16 axis motion controller with ethernet (34 pages)
Summary of Contents for Industrial Indexing Systems MSC-250
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SERVO CONTROLLER USER’S GUIDE INDUSTRIAL INDEXING SYSTEMS, Inc. Revision - C Approved By: Proprietary information of Industrial Indexing Systems, Inc. furnished for customer use only. No other uses are authorized without the prior written permission of Industrial Indexing Systems, Inc.
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626 Fishers Run Tel: (585) 924-9181 Victor, New York 14564 Fax: (585) 924-2169 Proprietary information of Industrial Indexing Systems, Inc. furnished for customer use only. No other uses are authorized without the prior written permission of Industrial Indexing Systems, Inc.
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE TABLE OF CONTENTS List of Illustrations......................... v Introduction.......................... vii SECTION 1 - DESCRIPTION Indexing Drive System Overview ............. 1 - 1 System Functions ..................1 - 5 1.2.1 Axis Control ................1 - 5 1.2.1.1...
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IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 SECTION 3 - OPERATION Control Program ..................3 - 1 3.1.1 Programming Considerations ..........3 - 1 3.1.2 Load Macroprogram To Memory ..........3 - 2 3.1.2.1 Load Program From MSC Tool Kit......3 - 3 3.1.2.2...
However, as sold, the MSC-250 controller only includes the controller, a line cord, and manual. All other items are optional ⎯ and must be specified separately ⎯ to allow total design flexibility.
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Industrial Indexing Systems fully supports all equipment it manufactures and supplies. If there are any problems with this equipment or if assistance is required for installation or operation, contact our Integrated Technical Services Department.
USER'S GUIDE SECTION 1 − DESCRIPTION The Industrial Indexing Systems MSC-250 is a microprocessor-based, position-loop servo controller. It is a dual 32-bit technology, 2½-axis, closed-loop servo controller that works with separate servo drives, motors, and encoder feedback devices to accurately fix the position of the motor shaft.
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Actuator: The actuator supplies the signal which causes the controller to initiate the specified sequences. It may be a separate device or part of a computer program from the Input Device.
Feedback Device: The feedback device (always a shaft encoder or equivalent A×B×M signal device with the MSC-250 servo controller) monitors the position of the motor shaft and sends this information to the controller. (Refer to Section 1.2.1.1 for additional details on the feedback device.)
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IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 The components of the basic indexing drive system form two information loops. The position loop is a closed-loop which consists of the controller, drive, motor, and feedback device. The controller, continually compares motor position, derived from the feedback pulses received from the drive, with the desired position calculated within the controller.
Macroprogram control. 1.2.1 AXIS CONTROL The MSC-250 can control one or two motion axes, providing precision position-loop control to each axis. The controller can provide indexing, positioning, cam following, and profiling control. It can also be used as a passive position sensing device. A third axis (referred to as a half axis) can only monitor information received from a master axis or controller or from the pseudo axis.
"following error". The feedback device is an A⋅B⋅M shaft encoder or electronic equivalent. The MSC-250 will accept inputs from a variety of encoders, but each drive system and its corresponding Macroprogram must be designed around a specific encoder line count.
Low line count encoders provide higher speed and acceleration, but resolution is reduced. The standard line count assumed by the MSC-250 controller and the Macroprogram software is 1024 pulses per revolution.
INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 When the absolute position of the system must be known, the system must be initialized after it is powered up. For encoders with marker bits less than 180° of encoder shaft rotation, use the find_mark_cw and find_mark_ccw commands to initialize the system and determine the absolute system position.
1.2.1.4 Master Angle Buses The MSC-250 controller has two master angle buses which can be used for reference by the real axes. The information on the two buses may be the same, although it is usually different, or the buses may not be used at all by the controller. These options are all programmable by the system designer.
1.2.3 INPUT/OUTPUT MODULES The MSC-250 controller has 16 on-board locations for I/O (Input/Output) modules (refer to Figure 1.6). In addition, two IOE-850 I/O Expanders of 16 positions each can be daisy- chained from the INPUT/OUTPUT EXPANDER PORT to provide an additional 32 I/O locations.
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Figure 1.6 - Input/Output Module Locations controller will change the state of the module at the location, as directed by the Macroprogram. Monitoring of each of the module locations is supplied by a status indicator on the front of the controller (refer to "Section 1.3 - Components).
MS-DOS environment to create the necessary program to operate the controller. Industrial Indexing Systems, Inc. provides a software system to assist the designer in creation of these programs. The system is the Macroprogram Development System. This software tool provides an effective environment for creating Macroprograms for the MSC family of motion controllers.
USER'S GUIDE COMPONENTS Figure 1.7 shows the various connectors and status indicators of the MSC-250 controller. Several of the connectors are attached to the printed circuit board of the controller and protrude through the side or bottom of the controller cabinet. These connectors are shown as dotted lines to indicate their relative position, even though they are not really visible from this view.
PORT 2: This 20 mA current-loop serial port is used for communication with the Industrial Indexing Systems' OPI-1 and similar current-loop communications devices. It is accessible through the Macroprogram language for sending and receiving data and commands. (Refer to "Section 2 - Installation"...
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Command Cable Connector: There is one six-pin command cable connector for each real axis controlled by the MSC-250. It is used to communicate indexing commands to the drive amplifier. (Refer to "Section 2 - Installation" for proper cable pin-outs for this connector.)
MOTION CONTROL SYSTEM, MSC-250 Figure 1.8 - ADDRESS and MODE Selector Switches 1.3.3 SELECTOR SWITCHES There are two 16-position rotary selector switches on the MSC-250 circuit board as indicated in Figure 1.8. ADDRESS: This selector switch is used in conjunction with communications PORT 1.
