the Over/Undershoot test, see Over-/Undershoot on
page 8.4.
Move the two turn-around points until they are slightly further apart than the value
for the Speed 1 Distance. Zoom in until the scale are showing the two turn around
points with a scale of mm resolution. In the Velocity field select Speed 1 or the speed
to be tested. Click the button to initiate motion.
B
Tip – If the vehicle can’t move, check the wiring, motor drive enable or the analog signal to
the motor drive.
Monitor the turn-around points and see if vehicle is undershooting or overshooting

the target..
C
Warning – If the vehicle moves over the turn-around point without stopping and changing
direction. The direction control is wrongly set up. Stop the motion and fix the problem, else
the vehicle will ultimately pass over the end limit.
B
Tip – If the vehicle pass over the turn-around point without stopping and change direction.
-If format A -change the polarity of the signal in the Reversed Polarity check box or
change the polarity on the wiring for the analog signal.
-If format B, C or D check the direction controls wirings.
Undershoots are characterized by the load stopping short of destination. Overshoots

are characterized by the load passing over target destination. Use either the
Overshoot or Undershoot button once to compensate for positioning error. Clicking
on Overshoot compensates for undershoots by adding more overshoot, and
clicking on Undershoot corrects for overshoots by adding more undershoot. Once

the vehicle starts moving again continue to check for overshoots and undershoots.
Repeat this process as many times as necessary to insure that the vehicle skids
exactly into position.
B Tip – If your Speed 1 Distance is less than your tolerance, you may temporarily set it
higher than your tolerance for experimentation purposes.
One of three things should have occurred:

1. The vehicle oscillated several times before it finally positioned itself. If this
occurred, decrease the Fine Position Jog Time and Wait Time from Control
Parameter screen. Repeat the previous test after you have corrected the
problem. Remember, the wait time should be approximately twice the jog
time.
2. The vehicle did not move. Increase the Fine Position Jog time from Control
Parameter and repeat the previous test. Repeat until the problem is corrected.
3. The vehicle positioned itself correctly. Decrease the Fine Position Fail Limit
using the Control Parameter and continue to the next procedure.
Save to disk and write to the unit.
10.6.4 Adding Multiple Speeds

At this point you are ready to begin implementing the higher speeds (speeds 2-7).
Go to the Control Parameter screen and enter in the Speed 2 Distance. Using the
Under/Overshoot test, spread the endpoints apart such that they are positioned at a
distance greater than the Speed 2 min. Distance. Select Velocity 2 and initiate
vehicle motion by using the Start button. If the vehicle appears to be spending too
much time at Speed 1 (creeping), decrease the Speed 2 Distance value from Control
Parameter screen.
Never use the Overshoot or Undershoot buttons to adjust overshoot or undershoot
of Speeds 2-7. These buttons only effect the minimum distance for Speed 1.
If the vehicle appears to be overshooting, increase the Speed 2 Distance. Once you
are satisfied with the 2 speed position control, add the Speed 3 Distance and repeat
the same procedure that you used for speed 2.
Note – Remember, you add speeds by entering values in the Speed n Distance and
Speed N Voltage fields of the Control Parameter screen. Never hit the Overshoot or
Undershoot buttons to tweak on the 2-7 speed control and make sure that your turn
around points are further apart than the Distance for the Speed you are trying to
adjust.
B
Tip – If the brake can’t release in time before the analog output starts ramping up,
configure a delay time. For details, see Brake/Start Delay, page 10.33.
The analog output performance of the speed settings can be checked in the Chart
Recorder tool, [Alt] + [T] + [6]

For information on using the Chart Recorder, see Chapter 8.2.6, Chart Recorder on
page 8.9.
Test the performance by sending the vehicle to a position, if the distance to travel is
long enough for all speeds to be used, all speed steps will be shown on the graph.
Note – Its important to understand what the Chart recorder only shows the analog
output from the BCS and not the actual velocity (performance) of the vehicle being
controlled.
Note – It can be difficult to view all the different steps if the lowest voltage is very
low.
Optimizing the Deceleration Phase of the BCS Algorithm

It is important that the Speed 1 Distance to Speed 7 Distance steps are long enough
so that the vehicle will not overshoot the destination when it is carrying maximum
load.
Figure 10.6 Deceleration from top speed with the Speed # Distance correctly adjusted.

Figure 10.7 Deceleration from top speed with the Speed # Distance set too short.
Testing Top Speed

After the speed steps have been implemented it is time to determine the Top Speed.
Go to the Top Speed Determination screen, [Alt] + [P] + [2]
For information on using the Top Speed Determination, see Top Speed on
page 10.17.
From the Top Speed Determination screen, adjust the top speed in mm/s that the
vehicle travels. This is done by selecting the maximum speed level, estimate the
actual Top speed and adjust the actual Top Speed value to the estimated.
Remember that this is a filtered value and takes a few seconds to stabilize.

10.6.5 Optimizing Velocity Failure Level

It is now time to adjust the Failure Level from the Control Parameter screen. This
data controls when the system shuts down because of Motor Failures. Once your
system is operational, it should consistently travel at the same velocities. It is often
fair to assume that if the vehicle’s velocity deviates at different speeds from what it
attained at start up, the system has in some way degraded. You may wish to have the
BCS algorithm stop the vehicle’s motion at this point, and in some manner indicate
to an operator that there is something wrong with the system he or she is working
with.
The Failure Level is the point of deviation from any of the vehicles different
velocities that the BCS algorithm shuts down your system. For example, if top
speed is found to be 1000 mm/s and the Failure Level is set to 10% of Top Speed,
the BCS algorithm will shut down operation at either 900 mm/s or 1100 mm/s. The
same would hold true for any other speed operation. Previously, this value has been
set quite high so that BCS algorithm operation may be initialized. Once the system
has been configured this safety and system performance feature should be
implemented.
From Control Parameter setup slightly lower the Failure Limit. Use the
Over/Undershoot test to cycle the vehicle back and forth. If a Motor Failure appears
on the screen, raise the Failure Level in Control Parameter setup. If a Motor Failure
does not appear, lower the Failure Level in Control Parameter setup menu until a
Motor Failure is detected. At this point raise the limit by approximately 20%.
This should be done for no load and full load situations. If motor failure problems
become a nuisance during normal BCS algorithm operation, raise this limit until the
problem goes away. Caution should be taken that this limit is not set so high as to
cause risk of injury to any plant workers, or to damage the equipment that the ICS
5000 is controlling.
C Warning – The Velocity Failure Level is incorporated into the BCS algorithm as a
safety feature and should not be ignored.
For information on Motor failure diagnostic, see Appendix A, Commands and

Diagnostics.
Brake/Start Delay
If the previous tests have shown problems with the brake releasing before the
acceleration starts, then the Brake/Start Delay field can be used to configure a delay
time between releasing the brake and the ramping of the analog output.
10.6.6 Finalizing the Configuration

After making sure the vehicle can travel properly according to the previously
described procedure. Save the parameters and use the use the Random Moves Test to
measure the settling time and move times, verifying they are meeting the design
requirements of the installation. For information on using the Random Move test,
see Random Moves on page 8.7.


CHAPTER
11
PDM Control Algorithm
Configuration 11
In this chapter:
• Introduction
• PDM Parameters Tab

11.1 Introduction
This chapter covers the configuration of the PDM (feedback only) control algorithm
in the ICS 5000. See Chapter 7.4, PDM Algorithm - Feedback Only and Collision
Avoidance on page 7.5 for information on the theory of operation of this algorithm.

The integration of the ICS 5000 as a Programmable Distance Meter (PDM) should
be approached with a more traditional state of mind. The PDM algorithm turns the
ICS 5000 into a pure positioning sensor that is primarily responsible for keeping
track of the absolute position of the vehicle. Some additional features have been
integrated to extend this scope of operation of the PDM algorithm (such as Collision
Avoidance support and Velocity and Acceleration monitoring), however the basic
application is still position feedback.
Figure 11.1 System Integration
Following table contains a brief summary of the ICS 5000 PDM algorithm error
handling responses. Also included in this listing is a suggestion as to how the PLC
should react once the error reported. For more detailed information on error
generation please see Commands and Diagnostics, page A.I.
Table 11.1 PDM Algorithm Error Handling Responses
Fault PDM Actions PLC Response
Loss of Data • Reports status of E 2 when polled by Ramps vehicle down
(Beam Break PLC. to zero speed and
declared). then opens Brake
contact. Retry move.
If data loss continues
then check alignment
of unit.
11 . 2 ICS 5000 Support Software User Manual

PDM Control Algorithm Configuration 11
Table 11.1 PDM Algorithm Error Handling Responses

Fault PDM Actions PLC Response
Warming Up • Reports status of E 32 when polled by Retry command for
he PLC. up to 10 seconds
upon first power up.
by he PLC. command then
check for status to
change.

To configure the ICS 5000 to use the PDM algorithm, select PDM from the
Algorithm section of the Control Options screen. The following sections provide
information on the I/O pin configuration for the PDM algorithm.
C
5000 Support Softwareerase the current setup.


The different main functions supported in the PDM algorithm are shown in
Table 11.2. The PDM algorithm does not support any sub versions as the other
control algorithms.
Table 11.2 PDM System Configuration Overview
Sub Version Selected Option I/O Functions
PDM Collision Avoidance Controlled slowdown, controlled halt and
System controlled emergency stop relay functions.
Monitoring Not applicable
Monitoring output via Analog output (configure signal from -10 to
Analog signal +10VDC). with one relay for status indication.
relay input used for system synchronization is a 24 Volt DC/AC coil. See the ICS
5000 Installation Manual for more information on output specifications.
configurations are explained in detail in the following paragraphs. The control I/O
performs the following functions:
Table 11.3 PDM Collision Avoidance I/O Configuration
I/O Name Description I/O Functions
3&4 Controlled Slow Normally closed contact Controlled slowdown and
Down (OUT1) that opens to indicate controlled halt relay
a controlled slow down. functions.
9 & 10 Controlled Halt Normally closed contact Controlled slowdown and
(OUT4) that opens to indicate controlled halt relay
a controlled halt. functions.
5&6 Emergency Stop Normally closed contact Controlled slowdown and
(OUT2) that opens to indicate controlled halt relay
an emergency stop functions.
PDM Configuration Codes


character set.

The sampling frequency (samples/sec. or Hz) in the IDM (Industrial Distance
Meter) inside the ICS can be configured during the set up. The available sampling
frequencies are: 19.35, 30.58, 49.32 and 69.50 Hz with the default being 30.58 Hz
(the old TCS/BCS/PDM system 4000 uses 30 Hz). If ICS 5000 is used as a
configure the parameters.
For information on configuring sampling frequency in Support Software, see
Sample Rate on page 3.5.
11.3.3 Filter Selection

The default Digital Filter values use by the PDM algorithm can be fully user
configured. There are three standard filters and one user defined filter to select
between.
• Small Filter - Standard filter with a smoothing by 4 samples for position,
velocity and acceleration.
• Medium Filter - Standard filter with a smoothing by 12 samples for position,
• Large Filter - Standard filter with a smoothing by 36 samples for positioning,
• User Defined Filter - Allows individual configuration for positioning,
velocity and acceleration filter parameters.
All filters are of the smoothing by N type. This means they are non-recursive with
all coefficients of equal magnitude. This type of filter has the best noise
performance of any non-recursive design. This filter is chosen by specifying n the
averaging window.

A large N implies much filtering; an N of one implies no filtering. Table 11.4 shows
the N values for the standard filters. It’s important to keep N as small as possible to
avoid unnecessary time delays in the data.
Table 11.4 PDM Standard Filters
Type Smoothing by ‘n’ value Operating Mode
Small 4 samples 4 4
Medium 12 samples 12 8
Large 36 samples 36 12
When N is the same for Position, Velocity and Acceleration, the delays introduced
by the individual filters match. This means Position, Velocity and Acceleration
measurements coincide with each other in time. However, the peak-to-peak noise
increases from Position to Velocity and Velocity to Acceleration.
The Velocity filtering is similar to the Position filtering except that the averaging
window is divided in half. Two running averages (one on the first half and one on
the second half) are used to compute Velocity. The Acceleration filtering makes four
running averages and computes Acceleration from the four positions.
For example: If the Position filter is smoothing by four samples, every X value (for
distance) you get will be the average of the four most recent readings. Velocity and
acceleration work the same way but are scaled to make the units come out in
mm/sec. and mm/sec2.
For information on selecting filter in the Support Software, see Digital Filters on
page 11.21.
User Filter
The User Filter is configured by specifying N individually for Position, Velocity and
Acceleration. If this is done, the time lag between Position, Velocity and
Acceleration readings must be considered as they will depend upon the individual n
value and could be different.
For example: a common user filter has N=10 for Position, 20 for Velocity and 40 for
Acceleration. The peak-to-peak noise is about the same but the delays are very
different. For this example, the filtered Position is five samples old by the time its
received. The Velocity data is 10 samples old and the Acceleration data is 20
samples old. If you would like the readings to coincide in time like the standard sets
then Position must be measured, wait five samples, measure Velocity, wait 10
samples and then measure Acceleration. For information on configuring user filter
in the Support Software, see User Filter on page 11.22.

11.3.4 Collision Avoidance

The PDM algorithm can also be configured to work as a collision avoidance system.
It can be used between different vehicles working on the same aisle, see Figure 11.2,
or on manually controlled vehicles to avoid running outside an allowed travel zone.
Figure 11.2 Collision Avoidance Overview
The PDM algorithm’s Collision Avoidance system is unique in that it uses relative
velocity along with vehicle proximity to determine if a collision is possible. The
allowable minimum distance between vehicles based upon the velocity at which
they approach each other. This permits correctly operating vehicles to ramp down to
within a few feet of each other without causing a fault. Output relays are configured
to insure that the approaching vehicles that exceed the velocity at a given distance
are forced to first Slowdown to correct the problem. If this does not succeed, a
second relay will instruct the vehicle to preform a controlled Halt. Finally, if all else
fails, a third relay will drop out the emergency stop circuit disabling the drive.
Collision Avoidance Operation Description

The Collision Avoidance system uses the first six stations in the look-up table for
configuring the Collision Avoidance outputs, see Figure 11.3. Stations 3 & 4 control
the Controlled Slowdown Zone output, stations 2 & 5 control the Controlled Halt
Zone output and stations 1 & 6 control the Emergency Stop Zone output. The
stations are configured as minimum and maximum distances using the Support
Software. Configuring the stations for the zones in the Support Software is simple,
just enter the minimum and maximum distance for the zones, or move the vehicle to
one of the distances and register it. For more information, see Minimum Distance
and Stopping Acceleration, page 11.17.

Note – More than six stations may be defined, however the first six will be used for
Collision Avoidance.
Figure 11.3 Collision Avoidance Zone Overview
The layout of the six stations in Figure 11.3 depicts the algorithm’s use on one
vehicle moving between two fixed objects, such as walls, with operation based
purely on distance (all Acceleration values set at the max value of 999,999). The
End of Travel distance at each end is a point just inside the wall that is still safe to
travel to with the vehicle. As the vehicle approaches each End of Travel (or wall in
this example) it will pass through the various zones. If the algorithm is applied to
two vehicles, then only the first three stations are really used as the distance
between the vehicles is always relative to their position, thus the far End of Travel
point is not clearly defined.
Once the estimated stopping position exceeds the safe operating zone (less than
Station 3 or more than Station 4) the Controlled Slowdown contact will open. If it
exceeds the Controlled Slowdown Zone (less than station2 or more than station5)
the Controlled Halt contact will also open. If it exceeds the Controlled Halt Zone
(less than station 1 or more than station 6) the Emergency Stop contact will open i.e.
all three will be open. The slower the machine approaches one of these stations, the
closer it can get before the relays will open.
For information on the I/O connector pin configuration for these outputs, see
Table 11.2 on page 11.4.
Table 11.5 PDM Collision Avoidance Zone Configuration
Zone Station # PDM Operation
Safe Operation Between 3 & 4 All contacts are closed. Normal operation
Controlled Outside 3 & 4 Sync. contact opens. This closure can be wired
Slowdown directly to PLC to ramp the crane down to a lower
velocity
Controlled Halt Outside 2 & 5 Sync. and fwd/reverse contacts are open. PLC
sends halt or stop command to the crane. Wire to
Brake contact.
Emergency Stop Outside 1 & 6 All three contacts are open. E-Stop condition to
motor drive. Wire to Safety contact.
The previous diagram in Figure 11.3 and Table 11.5 help to illustrate the operation
and setup of the stations for the PDM collision avoidance.

Basic Acceleration / Velocity Profile Setup

Once the zones are set-up, the vehicle’s operating parameters must be entered. The
time it takes the vehicle to react to a stopping command shall be determined. This
value is defined as the vehicles Reaction Lag Time.
Configuration of the Collision Avoidance outputs must also take into consideration
other aspects of the vehicle's performance (Velocity and Acceleration). If the
vehicle is approaching the Minimum Distance, but decelerates to a stop without
entering the Controlled Slowdown Zone, then all the contacts will remain closed.
See Figure 11.4 for a graphical representation of this concept.
As long as the distance and velocity measured by the ICS 5000 are with in the
appropriate operating zone, the corresponding contacts will remain closed.
Basically, the lower the approaching velocity, the closer the vehicle can get to the
Minimum Distance without opening any contacts.
Figure 11.4 Zone Setup
If the plane between the Safe Operating Zone and Controlled Slowdown Zone is
broken (velocity at specific distance exceeded), then the Controlled Slowdown
phase will be initiated. If that is not effective and the next plane is broken then the
Controlled Halt phase is initiated. Finally, if all else fails and the vehicle enters the
Emergency Stop Zone the Emergency Stopping condition is activated. This
illustrates why it is important to setup the Acceleration values and the Lag Factor
accurately. If more stopping time is required than was anticipated, then the vehicle
will overshoot the Minimum Distance station.
B
Tip – Its important to configure the acceleration values such that the Emergency Stop
Zone contact is associated with the highest value.
Multi-Vehicle Acceleration / Velocity Profile Setup

When configuring the acceleration values and stopping distances for two vehicles,
some special considerations need to be taken into consideration:

1. The worst case stopping distance occurs when all of the closing speed is due
to one vehicle. For example:
Stopping Distance = V2/(2*A) or 30002/(2*500) = 9000 mm if the relative
velocity is 3000 mm/sec and the acceleration is 500 mm/sec2.
2. While the relative velocity for two approaching vehicles is doubled, so is the
effective acceleration rate. Unfortunately, the ICS 5000 has no way of
determining the source of the velocity (if both vehicles or only one is
moving), and is therefore unable to safely take advantage of the higher
acceleration. With this in mind, the calculation for two approaching vehicles
would be:
Stopping Distance = (V2/(2*A) or 60002/(2*500) = 36000 mm if the relative
velocity is 6000 mm/sec. (each vehicle at 3000 mm/sec.) and the acceleration
is 500 mm/sec2.
3. In order for the Collision Avoidance algorithm to safely protect against all
collisions, alarms will be issued prematurely as two vehicles approach each
other. In the examples given in the previous points, one vehicle can safely
stop in 9000 mm, but the Collision Avoidance algorithm determines that the
two vehicles approaching each other require 36000 mm instead of just twice
the individual vehicle stopping distance (18000 mm). Because of the higher
velocity, all operating zones will be entered sooner.
The equations used to predict the position at which the PDM algorithm needs to
open the respective relays are as follows:
BRAKE = [S 1 < (SP1 ≈ TP + K*V + V2 /2A1) < S 6]
FWD/REV = [S 2 < (SP2 ≈ TP + K*V + V2 /2A2) < S 5]
SYNC = [S 3 < (SP3 ≈ TP + K*V + V2 /2A3) < S 4]
Table 11.6 Stopping Position
Variable Description
S# Distance in mm related to that specific station. Stations 1-6 need to be set
up as shown in the previous diagram.
SPn Calculated stopping point in mm. This value is compared to the Sn.
TP True position read from distance meter.
K Velocity lag factor in sec. entered by user from Modify Menu in setup
software.
V Sampled velocity in mm/sec. read from distance meter
An Acceleration rate entered by user.
Brake Open brake circuit. (Closed = ready to run.)
FWD/REV Open fwd/rev circuit. (Closed = ready to run.)
SYNC Open sync. circuit. (Closed = ready to run.)
11 . 1 0 ICS 5000 Support Software User Manual

A Hysteresis value can be programmed into the algorithm to deal with vehicles re-
entering into a zone as depicted in Figure 11.5 that follows.
Figure 11.5 Collision Avoidance Output Operation
As the vehicle moves towards “S 4” the state of the circuit stays closed until the
exact distance is reached. As the vehicle moves back away from “S 4” it must move
past “S 4” a distance equal to the Hysteresis value before the reset occurs.
The Hysteresis value should be kept as small as possible. Some experimentation
may be required before an optimal value is obtained.
The collision avoidance Acceleration values, Hysteresis and Lag Factor are all
entered via the ICS 5000 Support Software. For information, see Collision
Avoidance on page 11.16.
Beam Break Handling for Collision Avoidance Zones

The relays used in the Collision Avoidance system can be configured in one of three
ways to respond on Beam Breaks and Auto-Calibrations, see Table 11.7. Level 1 is
the most sensitive, the relays will open as soon as the measurement beam is
interrupted while Level 3 ignores interruption of the measurement beam. For
information on how to configure each relay’s response to Beam Breaks and Auto-
Calibrations, see Collision Avoidance Relays Output, page 11.16.
Table 11.7 Collision Avoidance Zone Beam Break Handling
Zone Number Error Handling - Relay Outputs
Level 1 The relays open as soon as the measurement is interrupted. It means
that the relay will open even on a short beam break (before the I value
is exceeded) or during an auto-calibration.
Level 2 The relays only open if the beam break to ignore value has been
exceeded.
Level 3 This choice has no sensitivity at all for beam breaks, the relays will only
react if the PDM can measure the distance and the vehicle are at the
desired position for opening or closing a relay.
Note – This Level is dangerous because if the PDM is blind it is a risk
for collision, but it can be necessary to use in installations with
frequent Beam Breaks.

Filter Setup Precautions

During setup some considerations need to be made when sizing filters for the
various feedback parameters. The filter that has the largest effect on the collision
avoidance equation is the Position Filter. If this filter is increased beyond a nominal
value of 1, the Response Lag constant then must be increased accordingly. Each
sample addition to the filter value adds approximately 1/60 second delay to the
Response Lag.
The Velocity Filter also effects the Response Lag constant, however, not as greatly
as the Position Filter. This filter needs to be kept as small as possible with a
recommended upper value of 10. A good rule of thumb is to evaluate the stopping
consistency of the vehicle with your filter settings and adjust the Response Lag to
correct for any errors. For information on selecting a filter value, see Filter Selection
on page 11.5. For information on configuring filter in the Support Software, see
Digital Filters on page 11.21.
11.3.5 Analog Output

The PDM algorithm can be configured to use the analog output signal to indicate
current Position, Velocity and/or Acceleration. The analog signal can be between 0
to ± 10 VDC. The analog output changes in response to Position, Velocity and
Acceleration according to a formula involving the position_gain, velocity_gain and
acceleration_gain parameters. For example: a pure position output can be obtained
by setting the position_gain to a non-zero value and the other two gains to zero.
The formula for the analog output voltage is:
Voltage = pos_gain * (position - user_offset)
+ vel_gain*velocity
+ accel_gain*acceleration
The resolution of the output signal is 2.5mV. Beam Breaks and Auto-Calibrations
can be indicated with the Sync output relay. The relay opens if the data is not fresh.
Note – If the Sync output relay is going to be used for indicating Beam Breaks and
Auto-Calibrations, the corresponding Collision Avoidance parameters and Stations
must be configured.
For information on configuring the Analog output in the Support Software, see
Chapter 11.4.3, Analog Output on page 11.19.

The PDM algorithm supports the modes listed in Table 11.8. The Mode codes are
bit mapped. This means that each unique mode has it’s own bit. If two or more
different modes are desired, send the summation of the individual modes. For more

information on configuring the modes using the ICS 5000 Support Software, see
Wakeup Mode on page 11.22. For information on configuring filters, see Digital
Filters on page 11.21.
Table 11.8 PDM Algorithm Modes
M Number Mode
The PDM can send a warning for beam breaks when half the I value is
exceeded.
break. # =0 mean no warning.
The total status on a travelling vehicle (status 8) with a beam break
warning will be: 2 * 256 + 8 = 520
2 Enable reporting status on auto-calibration (E 64) to be sent with the status
information.
passed.
status is 8 and the time is less than half to next auto-calibration, the status
will be: 64 * 256 + 8 = 16392.
4 Enable Small type of standard filter for position, velocity and acceleration
readings.
8 Enable Medium type of standard filter for position, velocity and acceleration
readings.
12 Enable Large type of standard Standard filter for position, velocity and
acceleration readings.
If beam is broken, position data (X & Y) responses will be withheld until the

page A.I.
For PROFIBUS-DP, DeviceNet, DF1 and MODBUS protocol information, see
For information on different Filters, see Filter Selection, page 11.5.
ICS 5000 Support Software User Manual 11 . 1 3

11.4 PDM Parameters Tab

[Alt] + [P]
When the PDM algorithm’s has been selected, then the PDM Parameters tab is
shown. The PDM Parameters tab (shown below) contains all the parameters used to
configure the operation of the PDM algorithm to match your applicaiton.
The PDM Parameters tab contains links to the following screens:

• Beam Breaks
• Collision Avoidance
• Analog Output
• Digital Filters
• Wakeup Mode
11.4.1 Beam Breaks

[Alt] + [P] + [1]
The Beam Breaks screen (image that follows) allows you to modify the methods
which the PDM algorithm uses to deal with Beam Breaks (data losses). The first
parameter is the Maximum Expected Velocity which is used to control the maximum
number of Beam Breaks to ignore. The next parameter, Number of Beam Breaks to

Ignore, determines the PDM’s sensitivity to Beam Break faults. Finally, the
Collision Avoidance Relay Outputs group allows Collision Avoidance users to
configure the relays reactions to Beam Breaks.

page A.I.
Maximum Expected Velocity

Use the Maximum Expected Velocity field to enter the maximum expected velocity
the vehicle will be able to achieve. The PDM algorithm’s tolerance of Bad data
samples depends on the maximum velocity of the vehicle. This parameter is crucial
to insure that the PDM will not be blind enough to lose track of the actual position
(sampling errors).
Note – As mentioned in the screen, if the PDM is a set up for a Collision Avoidance
System with two cranes, the Maximum Expected Velocity parameter must reflect the
speed of both cranes.

The I number for maximum consecutive bad samples to Ignore is calculated from
the Maximum Expected Velocity. It is based on the time it takes the vehicle to travel
2.4 meters at full speed. When this number is exceeded, the PDM algorithm will
issue a Beam Break fault status message and require a new absolute measurement.

Collision Avoidance Relays Output

Use this group to configure the reactions of each of the Collision Avoidance System
relays to Beam Breaks. The relays can be individually configured to react in one of
three different ways.
Select the Level matching the application to be controlled.
B
Tip – A combination of the three levels can be a good point to begin testing.
- Level 1 for Controlled slow down zone
- Level 2 for Controlled Halt zone
- Level 3 for Emergency Stop zone
For additional information on the different levels, see Beam Break Handling for
Collision Avoidance Zones, page 11.11.
11.4.2 Collision Avoidance

[Alt] + [P] + [2]
Use the Collision Avoidance screen (shown below) to configure the operation of the
Collision Avoidance system. From this screen adjustments are made to the Travel
Zones, Stopping Acceleration Time, Reaction Lag and, if required, Hysteresis.

Configuring a Collision Avoidance system requires the setup of 6 stations (1 to 6)

for the zone information. If this is the first time entering this menu, and the required
six stations have not yet been configured, the following message is displayed.
Click YES to automatically configure the first six stations (the operating zones) for
the Collision Avoidance System. Click No if this screen was entered by mistake or if
you prefer to configure the stations using the Stations tab.
Answering yes will set the Minimum Distance to 0 mm and the Maximum Distance
to infinity for the zones (stations).
Minimum Distance and Stopping Acceleration

Configuring the Collision Avoidance zones can be done by entering the values for
Minimum and Maximum Distances or by measuring the position of the distances.
To measure the distance, move the vehicle to the desired distance, then measure the
distance double-clicking the appropriate Distance mm field. The current position
will be measured and put into the selected field as a Minimum or Maximum Distance
value.
Note – If this is a crane-to-crane installation, the Maximum Distance can be left at
infinity.
Next enter the estimated Stopping Acceleration for all three zones.
In a normal setup the Brake relay is used for the Emergency stop zone, Fwd/Rev for
the Controlled halt zone and Sync is used for the Slow down zone.
C
Warning – The Stopping Acceleration value for the Emergency Stop (Brake relay) must
be low enough to provide enough distance to stop with.
The current status for each relay is indicated by the three circles to the right of the
parameters. A vehicle outside a zone is indicated with red circle, inside a zone is
indicated with green circle.In the above example the one red circle indicates that the
Brake relay is open, meaning the position of the vehicle is outside the Safe
Operating Zone. The remaining two green circles indicate that the vehicle is inside
the Controlled Slowdown Zone. The actual Position of the vehicle is shown in the
bottom left side of the screen. For information on the relays status, see Table 11.5 on
page 11.8.

For information on the I/O connector pin configuration for these outputs, see
Table 11.2 on page 11.4.
Note – Do not forget to configure the relays reaction to Beam Breaks and Auto-
Calibrations, see Collision Avoidance Relays Output on page 11.16.
Reaction Lag and Hysteresis

The vehicles Reaction Time Lag is entered in the Reaction Lag field. A Hysteresis
distance can be configured if required before indicating that the vehicle is back in
the zone.
B
Tip – A typical Reaction Lag value is 0.5 sec.
For information on Hysteresis, see Collision Avoidance Output Operation,

page 11.11.
Crane-to-Crane
If setting up a Crane-to-Crane Collision Avoidance system, click the
button to set the Maximum Distance back to infinity.
The following warning appears before the change takes place.
Select Yes to change the settings to a Crane-to-Crane setup, click No to get back to
the old values.
Velocity Independent
If you choose not to use the Velocity when calculating stopping distances, click the
button to set the Stopping Acceleration to infinity and the Reaction
Lag to zero.
The following warning appears before the changes take place.
Select Yes to change the settings to a Velocity Independent setup, click No to restore
the old values.

Disable the Collision Avoidance Configuration

The Collision Avoidance Setup can be disabled. A click on the button
disables the configuration.
The following warning appears before the Collision Avoidance Settings are
Disabled.
Select Yes to disable the settings, click No to restore the old values.
11.4.3 Analog Output

[Alt] + [P] + [3]
Use the Analog Output screen to configure the scaling of the analog output to
accurately indicate Position, Velocity and Acceleration. The analog output changes
in response to a formula involving position_gain, velocity_gain and
acceleration_gain. The resolution of the output signal is 2.5mV. Beam Breaks and
Auto-Calibrations can be indicated with the Sync output relay. The relay opens if
the data is not fresh.
The slider in the bottom of the screen indicates the current analog output value.
B
Tip – Do not forget to adjust the filter settings to match the application. Noise in the
measurements will affect the analog output signal.
B
Tip – Ignore this screen if not using the analog output.

POS_GAIN Calculator
The POS_GAIN can be calculated with the help of the POS_GAIN Calculator.
Enter the minimum required voltage in the Minimum volts field. Enter the minimum
position in the Minimum mm fields. Enter the Maximum position to be measured in
the Maximum mm field and enter the maximum required voltage in the Maximum
volts field.
Note – Entering values in the Minimum field puts an Offset value in the unit.
Calculate the new POS_GAIN value by click the button. The calculated
POS_GAIN value is shown in the POS_GAIN field.
ACCEL and VEL_GAIN Calculator

The ACCEL_GAIN and VEL_GAIN can be calculated with the help of the ACCEL
and VEL_GAIN Calculator. Select VEL_GAIN or ACCEL_GAIN and enter the
maximum velocity/acceleration in the Maximum field.
Select the parameter to calculate (VEL_GAIN or ACCEL_GAIN) and in the

Maximum field, enter the maximum velocity or acceleration. Calculate the selected
gain by click the button. The calculated value is shown in the VEL_GAIN
field or ACCEL_GAIN filed in the Output Gains group.
Output Gains
The Output Gains group shows the gain values for Position in the field POS_GAIN,
Velocity in the field VEL_GAIN and Acceleration in the field ACCEL_GAIN.
The different gain values can also be entered directly in the fields.
Note – The slider shows the actual value of the analog output from the ICS 5000
and will not be updated until the new parameters are written to the unit.

11.4.4 Digital Filters

[Alt] + [P] + [4]
The Digital Filters screen allows you to configure the filters for Position, Velocity
and Acceleration readings. The filter is a simple running average on the distance
meter measurement. Four different sets of filter are supported. Three pre-defined
filters are supported, Small, Medium, Large and one User filter with individual
configuration for the filtering of Position, Velocity and Acceleration readings.
The measuring result with different filter and sampling frequency settings are
shown in the Measured Values and Peak-to-peak Noise groups. This result can be
used for configuring proper settings of filters to match your specific installation
needs.
Note – The result from a change in filter settings, is shown in the groups as soon as
the new settings are written to the PDM unit.
The Measured values group shows the PDM’s Position, Velocity and Acceleration
readings.
The Peak-to-peak Noise group shows the noise in the Position, Velocity and
Acceleration readings.
Note – If a Collision Avoidance system is used, some considerations need to be

taken when sizing the filters for the various feedback parameters. For information,
see Filter Setup Precautions, page 11.12.
Its important to be aware of the consequences different filter settings can have on
the measuring result. For information on different filters characteristics, see Filter
Selection on page 11.5.

User Filter
The User Filter allows you to define the filter characteristics for Position, Velocity
and Acceleration readings. This is configured in the three fields shown below.
Configuring the User Filter is simple, just enter the N value for position readings in
the Position Filter field. Enter the N value for velocity readings in the Velocity Filter
field and the N value for acceleration readings in the Acceleration Filter field.
For detail information on User Filter settings, see User Filter on page 11.6.
11.4.5 Wakeup Mode

[Alt] + [P] - [5]
The Wake-up Mode screen (shown below) allows you to modify the basic
operational modes of the PDM algorithm including: enable Warning Codes, report
Auto-Calibration and Wait for Good Data. For information on the different PDM
algorithm modes, see Table 11.8 on page 11.13 or the following sections.
B
Tip – By default after a configuration Mode 0 is used. (Warnings off, calibrating info off and
Waiting for good data off.) Mode 0 or one of the filter modes are the most commonly used
modes for the PDM.
Mode 1 Warnings
controller know when a Beam Break warning occurred (this is a rarely used
feature). Adds 1 to the MODE sum. For protocol information, see Table 11.8 on
page 11.13.

Mode 2 Calibration
2 to the MODE sum. For protocol information, see Table 11.8 on page 11.13.
Mode 16 Wait
measurement beam is broken. Adds 16 to the MODE sum. For protocol
information, see Table 11.8 on page 11.13.
11.4.6 Finalizing the Configuration

After making sure the vehicle can be monitored. Save the parameters and, if the
Collision Avoidance system is configured, test the zone reaction and the resulting
stopping distance to insure proper operation.
B
Tip – For Collision Avoidance, test one zone reaction at a time to isolate the configuration
for each one, then test all three together to insure they react correctly.


APPENDIX
A
Commands and Diagnostics A
In this appendix:
• Introduction
• ACK/NAK
• Special Characters
• Commands and Responses
• Single or grouped Commands
• Status Codes
• Warning Codes
• Diagnostic Commands
ICS 5000 Support Software User Manual A.I

1 Commands and Diagnostics
A.1 Introduction
With the standard configuration, communication between the ICS 5000 and the PLC
is carried out using a command set of ASCII characters. Remember that the ICS
5000 only responds to capital letters. All commands listed must be followed by a
postamble (default = carriage return), or a postamble/line feed combination. Insure
that each command used, and it’s expected response, is allowed for by the I/O driver
routine.
In general the minimum number of commands should be used. It is possible to build
a successful command set with only the “E” (Status code) and “D” (go to a
destination in millimeters) commands, but transmission errors and time-outs would
then not be handled.
In addition to the standard ASCII character protocol the system can be configured
for Modbus, DF1 DeviceNet, PROFIBUS or INTERBUS. These special protocol
versions also allow the ASCII protocol to be used for the ICS 5000 Support
Software to communicate with the ICS 5000 from the PC.
Note – DeviceNet, PROFIBUS, INTERBUS, Modbus and DF1 configuration is
described in Advanced Communications Configuration on page 5.1 of this manual.
A.2 ACK/NAK
During ASCII communications, the ICS 5000 responds by returning the requested
information (distance for example) or by sending back the acknowledge (ACK)
character to confirm that the last command was received successfully. The
acknowledge string is sent immediately after a “D” or “S” command is received by
the ICS 5000. If the transmission of data is unsuccessful, the ICS 5000 will respond
with a not acknowledge (NAK) character requesting re-transmission.
The ICS 5000 can also be programmed to send a NAK message when there is too
much time between characters. To turn on the feature, select NAK Slow Messages
from the ASCII Options -User Settings screen ( [Alt] + [M] + [8] ).
A.3 Special Characters

Understanding the following special characters will be helpful during the
development of your communications driver.
Table A.1 ICS 5000 Special ASCII Characters
Command ASCII Symbol Function
Value
Acknowledge (ACK) 6 ♠ Indicates successful transmission of data.
A user defined sequence of up to 3
characters can be used instead.
Backspace (BS) 8 BS Deletes last character sent (except
postamble).
Carriage Return 13 CR Indicates end of transmission.
<CR>
A.II ICS 5000 Support Software User Manual

Commands and Diagnostics 1
Table A.1 ICS 5000 Special ASCII Characters

Command ASCII Symbol Function
Value
Not Acknowledge 21 § Request re-transmission of data. A user
defined sequence of up to 3 characters
can be used instead.
Escape (ESC) 27 ^ Aborts Q, W and Z commands and
pending X and Y (“wait for good data”)
commands if it is necessary to perform
some operations immediately such as H
(Halt).
Semi-Colon (;) 59 ; Separates multiple commands transmitted
with only one carriage return. No (;) must
follow the Escape <ESC> character.
NUL (not ASCII 0 = 0 Can be inserted in commands whenever
48) needed (i.e. If a certain number of
characters are necessary in a PLC).
A.4 Commands and Responses

Table A.2 that follows contains all of the ASCII command characters and their
expected response when sent to the ICS 5000. Use these commands from a terminal
program or in the communications driver you develop for your PLC or Host
controller. Note that some of these commands have different meanings or do not
apply depending upon which control algorithm you are using - TCS, BCS or PDM.
Table A.2 ASCII Commands and Responses
Command TCS BCS PDM Description
Response Response Response
A A# N/A A# Operating Acceleration

For the TCS this command returns the working acceleration
limit set in the ICS 5000 where # is the limit in mm/sec2. This is
not necessarily the maximum allowable value.
For the PDM, this command returns the actual acceleration in
mm/sec2.
A# ♠ N/A N/A Operating Acceleration
Sets the working acceleration limit where # is the new limit in
mm/sec2. If a number greater than the maximum is entered,
the maximum will be used.
A value entered in this manner is only temporary and will be
replace by the Wake-up Value when power is turned off or the
unit is reset.
BT Resets Resets Resets Boot
Unit Unit Unit Use the BT command to reset the ICS 5000. This is not
desirable under normal conditions, as this will cause a 5 to 15
second delay before the unit is capable of measuring again.
D D# D# D# Distance Destination
Returns the last destination to which the ICS 5000 was
commanded to move. Distance (#) is measured in mm.
ICS 5000 Support Software User Manual A.III


D# ♠ ♠ ♠ Distance Destination
Commands the ICS 5000 to move to an absolute value of #
millimeters from the target. For the TCS and BCS this
command will cause motion. For the PDM, this command just
triggers a status change from E 8 to E 16 at the value entered.
E E# E# E# Status
Returns the current status of the ICS 5000 units. See Status
Codes on page A.VII for more information.
F F# F# F# Sampling Frequency
Reads the current sampling frequency # of the ICS 5000 in
hertz.
H1 ♠ ♠ ♠ Halt
Causes the ICS 5000 to ramp the analogue output signal to 0
VDC at the working acceleration rate and stop trying to control
the machine.
Note – Note: Two types of Halt modes can be used for
the TCS algorithm. Normal Halt and Simple Halt.
Simple Halt is configured by selecting Mode 128 for the
TCS.
H #2 ♠ N/A N/A Halt Acceleration
Causes the ICS 5000 to ramp the analogue output signal to 0
VDC at the acceleration rate entered (#) in mm/sec2
The value entered can exceed the maximum value established
during the Characterization and could cause the vehicle to
skid.
I I# I# I# Beam Breaks to Ignore
Returns the working number (#) of “Bad data samples to
Ignore” before declaring a Beam Brake Error. If RETRY>0 the
RETRY # multiplied by 256 is added to the working I-number.
I# ♠ ♠ ♠ Beam Breaks to Ignore

Sets the working “Bad data samples to Ignore” limit where # is
the new limit. If a number greater than the maximum is
entered, the maximum will be used.
unit is reset.
J J# J# J# Diagnostic Array
Reads data from diagnostic register. Used in combination with
the U command. See Diagnostic Codes.
K K# K# K# Internal Path Strength

Returns the percentage of signal received by the internal path.
Working values will be between 30 and 90 percent.
M M# M# M# Operating Mode
Read the Operating Mode of the ICS 5000 units.
M# ♠ ♠ ♠ Operating Mode
Sets the working mode to #. See the description of the Mode
command in the Operational Modes section later in this
chapter.
replaced by the Wake-up Value when power is turned off or the
unit is reset.
A.IV ICS 5000 Support Software User Manual


N N# N# N# Next Station
Reads the closest station number that can be stopped at.
O O# O# O# Measurement Offset
Reads the current measurement Offset # in millimeters.
O# ♠ ♠ ♠ Measurement Offset
Sets the working measurement offset where # is the new offset
in millimeters.
unit is reset.
Q Q# Q# Q# Command Queue
Reads the Queue distance to suspend a command from
processing.
Q# ♠ ♠ ♠ Command Queue
Sets a Queue distance.
R R ## R ## R ## Return Signal Strength
Reads percentage of signal returned from target.
This command will disrupt the measurement process and
automatically ramp down to a stop and sets the Operating
Mode to 1 (halted). Should not be used while the vehicle is in
motion.
RON R# R# R# Return Signal Strength
Polls percentage of signal returned from target from the ICS
5000 at the sampling rate. This command is helpful when
aligning the unit. See note above for R.
S S# S# S# Station Destination
Returns last station to which the ICS 5000 was commanded to
move.
S# ♠ ♠ ♠ Station Destination
Commands the ICS 5000 to move to the entered station (#). If
no stations have been established the resulting response will
be an E 0. For the TCS and BCS this command will cause
motion. For the PDM, this command just triggers a status
change from E 8 to E 16 at the station entered.
T T# T# T# Positioning Tolerance
Reads the working positioning tolerance # in millimeters. This
value determines how accurately the ICS 5000 will position the
vehicle. Values entered are +/- #.
T0 ♠ ♠ ♠ Positioning Tolerance
Initiates an auto-calibration (takes less than 1 sec.). If issued
during a move the vehicle will position with the old calibration
value, then re-calibrate and, if necessary adjust the position
and finally declare E 16.
T# ♠ ♠ ♠ Positioning Tolerance
Sets the working positioning tolerance where # is the new
tolerance in millimeters. Values entered are +/- #.
unit is reset.
ICS 5000 Support Software User Manual A.V


U# ♠ ♠ ♠ Array Index Variable

Sets the diagnostic register pointer to the desired (#) value.
See the section on Diagnostic Commands later in this chapter.
V V# V# V# Operating Velocity
Reads the working velocity limit # in millimeters/sec for the
TCS or a number from 1-7 indicating the speed setting for the
BCS.
For the PDM, this command returns the actual velocity in
mm/sec
V# ♠ ♠ ♠ Operating Velocity
Sets the working velocity limit where # is the new limit in
millimeters/second for the TCS or a number from 1-7 indicating
the speed setting for the BCS. If a number greater than the
maximum limit is entered, the maximum will be used.
unit is reset.
W W# W# W# Wait Command
Suspends the execution of any command enter after it until the
completion of the command enter before it.
X X# X# X# Current Distance
Reads the absolute distance # in millimeters from the ICS 5000
units to the target.
Xn X# X# X# Current Distance
Reads the absolute distance # in millimeters from the ICS 5000
units to the target averaged over n number of samples. n can
be any number between 2 and 255
XON X# X# X# Current Distance

Polls the absolute distance # in millimeters from the ICS 5000
to the target at the sampling rate.
Y Y# Y# Y# Station Location
Reads the present station location #. Two formats are
available. In both formats, the Y number returns the station the
machine is at if it is within tolerance of that station.
Format 0 returns a Y-y (y is the closest station #) regardless of
the direction it is off station. This is the default format.
Format 1 adds 10000 to the station location when out-of-
tolerance and the sign implies the direction. For example, -
10005 means the machine's distance is less than station 5,
+10005 means it is greater than station 5.
YON Y# Y# Y# Station Location
Polls the present station location # at the sampling rate. Same
format as for Y.
Z Z SS, Z SS, Z SS, Self-Test

50VVV, 50VVV, 50VVV, Conducts Self-test on unit and returns the result in the
RR.RR, RR.RR, RR.RR, following format:
######## ######## ########
• Z SS, 500VV, RR.RR, ########
• SS = Self-test Code.
• VVV = Version of ICS 5000 program.
• RR.RR = Revision level of ICS 5000 firmware.
• ######## = Serial number of ICS 5000.
A.VI ICS 5000 Support Software User Manual

1The noise filter together with the transient P and D gains act like a low pass filter and reduce the jerk (how quickly the
acceleration changes). This causes the deceleration profile to be rounded on the corners which means the effective or average
deceleration rate is lower than one might expect. There will also appear to be a reaction time delay processing the halt
command. In those cases where the noise filter is high and/or the P and D gains are low, this filtering effect can be very
noticeable. Increasing the deceleration rate helps to stop the machine faster but only up to a point; after that the filtering effects
limits how fast the TCS algorithm will halt the machine. This has been addressed with the Simple Halt feature. Simple Halt is
configured by selecting Mode 128 for the TCS
2
Same as 1 above.
A.5 Single or grouped Commands

Commands can be sent separately with a carriage return <CR> after each one or
they can be sent as a group with only one <CR>. When sent as a group, the
commands must be separated by a semicolon (;) character. Replies will be in the
same format. The maximum grouped message length is 120 characters including
spaces and semicolons.
For example, you can send the following string to the ICS 5000:
E; X; D <CR>
This will read the status followed by the current distance in mm followed by the
destination in mm. You can use this to determine if the move is complete (status)
and once complete by how many mm the current distance varies from the
destination. The response from the ICS 5000 will look like the following:
E 16; X 34567; D34568 <CR>
A.6 Status Codes
A.6.1 Self-Test Results

The Self-Test is conducted automatically by the ICS 5000 Support Software when
initializing communications or anytime a Z command is sent to the ICS 5000. Data
returned from the ICS 5000 unit includes the Self-Test code, Program Version,
Revision Level and Serial Number.
Format
The format of the Self-Test is as follows:
Z SS, 500VV, RR.RR, ########
SS = Self-test Code
VVV = Version of ICS 5000 program
RR.RR = Revision level of ICS 5000 firmware
######## = Serial number of ICS 5000
ICS 5000 Support Software User Manual A.VII

Self-Test Codes
The codes returned by the Self-Test can be interpreted as follows:
Table A.3 Self-Test Codes
Code # Description
1 Fatal error in the Program Memory (PROM)
2 Fatal error in the Working Memory (RAM)
3 Fatal error in some support chips (LSI)
4 Fatal error in the distance meter
5 Calibration constants are lost (correctable with software)
6 Control loop parameters are lost (correctable with software)
7 Station loop-up table is lost (correctable with software if necessary)
8 Fatal error in the digital to analog converter (DAC)
9 Fatal error in digital part of interface board
10 Time-out error. Intermittent failure in distance meter
11 Short term power glitch. Check your power supply for mains
interference problems
A.6.2 E Numbers
The status of the ICS 5000 units can be accessed by transmitting the E command to
the unit. The response from the unit will be the following:
E # Where # represents a status code from the following list.
Table A.4 Status Codes
E Number Status
0 SYNTAX OR OUT OF RANGE ERROR – message not within the ICS
5000’s command structure, or the distance commanded to move to exceed
the established limits.
1 HALTED DUE TO“H” OR “R” COMMAND (CONTROL LOOP NOT ACTIVE)
– last command transmitted to the TCS was the H command or the R
command. Both of these commands will disable the ICS 5000’s control loop
if it is actively holding a vehicle on position.
2 HALTED DUE TO BEAM BRAKE (CONTROL LOOP NOT ACTIVE) – this
fault occurs when the number of bad samples to Ignore (I) is exceeded.
4 HALTED DUE TO MOTOR FAILURE (CONTROL LOOP NOT ACTIVE) –
actual position measured has deviated from the theoretical position
expected by more than the user defined limit.
8 IN TRANSIT TO DESTINATION (CONTROL LOOP ACTIVE) – no faults.
16 POSITIONED AT DESTINATION (CONTROL LOOP ACTIVE) – vehicle has
been successfully positioned within the defined tolerance.
32 ICS 5000 UNIT IS WARMING UP (CONTROL LOOP NOT ACTIVE) – if this
Error condition persists for more than 5 minutes upon initial power up
contact Trimble for more information.
A.VIII ICS 5000 Support Software User Manual

Table A.4 Status Codes

E Number Status
64 CALIBRATION CYCLE (CONTROL LOOP ACTIVE) – auto calibration cycle
in progress.
Note – This status code must be enabled using the ICS 5000 Support
Software before it is displayed.
128 FAILED POWER UP SELF TEST (CONTROL LOOP NOT ACTIVE) –
hardware or parameter failure use Z command for more information.
The Status Codes are bit mapped. This means that each unique code has its own bit.
Only one bit can be set at a time. Therefore each Status Code is unique. No bits set
(E 0) means invalid command or Syntax Error.
A.6.3 W Numbers
Status can also be obtained using the W command. This command will return the
status once the move has been completed successfully or a fault has occurred. The
W command is used with the following syntax:
D 1000; W
This command sequence when transmitted to the TCS will cause the vehicle to
move to 1000 millimeters and suppress the ACK and the W response until the TCS
finishes processing that command. When the response to the W command is finally
received it will look as follows:
ACK;W ## Where ## represents a status code from the previous list for the E
command.
A.7 Warning Codes

The Warning Code is enabled using the Wakeup Mode screen [Alt] + [P] + [5] of the
Parameters tab. Select option 1 to enable the Warning Codes. The display will
change to WARNINGS ON: followed by a brief description of the codes.
When the status is requested and the warning code is enabled the response from the
ICS 5000 will appear as follows:
E <status>, ## Where ## represents a status code from the following list.
Table A.5 Warning Codes
Warning No Status
,2 HALTED DUE TO BEAM BRAKE (CONTROL LOOP NOT ACTIVE) –
this fault occurs when half the number of bad samples to Ignore (I) is
exceeded.
ICS 5000 Support Software User Manual A.IX

Table A.5 Warning Codes

Warning No Status
,4 HALTED DUE TO MOTOR FAILURE – when a user definable % of
allowable deviation between the actual position and the profile
generated for the move is exceeded this warning code is activated.
,64 CALIBRATION CYCLE PENDING – at 50% of the time interval between
calibration cycles this warning code is activated.
Note – This status code must be enabled using the ICS 5000 Support
Software before it is displayed.
The Warning codes are bit mapped. This means that each unique code has its own
bit. If more than one bit is set, multiple warnings have occurred and the Warning
Number issued will be the sum of the individual warning numbers. No bits set
means no Warnings have occurred.
A.8 Diagnostic Commands

When a Beam Break or Motor Failure error is reported by a ICS 5000, some helpful
information about the fault is stored in that specific fault’s diagnostic register. The
U# preceding the J is the pointer used to distinguish between the Beam Break,
Motor Failure and the Settling Time diagnostic registers. Information is stored in the
register until another fault occurs and changes the code or the unit is shut off.
A.8.1 Beam Break Diagnostics

The Beam Break diagnostic register can tell at what point in the measurement
process a fault occurred. This information is especially helpful resolving whether a
Beam Break was the result of an internal problem with the Distance Meter or an
external blocking of the Beam or mis-alignment.
To read this register send:
U0; J
The response from the ICS 5000 will be:
♠;J#
Where # is the diagnostic code - see Table A.6 that follows for details.
When using the register to isolate a problem it is necessary to first initialize the
register by setting the value to zero as follows.
U0;J0
This insures that the code being received was actually generated by the fault
observed.
Table A.6 Beam Break Diagnostic Codes
J# Code Translation
J0 No problem with the unit, Beam Break caused externally.
J1 Interrupted target signal in fine frequency mode during start up.
A.X ICS 5000 Support Software User Manual

Table A.6 Beam Break Diagnostic Codes

J# Code Translation
J2 Noisy target signal in fine frequency mode during start up.
J3 Interrupted reference signal in fine frequency mode.
J4 Noisy reference signal in fine frequency mode.
J5 Interrupted reference signal in coarse frequency mode.
J6 Noisy reference signal in coarse frequency mode.
J7 Interrupted target signal in coarse frequency mode.
J8 Noisy target signal in coarse frequency mode.
J9 Interrupted target signal in fine frequency mode (2nd time).
J 10 Noisy target signal in fine frequency mode (2nd time).
J 11 Distance out of range (less than zero or greater than 1000 Meters).
J 12 Fine and coarse frequencies disagree.
J 13 Distance computes to zero.
J 14 Five meter Error in phase meter.
J 20 Beam Break caused external.
J 21 Measuring range exceeded.
J16000 Could not read zero-constants in memory. This error code can occur together
with the other J codes. (J0 to J14)
J31000 The internal Grey wedge is not in the expected position. This error can occur
together with the other J codes. (J0 to J14)
J33000 Time-out during measurement. The measurement routine was delayed for
some reason. This error can occur together with the other J codes. (J0 to
J14)
A.8.2 Motor Failure Diagnostics

The Motor Failure diagnostic register tells if a failure was in a leading (over speed)
or lagging (under speed) direction. There is also a diagnostic register that carries the
information about the settling time of the last positioning.
U1; J
The response from the unit will be:
♠ ; J#
Where # is the diagnostic code - see Table A.7 that follows for details.
register by setting the value to zero.
U1;J0
ICS 5000 Support Software User Manual A.XI

observed.
Table A.7 Motor Failure Diagnostic Codes
J# Code Translation
J -# A negative value implies the machine was lagging behind schedule by “value”
millimeters. This is the situation when the motor is not working at all or has
insufficient acceleration/velocity. The ICS 5000 ramps the analog output down
to zero then opens the Safety and Brake outputs.
J# A positive value implies the machine was ahead of schedule by “value”
millimeters. This is the situation when the motor has gone wild or has
insufficient deceleration. The ICS 5000 immediately opens the Safety and
Brake outputs, then ramps down the analog output to zero.
J -99999 This special case means that the analog output circuitry has failed. The ICS
5000 reacts by immediately opening the Safety and Brake outputs, then
ramping the analog output down.
A.8.3 Settling Time Diagnostics

Settling time is updated each time a move completes and is a measure of how long it
took to do the fine positioning (time from when the machine should be on station to
when it actually gets on station). Another way of describing this register is that it is
the “hunting around” time or the “fine positioning” time. Typical values are between
0.1 and 2 seconds for the TCS algorithm. For the BCS algorithm there should
normally be no units set.
You may want to program your PLC to check the settling time from time to time and
display an alarm if its more than some value. As a machine degrades, one of the first
indications is that the settling time increases.
U2; J
The response from the unit will be:
♠ ; J#
Where # is the settling time - see Table A.8 that follows for details.
register by setting the value to zero as follows.
U2;J0
observed.
Table A.8 Settling Time Diagnostic Code
J# Code Translation
J# For a TCS algorithm the units are samples (1 sample=1/30 sec.) and for a
BCS algorithm, the units are the number of jogs (1 jog is approx. 1 sec.).
A.XII ICS 5000 Support Software User Manual

A.8.4 Laser Pointer (U3;J)

The optical alignment is easier when the laser pointer is turned on. It may be turned
on for periods longer than 2 seconds by sending U3; J1 over and over. The laser
pointer will automatically shut off when the PLC stops sending the command.
Note – Laser pointer is only available on ICS 5000 L.
Table A.9 Laser Pointer Diagnostic Code
J# Code translation
J1 U3;J1 turns the laser pointer on for about 2 seconds. U3;J0 turns the laser
pointer off immediately.
ICS 5000 Support Software User Manual A .X I I I

A.XIV ICS 5000 Support Software User Manual

APPENDIX
B
Advanced Protocol Specifics B
In this appendix:
• DF1 Protocol Information

• MODBUS Protocol Information
B.1 DF1 Protocol Information
B.1.1 Supported DF1 Functions

Of the many functions defined in the DF1 protocol, only these functions (FNC byte)
are currently supported:
0 - word range read (typically used by PLC-3 “message” command)
1 - word range write (typically used by PLC-3 “message” command)
67 - typed range write (typically used by PLC-5 “message” command)
68 - typed range read (typically used by PLC-5 “message” command)
Any other function requested by the PLC will result in an ILLEGAL FUNCTION
response (STS byte = 0x60). Exception responses are listed later in this document.
B.1.2 Message Framing

With DF1, it takes 4 messages to complete a data transfer or transaction as it is
commonly called. These are:
1. Command (sent by PLC)
2. Command acknowledge (sent by ICS 5000)
3. Reply (sent by ICS 5000 after a short time)
4. Reply acknowledge (sent by PLC)
Acknowledges are always DLE ACK (0x10 and 0x06). Commands and replies
always begin with DLE STX (0x10 and 0x02) and end with DLE ETX BCC (0x10,
0x03 and check sum byte). The BCC or check sum is calculated on everything
between but not including the DLE STX and the DLE ETX.
ICS 5000 Support Software User Manual B.I

A Advanced Protocol Specifics
Note – All of the details of the protocol are handled automatically by the PLC. you
just need to use a properly configured “message” command in your ladder
program.
The details at the protocol level are listed in this document because sometimes you
have to debug communications at a more primitive level.
B.1.3 Function 0, Word Range Write

This command is used to write one or more words of data to the ICS 5000. The
command message format from the PLC is:
DLE
STX
DST Destination byte, ICS 5000 address/station #
SRC Source byte, PLC address/station #
CMD Command byte=0x0F indicates word range read & write
STS Status byte=0x00
TNS_LO Transaction # low byte (to make each transaction unique)
TNS_HI Transaction # high byte
FNC Function code=0x00, indicates write (see CMD above)
OFFSET_LO Low byte of packet offset (often 0x00)
OFFSET_HI High byte of packet offset (often 0x00)
WORDS_LO Low byte of number of words to read
WORDS_HI High byte of number of words to read
FLAG Bits in flag indicate what data is to follow
TABLE_# Data table number, optional depending on flag byte
FILE_# File number, optional depending on flag byte
ELEMENT_# Which element in file to start with, optional
SUB_ELEMENT Which bit in element to start with, optional
DATA_LO Low byte of transmitted data starting with ELEMENT_#.
DATA_HI High byte of transmitted data.
.
.
.
DATA_LO Low byte of data (ELEMENT_# + WORDS - 1)
DATA_HI High byte of data.
DLE
ETX
BCC
The reply message packet format from the ICS 5000 is:
DLE
STX
DST Destination byte, PLC address/station #
SRC Source byte, ICS 5000 address/station #
STS Status byte 0x00=ok, 0x10=illegal command, 50H=address-
ing problem,
0x60=function disallowed.
DLE
ETX
BCC
B.II ICS 5000 Support Software User Manual

Advanced Protocol Specifics A
B.1.4 Function 0, Word Range Read

This command is used to read one or more words of data from the ICS 5000. The
DLE
STX
FNC Function code=0x01, indicates read (see CMD above)
#_BYTES How many bytes to read, 2*WORDS
DLE
ETX
BCC
DLE
STX
STS Status byte 0x00=ok, 0x10=illegal command,
50H=addressing problem, 0x60=function disallowed.
DATA_LO Low byte of requested data starting with ELEMENT_#.
DATA_HI High byte of requested data.
.
.
.
DLE
ETX
BCC
B.1.5 Function 67, Typed Write

This command is used to write one or more words of data to the ICS 5000. The
DLE
STX
ICS 5000 Support Software User Manual B.III

FNC Function code=0x67, indicates typed write

A_FLAG 0x97 indicates array
A_DESC 0x09 of similar elements
A_SIZE 0x02 type is integer with 2 bytes per integer
DATA_LO Low byte of transmitted data starting with ELEMENT_#.
DATA_HI High byte of transmitted data.
.
.
.
DLE
ETX
BCC
DLE
STX
DLE
ETX
BCC
Note – The PLC-5 “message” command normally uses a typed read/write command
when reading or writing integer files.
B.1.6 Function 68, Typed Read

This command is used to read one or more words of data from the ICS 5000. The
DLE
STX
FNC Function code=0x68, indicates typed read
B.IV ICS 5000 Support Software User Manual


BYTES_LO How many bytes to read, 2*WORDS
BYTES_HI High byte of number of words to read
DLE
ETX
BCC
DLE
STX
A_FLAG 0x97 indicates array
A_DESC 0x09 of similar elements
A_SIZE 0x02 type is integer with 2 bytes per integer
DATA_LO Low byte of requested data starting with ELEMENT_#.
DATA_HI High byte of requested data.
.
.
.
DLE
ETX
BCC
B.1.7 Exception Responses

There are 3 exception responses supported by the ICS 5000:
• 0x10 ILLEGAL COMMAND - the CMD byte was not 0x0F
• 0x50 ADDRESSING PROBLEM - the ELEMENT_# byte was out of the
range 0-22 of ELEMENT_# + WORDS was out of the range 0-22.
• 0x60 ILLEGAL FUNCTION - the FNC byte was not 0, 1, 67 or 68.
These codes are returned in the STS byte of the reply message. Any of these
conditions cause the syntax LED to turn on until the next message is received.
B.2 MODBUS Protocol Information
B.2.1 Supported MODBUS Functions

Of the 17 functions defined in the MODBUS protocol, only functions 3 (read
multiple registers), 6 (write single register) and 16 (write multiple registers) are
supported. Any other function requested by the PLC will result in an ILLEGAL
FUNCTION exception response. Exception responses are listed later in this
document.
ICS 5000 Support Software User Manual B.V

RTU Mode Message Framing

In RTU mode, messages are made of 8 bit binary entities called bytes. Functions 3
and 6 always use 8 bytes per message which can be broken down as follows:
Table B.3 RTU Message Framing
Address Function MSB of LSB of MSB of LSB of MSB of LSB of
Data1 Data1 Data 2 Data 2 CRC CRC
The Address is 1 to 255...The ICS 5000 will ignore any message that does not have
an address that matches its address defined in the setup software.
The Function must be 3, 6 or 16 or the ICS 5000 will reply with an ILLEGAL
FUNCTION exception response.
Data1 and Data2 are parameters whose definition depends on the function being
used.
The CRC is error checking information so the ICS 5000 can detect when a data
transmission error has occurred. If such an error has occurred, the ICS 5000 ignores
the message.
The beginning and ending of messages is done by inserting time gaps greater than or
equal to 3.5 characters (once synchronized with the host, the ICS 5000 does not
need the time gap). If any byte in a message has a parity, framing or over-run error
associated with it, the entire message is discarded. The ICS 5000 can be receiving a
message at the same time it is transmitting a reply to the previous message (full
duplex).
Function 3, Read Multiple Registers

When the function byte is 3, Data1 is interpreted as the first register of a group to be
read, and Data2 is interpreted as the number of registers in the group. Therefore, the
length of the reply will depend on Data2. In the PLC, the registers are numbered
40001, 40002, etc. but at the protocol level, the same registers are 0, 1, etc. This
means that the range of registers the ICS 5000 will support is 40001 to 40026 at the
PLC level and 0 to 25 when referring to Data1. Hence, if Data1 is not in the range 0
to 25, an ILLEGAL REGISTER exception response will be sent. If Data1 + Data2 is
outside the range, an ILLEGAL DATA VALUE exception response will be sent.
The normal reply from the ICS 5000 is formatted as follows:
Table B.4 ICS 5000 Message Framing
Address Function 2*data 2 MSB of LSB of MSB of LSB of etc.
register register register Register
Data1 Data1 Data1 Daten1+1
After all the registers as requested by Data2 have been added to the message, a 2
byte CRC is calculated and appended.
B.VI ICS 5000 Support Software User Manual

Function 6, Write Single Register

When the function byte is 6, data1 is interpreted as the register number to be written
to. Data2 is interpreted as the value to write to it. If data1 is not in the range 0..25
(40001..40026 to the PLC), an ILLEGAL REGISTER exception response is sent. If
data2 is outside the range permitted by the register, an ILLEGAL DATA VALUE
exception response is sent. Only registers 1 (40002) and 4 (40005) have range
limits. Consult the detailed register description below for more detail.
The normal response from function 6 is to send back the same message the ICS
5000 received.
Function 16, Write Multiple Registers

When the function byte is 16 (0x10), data1 is interpreted as the first register of
several registers to write to. Data2 is interpreted as the number of registers to be
written. The last register to be written is data1+data2-1; if this value exceeds 25 an
ILLEGAL REGISTER exception response will be sent to the PLC. Function 16
includes some extra data before the CRC which is a byte count and 2 bytes of data
per register.
Exception Responses
There are 7 exception responses outlined in the MODBUS® protocol, only 3 were
applicable to the ICS 5000 situation.
1. ILLEGAL FUNCTION, used when the message contains a function byte
other than 3, 6 or 16.
2. ILLEGAL REGISTER, used when data1+data2-1 is greater than 25 for
functions 3 & 16 and when data1 is greater than 25 for function 6.
3. ILLEGAL DATA VALUE, used when the data written to 40002 or 40005
exceeds the end-of-travel limits. (Old TCS/BCS system 4000 only)
Any of these conditions cause the syntax LED to turn on until the next message is
received.
Exception response formatting is as follows:
Table B.5
Address Function Code MSB of LSB of
+128 1.3 CRC CRC
Examples
Numbers in the following messages are grouped in hexadecimal bytes. The PLC
address is assumed to be 1.
Read register 40001

HOST MSG: 01 03 00 00 00 01 84 0A
TCS/BCS REPLY: 01 03 02 00 20 B9 9C
MEANING: 40001 IS DECIMAL 32 (TCS/BCS IN WARM-UP MODE)
ICS 5000 Support Software User Manual B.VII

Read registers 40001 through 40005

HOST MSG: 01 03 00 00 00 05 85 C9
TCS/BCS REPLY: 01 03 0A 00 10 00 07 00 07 04 CE 04 CC 48 2C
MEANING: 40001 IS DECIMAL 16 (TCS/BCS IS ON-STATION)
40002 IS DECIMAL 7 (STATION DESTINATION IS 7)
40003 IS DECIMAL 7 (ACTUAL POSITION IS STATION 7)
40004 IS DECIMAL 1230 (DESTINATION IS 1230*65536+1228)
40005 IS DECIMAL 1228 (DESTINATION IS 1230*65536+1228)
Read register 40001 with CRC error

HOST MSG: 01 03 00 00 00 01 84 0B
TCS/BCS REPLY:
MEANING: NO REPLY, CRC ERROR IN HOST MSG.
Read register 40001 in PLC number 2

HOST MSG: 02 03 00 00 00 01 84 39
TCS/BCS REPLY:
MEANING: NO REPLY, PLC ADDRESS DOES NOT MATCH TCS/BCS.
Read register 30001 via Function 4

HOST MSG: 01 04 00 00 00 01 31 CA
TCS/BCS REPLY: 01 84 01 82 CD
MEANING: ILLEGAL FUNCTION EXCEPTION RESPONSE BECAUSE FUNCTION 4
IS NOT SUPPORTED (ONLY 3 AND 6 ARE SUPPORTED)
Read register 40027

HOST MSG: 01 03 00 1B 00 01 C4 0E
TCS/BCS REPLY: 01 83 02 C0 F1
MEANING: ILLEGAL REGISTER EXCEPTION RESPONSE BECAUSE REGISTER
40027 DOES NOT EXIST.
Read registers 40001 through 40027

HOST MSG: 01 03 00 00 00 1B 84 05
TCS/BCS REPLY: 01 83 03 01 31
MEANING: ILLEGAL DATA VALUE EXCEPTION RESPONSE BECAUSE REGISTER
40027 DOES NOT EXIST
Write register 40002 to decimal 8

HOST MSG: 01 06 00 01 00 08 D9 CC
TCS/BCS REPLY: 01 06 00 01 00 08 D9 CC
MEANING: THE TCS/BCS BEGINS MOVING THE MACHINE TO STATION 8.
READING REGISTER 40002 WILL RETURN 8 ANDREADING
REGISTER 40004 & 5 WILL RETURN THE EQUIVALENT
DESTINATION IN MM. REGISTER 40001 WILL CHANGE TO 8
(IN TRANSIT) EVENTUALLY, REGISTER 0003 WILL EQUAL 8
AS WELL UNLESS THERE IS A PROBLEM.
Write register 40005 to decimal 1000

HOST MSG: 01 06 00 04 03 E8 79 74
TCS/BCS REPLY: 01 06 00 04 03 E8 79 74
MEANING: THE TCS/BCS BEGINS MOVING THE MACHINE TO A
DESTINATION OF 1000 MM. READING REGISTER 40005 WILL
B.VIII ICS 5000 Support Software User Manual

RETURN 1000. REGISTER 40002 REMAINS UNCHANGED.

REGISTER 40001 WILL CHANGE TO 8 (IN TRANSIT).
EVENTUALLY, REGISTER 40007 WILL BE WITHIN TOLERANCE
OF 1000 UNLESS THERE HAS BEEN A PROBLEM.
Write register 40004 to decimal 1000 with CRC error

HOST MSG: 01 06 00 03 03 E8 79 73
TCS/BCS REPLY:
MEANING: NO REPLY, CRC ERROR IN HOST MSG
ICS 5000 Support Software User Manual B.IX

B.X ICS 5000 Support Software User Manual

APPENDIX
C
Network Configuration Files C
In this appendix:
• DeviceNet EDS File Example

• PROFIBUS GSE File Example
ICS 5000 Support Software User Manual C.I

A Network Configuration Files
C.1 DeviceNet EDS File Example

The ICS 5000’s EDS file name is ICS500.eds.
$ Electronic Data Sheet for Trimble ICS5000 with DeviceNet protocol
$
[File]
DescText = "ICS5000 EDS File";
CreateDate = 08-24-2000;
CreateTime = 16:10:00;
ModDate = 05-24-2001;
ModTime = 14:14:00;
Revision = 1.2;
[Device]
VendCode = 639; $ Vendor Id
VendName = "Trimble AB"; $ Vendor Name
ProdType = 12; $ Device Type
ProdTypeStr = "Communications Adapter"; $ Device Type String
ProdCode = 1; $ Product Code
MajRev = 2; $ Major Rev
MinRev = 5; $ Minor Rev
ProdName = "ICS5K"; $ Product Name
$ Catalog = ""; $ Catalog Number
Icon = "Ics5k.ico"; $ ICON File
[IO_Info]
Default = 0X0001; $ Poll (bit 0)
PollInfo = 0X0001, $ Can't be combined with anything
1, $ Default Producing Connection
1; $ Default Consuming Connection
$ Communication with the device is done via polled I/O. There is no actual
$ attribute that can be read, and the length is pre-configured.
$ So we specify a dummy vendor specific object class instance
$ which is inaccessible via the explicit route.
$ Trying to access it will result in a "Service Not Supported" error.
Output1 = 30, $ 30 bytes
0, $ All bits are significant
0x0001, $ Poll Connection
"Output", $ Name String
6, $ Path Size
"20 64 24 01 30 64", $ Class 64, Instance 01, Attribute 64
""; $ Help String
$ OUTPUT SIZE for the scanner (same as Tx Size)
$ tells the scanner how many bytes of data to send to the ICS.
$ You configure it in the setup software WRITE REGISTER screen
$ (found in MODIFY WAKEUP MODE-I/O REGISTERS) by specifying the size
$ and quantity of elements in the register list. The ICS only works
$ in a polled mode (group 2 master-slave conn.) i.e. no explicit
$ messaging.
Input1 = 30, $ 30 bytes

0, $ All bits are significant
0x0001, $ Poll Connection
"Input", $ Name String
6, $ Path Size
"20 64 24 01 30 64", $ Class 64, Instance 01, Attribute 64
""; $ Help String
$ INPUT SIZE for the scanner (same as Rx Size)
$ tells the scanner how many bytes of data to expect from the ICS.
$ You configure it in the setup software READ REGISTER screen
$ (found in MODIFY WAKEUP MODE-I/O REGISTERS) by specifying the size
$ and quantity of elements in the register list. The ICS only works
$ in a polled mode (group 2 master-slave conn.) i.e. no explicit
$ messaging.
C.II ICS 5000 Support Software User Manual

Network Configuration Files A
$[ParamClass]
$[Params]
$[EnumPar]
$[Groups]
C.2 PROFIBUS GSE File Example

The ICS 5000’s GSE file name is ICS_068A.gse. A bitmap file named
ICS5000n.BMP is also available for the PROFIBUS master configuration tool.
;===========================================================
; GSD File for ICS5000
; Freeze_Mode_supp, Sync_Mode_supp, Auto_Baud_supp, 12Mbit/s
;
; Copyright (C) Trimble AB 2002 All Rights Reserved. Confidential
;
; Date : 14.11.02
; File : ICS_068A.GSE
;===========================================================
#Profibus_DP
;
; Unit-Definition-List:
GSD_Revision=2
Vendor_Name="TRIMBLE AB"
Model_Name="ICS 5000"
Revision="V1.0"
Ident_Number=0x068A
Protocol_Ident=0
Station_Type=0
Hardware_Release="V1.0"
Software_Release="V1.1"
9.6_supp=1
19.2_supp=1
45.45_supp=1
93.75_supp=1
187.5_supp=1
500_supp=1
1.5M_supp=1
3M_supp=1
6M_supp=1
12M_supp=1
MaxTsdr_9.6=60
MaxTsdr_19.2=60
MaxTsdr_45.45=60
MaxTsdr_93.75=60
MaxTsdr_187.5=60
MaxTsdr_500=100
MaxTsdr_1.5M=150
MaxTsdr_3M=250
MaxTsdr_6M=450
MaxTsdr_12M=800
Implementation_Type="SPC3"
Bitmap_Device="ICS5000N"
Bitmap_SF="ICS5000N"
;
; Slave-Specification:
Freeze_Mode_supp=1
Sync_Mode_supp=1
Repeater_Ctrl_Sig=0
Redundancy=0
24V_Pins=0
Auto_Baud_Supp=1
Set_Slave_Add_Supp=0
ICS 5000 Support Software User Manual C.III

Min_Slave_Intervall=1
Max_Diag_Data_Len=10
Modul_Offset=0
Slave_Family=0
fail_safe = 0
Modular_Station=1
Max_Module=34
Max_Input_Len=224
Max_Output_Len=224
Max_Data_Len=448
; User-Parameter-Definition
PrmText=1
Text(0)="Not Active"
Text(1)="Active"
EndPrmText
PrmText=2
Text(0)="INTEL (low-high)"
Text(1)="MOTOROLA (high-low)"
EndPrmText
;
ExtUserPrmData=1 "Ext. diagnostics"
Bit(0) 0 0-1
Prm_Text_Ref=1
EndExtUserPrmData
ExtUserPrmData=2 "Word format"
Bit(1) 1 0-1
Prm_Text_Ref=2
EndExtUserPrmData
; UserPrmData: Length and Preset:

Max_User_Prm_Data_Len=2
Ext_User_Prm_Data_const(0)=0
Ext_User_Prm_Data_Ref(1)=1
Ext_User_Prm_Data_Ref(1)=2
;
; Module-Definitions:
;
Module = "R E Status 1 Byte" 0x10

EndModule
Module = "R E Status 1 Word" 0x50
EndModule
Module = "R E Status 2 Word" 0x51
EndModule
Module = "R S Station Destination 1 Byte" 0x10

EndModule
Module = "R S Station Destination 1 Word" 0x50
EndModule
Module = "R S Station Destination 2 Word" 0x51
EndModule
Module = "W S Station Destination 1 Byte" 0x20
EndModule
Module = "W S Station Destination 1 Word" 0x60
EndModule
Module = "W S Station Destination 2 Word" 0x61
EndModule
Module = "R Y Station Location 1 Byte" 0x10

EndModule
Module = "R Y Station Location 1 Word" 0x50
EndModule
Module = "R Y Station Location 2 Word" 0x51
C.IV ICS 5000 Support Software User Manual

EndModule
Module = "R D Distance Destination 1 Word" 0x50

EndModule
Module = "R D Distance Destination 2 Word" 0x51
EndModule
Module = "W D Distance Destination 1 Word" 0x60
EndModule
Module = "W D Distance Destination 2 Word" 0x61
EndModule
Module = "R X Current Distance 1 Word" 0x50

EndModule
Module = "R X Current Distance 2 Word" 0x51
EndModule
Module = "R R Return Signal Str 1 Byte" 0x10

EndModule
Module = "R R Return Signal Str 1 Word" 0x50
EndModule
Module = "R R Return Signal Str 2 Word" 0x51
EndModule
Module = "W R Return Signal Str 1 Byte" 0x20
EndModule
Module = "W R Return Signal Str 1 Word" 0x60
EndModule
Module = "W R Return Signal Str 2 Word" 0x61
EndModule
Module = "W H Halt Acc 1 Byte" 0x20

EndModule
Module = "W H Halt Acc 1 Word" 0x60
EndModule
Module = "W H Halt Acc 2 Word" 0x61
EndModule
Module = "R A Op Acceleration 1 Word" 0x50

EndModule
Module = "R A Op Acceleration 2 Word" 0x51
EndModule
Module = "W A Op Acceleration 1 Word" 0x60
EndModule
Module = "W A Op Acceleration 2 Word" 0x61
EndModule
Module = "R A Neg Op Acc 1 Word" 0x50

EndModule
Module = "R A Neg Op Acc 2 Word" 0x51
EndModule
Module = "W A Neg Op Acc 1 Word" 0x60
EndModule
Module = "W A Neg Op Acc 2 Word" 0x61
EndModule
Module = "R A Pos Op Acc 1 Word" 0x50

EndModule
Module = "R A Pos Op Acc 2 Word" 0x51
EndModule
Module = "W A Pos Op Acc 1 Word" 0x60
EndModule
Module = "W A Pos Op Acc 2 Word" 0x61
EndModule
Module = "R I Beam Breaks to Ignore 1 Byte" 0x10

EndModule
Module = "R I Beam Breaks to Ignore 1 Word" 0x50
ICS 5000 Support Software User Manual C.V

EndModule
Module = "R I Beam Breaks to Ignore 2 Word" 0x51
EndModule
Module = "W I Beam Breaks to Ignore 1 Byte" 0x20
EndModule
Module = "W I Beam Breaks to Ignore 1 Word" 0x60
EndModule
Module = "W I Beam Breaks to Ignore 2 Word" 0x61
EndModule
Module = "R M Op Mode 1 Byte" 0x10

EndModule
Module = "R M Op Mode 1 Word" 0x50
EndModule
Module = "R M Op Mode 2 Word" 0x51
EndModule
Module = "W M Op Mode 1 Byte" 0x20
EndModule
Module = "W M Op Mode 1 Word" 0x60
EndModule
Module = "W M Op Mode 2 Word" 0x61
EndModule
Module = "R O Measurement Offset 1 Word" 0x50

EndModule
Module = "R O Measurement Offset 2 Word" 0x51
EndModule
Module = "W O Measurement Offset 1 Word" 0x60
EndModule
Module = "W O Measurement Offset 2 Word" 0x61
EndModule
Module = "R T Positioning Tolerance 1 Byte" 0x10

EndModule
Module = "R T Positioning Tolerance 1 Word" 0x50
EndModule
Module = "R T Positioning Tolerance 2 Word" 0x51
EndModule
Module = "W T Positioning Tolerance 1 Byte" 0x20
EndModule
Module = "W T PositioningTolerance 1 Word" 0x60
EndModule
Module = "W T Positioning Tolerance 2 Word" 0x61
EndModule
Module = "R V Op Velocity 1 Word" 0x50

EndModule
Module = "R V Op Velocity 2 Word" 0x51
EndModule
Module = "W V Op Velocity 1 Word" 0x60
EndModule
Module = "W V Op Velocity 2 Word" 0x61
EndModule
Module = "R V Neg Op Velocity 1 Word" 0x50

EndModule
Module = "R V Neg Op Velocity 2 Word" 0x51
EndModule
Module = "W V Neg Op Velocity 1 Word" 0x60
EndModule
Module = "W V Neg Op Velocity 2 Word" 0x61
EndModule
Module = "R V Pos Op Velocity 1 Word" 0x50

EndModule
Module = "R V Pos Op Velocity 2 Word" 0x51
C.VI ICS 5000 Support Software User Manual

EndModule
Module = "W V Pos Op Velocity 1 Word" 0x60
EndModule
Module = "W V Pos Op Velocity 2 Word" 0x61
EndModule
Module = "R U0 Beam Break Diag Code 1 Byte" 0x10

EndModule
Module = "R U0 Beam Break Diag Code 1 Word" 0x50
EndModule
Module = "R U0 Beam Break Diag Code 2 Word" 0x51
EndModule
Module = "W U0 Beam Break Diag Code 1 Byte" 0x20
EndModule
Module = "W U0 Beam Break Diag Code 1 Word" 0x60
EndModule
Module = "W U0 Beam Break Diag Code 2 Word" 0x61
EndModule
Module = "R U1 Motor Failure Diag 1 Word" 0x50

EndModule
Module = "R U1 Motor Failure Diag 2 Word" 0x51
EndModule
Module = "W U1 Motor Failure Diag 1 Word" 0x60
EndModule
Module = "W U1 Motor Failure Diag 2 Word" 0x61
EndModule
Module = "R U2 Settling Time 1 Byte" 0x10

EndModule
Module = "R U2 Settling Time 1 Word" 0x50
EndModule
Module = "R U2 Settling Time 2 Word" 0x51
EndModule
Module = "R U3 PointingLaser Status 1 Byte" 0x10

EndModule
Module = "R U3 PointingLaser Status 1 Word" 0x50
EndModule
Module = "R U3 PointingLaser Status 2 Word" 0x51
EndModule
Module = "W U3 PointingLaser Status 1 Byte" 0x20
EndModule
Module = "W U3 PointingLaser Status 1 Word" 0x60
EndModule
Module = "W U3 PointingLaser Status 2 Word" 0x61
EndModule
Module = "R U4 Digital I/O Status 1 Byte" 0x10

EndModule
Module = "R U4 Digital I/O Status 1 Word" 0x50
EndModule
Module = "R U4 Digital I/O Status 2 Word" 0x51
EndModule
Module = "R U5 DAC Voltage 1 Word" 0x50

EndModule
Module = "R U5 DAC Voltage 2 Word" 0x51
EndModule
Module = "R Z System Self-test 1 Byte" 0x10

EndModule
Module = "R Z System Self-test 1 Word" 0x50
EndModule
ICS 5000 Support Software User Manual C.VII

Module = "R Z System Self-test 2 Word" 0x51

EndModule
Module = "R General Purpose 1 Byte" 0x10

EndModule
Module = "R General Purpose 1 Word" 0x50
EndModule
Module = "R General Purpose 2 Word" 0x51
EndModule
Module = "W General Purpose 1 Byte" 0x20

EndModule
Module = "W General Purpose 1 Word" 0x60
EndModule
Module = "W General Purpose 2 Word" 0x61
EndModule
C.VIII ICS 5000 Support Software User Manual

Index
A CANNEL 0 5.9, 5.13
CANNEL 1A 5.10
Acceleration 9.19
Capture button 3.8
acceleration 9.41
CHANNEL 0 5.8
Acceleration and Velocity 9.19
CHANNEL 1 5.8
acceleration filtering 11.6
CHANNEL 1A 5.15
acceleration time 10.27
characterization 9.27
acceleration_gain 11.19
Characterization Log 9.43
ACK/NAK A.II
Characterization Menu 9.29
Adding Multiple Speeds 10.30
Characterization Program 9.21
Address Monitor 5.60
Chart Recorder 8.9
advanced communications protocols 5.2
Collision Avoidance 11.7
Advanced Skew Controller 9.6, 9.26
collision avoidance 3.4
Algorithm 3.3, 3.4
collision avoidance outputs 11.7
Analog Output 8.9
COM 4.16
analog output 11.19
Command Listing 5.67
Analog Output Calibration 8.13
Company name 2.4
analog output signal 11.12
Configure zones 11.17
ASC Parameters 9.26
Connections menu 2.10
Auto Gain Limit 9.10, 9.17
Control Block 5.11, 5.15
Auto-Calibration 9.23
Control Options screen 3.3
Automatic Retries 9.22, 10.19
Control Parameters 9.15, 10.14, 10.22
Average Settling Time 8.7
Controlled Halt 11.8
Controlled Halt Zone 11.7, 11.17
Controlled Slow Down Zone 11.7, 11.9
B Controlled Slow down Zone 11.9
BCS algorithm 10.4 Controlled Slowdown 11.8
BCS algorithm error handling 10.2 CPU/PROFIBUS master 5.46
BCS Parameters tab 10.13, 11.14 Crane-to-Crane Collision Avoidance 11.18
BCS1 10.5 Curve Fitting 9.45
BCS2 10.5 curve fitting routine 9.44
Beam Break 5.42 cycle power 2.16
Beam break 5.42
Beam Break Handling 11.11
Beam Breaks 9.21, 10.18, 11.14 D
Beam Breaks to Skip 9.22, 10.19
Data folder 2.7
bi-polar 10.5
Data Highway Plus (DH+) 5.8
Bi-Polar Output 9.6
Deadband 9.40
bi-polar output 9.6
Deadband holding 9.23
BRAKE 9.16, 10.14, 10.15
default communications parameters 2.15, 2.16
Brake 11.17
Default settings 2.15
Brown tuning 9.48
Description screen 3.3
Destination Folder 2.5
destination folder 2.7
C Device Parametrization 5.58
CAN_High 5.31 DeviceNet communications 5.20
CAN_Low 5.31 DF1 B.I–??
ICS 5000 Support Software User Manual I n d e x .I

Index
DF1 network 5.7 H

DF1 protocol 5.4
Halt 9.12, 9.24, 10.27
digital filter 11.5
Hardware Configuration 8.12
Digital Filters 11.21
head room 9.19
Digital I/O Status Word 5.71
Help menu 2.12
Direct Connection 3.5
Help, context-sensitive 1.2
direction of motion 9.40
Horizontal vs. Vertical 9.33
disaster 9.51
Hysteres 11.18
Disturbance Response 9.49
hysteresis 11.11
Disturbance response 9.47
disturbance response 9.46
DOS based Support Software 2.14
Downloading firmware 8.10 I
ICS 5000 Modules Object Properties 5.49
importing data 2.14
E Incorrect data 10.23
install 2.3
EDS file 5.65
installation 2.2
EDS file(s) 5.24
installation folder 2.5
Emergency Decel Time 10.16
installation type 2.6
Emergency deceleration 10.27
Installing new GSE 5.44
Emergency Stop 11.8
Installing the Software 2.8
Emergency Stop Zone 11.7, 11.9, 11.17
InstallShield Wizard 2.4
Emergenzy STOP 9.38
insulator 5.32
Enabling the DF1 Protocol 5.5
integrator 9.24
Ending Position 9.35
Interpolate 6.4
END-OF-THE-CHAIN 5.55
ITAE tuning 9.48
Extended Diagnostic 5.42
Extended Diagnostic Register 5.42
J
F JOG pulses 10.15
Jog Time 10.26
Fail Limit 10.27
fail-safe design 9.2
File Menu 2.9
filter 9.47, 11.21 K
Fine Pos. Fail Limit 10.16 KF-2 Module 5.8
Fine Pos. Jog Time 10.15
Fine Pos. Wait Time 10.15
Fine Pos.Wait Time 10.27 L
Firmware 8.10
Firmware Revision 3.3 Lagging 5.42
Firmware/Version Check 2.16 lagging 9.13
Flash Loader 2.11, 8.10 Laser Alignment 3.6
Full servo 9.11 Leading 5.42
Fwd/Rev 11.17 leading 9.13
load sway 9.46
log file 9.39
G Loss of Data 9.3
Low Pass Filter 9.20, 9.49
gear box 9.31 LSW 5.66
Gear Box Considerations 9.32
General 3.1
general configuration 3.2 M
Go ON Line 2.15
Manual Controls 9.47
Manuals folder 2.7
Index.II ICS 5000 Support Software User Manual

Index
Menu bar 2.2 performance related deviations 9.3

menu bar 2.9 PID gains 9.17
Message instruction 5.11 pin configuration 5.50
Message instruction usage 5.16 Pink Noise 9.30
MODBUS B.V–B.IX Pink Noise Data 9.44
MODBUS Address 5.20 pink noise ramps 9.43
MODBUS communications 5.17 PLC 5.8
MODBUS protocol 5.18 PLC's Serial Port 5.9
Mode 10.20, 11.22 PLC-5 5.9
Modes 9.10, 9.11, 10.11, 11.13 Pointing Laser 3.7
Modify Stations 6.3 polarity 9.39, 10.28
Modify Stations screen 6.3 Polarity and Deadband tests 9.40
Monitoring 5.57 position drift 9.39
Monitoring State 5.58 position filter 11.12
Motor Drive tuning 9.34 position filtering 11.6
Motor Failure 5.42, 9.15 position smoother 9.20
Motor Tuning 9.29 Position vs. Time Graph 8.5
Motor Tuning Aid 8.5 position_gain 11.19
Motor Warning 9.15 Positive Deadband 9.18
MSW 5.66 PROFIBUS Master 5.46
Multi-Speed Algorithm 10.24 Profibus.txt 5.48
Multi-speed algorithms 10.23 Program Window 2.2
protocol switch-over 5.3
N
R
Navigation 2.2
Negative Deadband 9.18 RA 4.16
Noise and Filter 9.20 ramp generator 9.35
Noise Gain 9.20 Ramp Rate 8.7, 9.34
Noise Limi 9.48 Ramp Retardation 9.24
non-ideal machine 9.32 Ramp retardation 9.12
non-recursive filters 11.5 Random Moves 8.7
Normal limits 3.8 RB 4.16
Number Conventions 5.66 Reaction Lag time 11.9
Number of Speeds 10.23 Reaction Time Lag 11.18
Read from ICS 2.16
read service 5.57
O Read Table Configuration 5.64
readme.txt file 1.2
ON Line 2.15 Relay Outputs 8.9
online help 1.2 relays reaction 11.16
Opening an Existing Data File 2.13 release notes 1.2
Operating State 5.57 re-release brake 9.16
Options Menu 2.11 RS-232 port 5.50
Output Format 3.3, 3.4 RS232 port 4.15
Output Status 9.12, 10.11 RS422 port 4.15
Output Test 8.8 RTU B.VI
Over/Undershoot 10.29 RXD 4.16
Over-/Undershoot Control 8.4
Overshoot 8.4, 10.29
S
P Safe Operating Zone 11.9
Sample Rate 3.5
Parameterization Telegram 5.43 sampling frequency 9.9, 10.10
Pause 9.36, 9.38 sealing nut 5.33
PDM Parameters tab 11.14
ICS 5000 Support Software User Manual Index.III

Index
Self Adaptive Function 9.10 TCS1 9.5

Self Test 9.7, 10.6 TCS2 9.5
Self-Test 2.16 technical support 1.2
serial communications parameters 5.6 Temporary limits 3.8
Serial Number 3.3 Terminal 8.2
settling times 9.31 Toolbar 2.2, 2.12
Setup Description 2.14, 2.15 top speed 10.17
Setup Description window 3.3 Top Speed Determination 10.17
shortcut 2.7 transaction B.I
Siemens Step 7 software 5.43 Transient Response 9.46, 9.47, 9.49
Signal Strength 3.7 transient response 9.46
Skew Distance 9.27 Trapezoid Wave 8.7
Skew Limit 9.26 Travel Limits 3.8, 6.3
SLC 5.8 Triangle Wave 8.7
SLC 5/0X 5.12 Trimble License Agreement 2.4
SLC 5/0X message instruction 5.14 Tuning Algorithm 9.47
Slow Down Zone 11.17 Tuning Strength 9.47, 9.48
Software Organization 2.3 Two Speed 10.9
Speed 1 min. Distance 10.15 TXD 4.16
Speed 1 Voltage 10.15 Typical Settling Time 8.8
Speed 2 min. Distance 10.15
Speed 2 Voltage 10.15
Speed Regulation test 9.41 U
speeds 10.14
Square Wave 8.6 Undershoot 8.4, 10.29
start delay 9.36 Uni-Polar 10.6
Starting Station Number 6.2 Uni-Polar Output 9.7
Static Data 9.44 usage 2.8
Static Data tab 9.37 USB to serial converters 2.2
Station Location (Y command) Format 6.2 User Filter 11.22
Station Setup 6.2 User name 2.4
Stations 6.3 User settings 2.15
Step Response 9.45 Utilities menu 2.11
Step response 9.45
sticky test 9.41
stop swinging 9.16, 9.17 V
Stopping Acceleration 11.18 V- 5.31
stopping distance 11.10 V+ 5.31
stopping position 11.8 Velocity 9.19
strain relief cleat 5.32 velocity 9.41, 11.15
strain relief collet 5.33 velocity filter 11.12
string multiple commands 8.4 velocity filtering 11.6
support 1.2 velocity_gain 11.19
support computer 2.2 Vertical Application 9.33, 9.42
Sync 11.17 visible pointing laser 3.7
Sync input relay 9.25, 10.21
synchronization of the data 2.16
synchronization process 2.16
W
system model 9.2, 9.44
Wake-up Mode 9.22
Wake-up values 9.14
T warning 9.51
Warning code 9.23
TA 4.17 Windows operating system 2.2
TB 4.17 Work ON Line 2.15
TCS algorithm 9.5 worm-gears 9.31
TCS Parameters tab 9.14 worst case stopping distance 11.10
Index.IV ICS 5000 Support Software User Manual

Index
write service 5.57

Write Table Configuration 5.65
Write to ICS 2.16
ICS 5000 Support Software User Manual Index.V

Index
Index.VI ICS 5000 Support Software User Manual

Reader Comment Form
ICS 5000 Support Software User Manual March 2004
571 701 721 Revision 1.0
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ICS 5000 Support Software

4 Basic Communications Configuration

5 Advanced Communications Configuration

a.ii ICS 5000 Support Software User Manual

7 Motion Control Overview

8 Tools & Utilities

ICS 5000 Support Software User Manual a . i ii

9 TCS Control Algorithm Configuration

10 BCS Control Algorithm Configuration

11 PDM Control Algorithm Configuration

A Commands and Diagnostics

B Advanced Protocol Specifics

a.vi ICS 5000 Support Software User Manual

C Network Configuration Files

ICS 5000 Support Software User Manual a .v ii

ICS 5000 Support Software User Manual 1.1

1.2 Getting Started

1.3 Related Information

1.4 Technical Assistance

1.2 ICS 5000 Support Software User Manual

• Send an e-mail to trimble_support@trimble.com.

1.5 Your Comments

ICS 5000 Support Software User Manual 1.3

1.4 ICS 5000 Support Software User Manual

ICS 5000 Support Software User Manual 2.1

or the Toolbar shown below.

2.2 Support Computer Requirements

2.2 ICS 5000 Support Software User Manual

2.3 Installing The Software

2.3.1 InstallShield Operation

ICS 5000 Support Software User Manual 2.3

User Information and Destination Folder

2.4 ICS 5000 Support Software User Manual

ICS 5000 Support Software User Manual 2.5

2.6 ICS 5000 Support Software User Manual

Completing the Installation

2.4 Installed Directory Overview

ICS 5000 Support Software User Manual 2.7

2.5 Starting the Software

2.6 Software Overview

2.8 ICS 5000 Support Software User Manual

2.6.1 Menu Bar

From this menu you have the following options:

ICS 5000 Support Software User Manual 2.9

2.10 ICS 5000 Support Software User Manual

From this menu you have the following options:

ICS 5000 Support Software User Manual 2 . 11

2.6.3 Status Bar

2.6.4 Shortcut Key Combinations

2.12 ICS 5000 Support Software User Manual

2.7 Opening An Existing Data File

2.7.1 Existing .i5k Data Files

or from the Toolbar by using the tool.

ICS 5000 Support Software User Manual 2.13

2.7.2 Importing DOS Software .dat Data Files

2.14 ICS 5000 Support Software User Manual

2.8 Going On Line

2.8.1 Establishing Communication

ICS 5000 Support Software User Manual 2.15

2.8.2 Synchronizing Data

2.16 ICS 5000 Support Software User Manual

2.8.3 Working On Line