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Position 0 = Normal Operation Position 1 = Test Mode 1 Position 2 = Test Mode 2 Position 3 = Test Mode 3 Position 4 - 9 = Reserved The Ports not mentioned in the following setting definitions stay at their "Normal Operation"...
MOTION CONTROL SYSTEM, MSC-250 1.3.4 TEST POINTS AND LED INDICATORS There are a variety of test points and LED indicators on the MSC-250 circuit board which are used for diagnostic and trouble-shooting purposes (refer to Figure 1.9). Procedures for use of these items are discussed in "Section 4 - Maintenance".
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Encoder Signal Monitor: There is one set of three LED encoder signal indicators for each axis (refer to Figure 1.10 and Figure 1.11). One LED is assigned to each channel of the encoder and illuminates each time the channel generates a pulse.
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Position-error Output Signal: One test point for measuring the following error is provided for each axis (refer to Figure 1.11). J3 is the test point for axis 1 and J5 is the test point for axis 2. (Refer to "Section 4 - Maintenance"...
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Figure 1.13 - Low Input Line Power Indicator DESCRIPTION 1 - 21 MARCH 2003...
National Semiconductor NMC27C256 Signetics 27C256 NOTE The PROM package types shown are those which have been tested by Industrial Indexing Systems, Inc. and found satisfactory for this application. Equivalent PROMs from other manufacturers may also be acceptable. 1.4.4 ANALOG INPUT CHANNELS...
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 DIGITAL FILTERING (Slew Control): Unit Bits per 10 Milliseconds Range (programmable) 1 to 2048 bits Resolution 1 part in 2048 bits 1.4.5 INPUT/OUTPUT MODULES I/O INTERFACE: 16 positions, on-board, discrete 32 positions, on expansion modules (16 Programmable Limit Switches max.)
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE AC INPUT MODULE (IAC15) Input Voltage Range 12 to 140 VAC Input Current at Max. Line 11 ma Input allowed for No Output 3 ma (45 V) Isolation Voltage (Input-to-output)
USER'S GUIDE SECTION 2 − INSTALLATION The MSC-250 servo controller is designed for use in custom indexing systems. Therefore, each installation may vary, depending on the application. The instructions in this section are general guidelines to assist in the design and installation of the controller. Specific cables and optional equipment indicated on the illustrations are for reference only and may not required.
Supply a separate terminal location for connecting incoming 120 VAC electrical power. DO NOT APPLY INCOMING POWER AT THIS TIME! Connect the 110V power cable that is provided for the MSC-250. Plug the connector end of the power cable into the receptacle on the side of the MSC-250 controller.
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Attach the brown and light blue power and the green with yellow stripe neutral wires from the cable to the appropriate terminals on the 120 VAC terminal strip. 2.2.1 INPUT/OUTPUT MODULES Use of input and output modules will depend on the design of the system.
These must be supplied by the customer. An illustration on the bottom of the MSC-250 front panel shows the appropriate connection points for the "A" and "B" terminals of each I/O module location (refer to Figure 2.3).
Connect each wire of cable C-300yyy to the correct terminal of the INT-810 interface module (refer to Figure 2.4) and plug the encoder connector from the INT-810 into the encoder cable connector on the MSC-250 controller. Make sure all wires terminals are tight and that the connector is securely seated.
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 If using the INT-810 interface module, connect the 5 VDC power supply to the proper terminals on the interface module (refer to Figure 2.4). Connect the communications cables from PORT 1, PORT 2, and PORT 3 to their respective communication devices.
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Figure 2.9 Figure 2.8 PORT 3 Pinouts PORT 2 Pinouts Connect the analog input/output channels and reference voltages. Connect the controller end of the cable for the analog input...
USER'S GUIDE SECTION 3 − OPERATION The operation sequence of the MSC-250 servo controller is provided by the Macroprogram stored in its memory. Other than the specific procedures for loading the program into memory and certain setup and test procedures, there is no operator control over the MSC- 250 functions.
3.1.2 LOAD MACROPROGRAM TO MEMORY The MSC-250 has 32,000 bytes of non-volatile memory for storage of the control program. This memory location is protected by a lithium battery to maintain the information when the power is turned off to the controller. Once a control program is loaded into memory, the MSC-250 will continue to use the program until a new program is loaded.
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE 3.1.2.1 Load Program From MSC Tool Kit Turn off all power to the controller. Open the controller cover and set the ADDRESS selector switch to "0" for RS-232C communications (refer to Figure 3.1). For RS-485 communications, set the switch to location "1"...
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IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Make sure the MODE selector switch is set to the desired power-up configuration (refer to Figure 3.1). Normal operation = Port 1, 2, & 3, default to 9600 Baud - Packet Protocol.
Turn on power to the controller. If the first file on the PROM contains a Macroprogram, that Macroprogram will be loaded into memory, execution of the program will begin, and the MSC-250 AUTOSTART bit will be set. In future applications, with the PROM removed, the MSC-250 will start execution of this Macroprogram as soon as power is applied to the controller.
MOTION CONTROL SYSTEM, MSC-250 CONTROLLER USE AND STATUS As discussed in Section 1, the MSC-250 servo controller is extremely flexible in its uses for indexing system control. Depending on how the Macroprogram is written and how the system is designed, it can be used in a variety of applications.
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Figure 3.2 - Main System Status and Fault Codes OPERATION 3 - 7 AUGUST 1998...
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Figure 3.3 - Axis Status and Fault Codes 3 - 8 OPERATION AUGUST 1998...
PERSONNEL TO SERVICE THIS EQUIPMENT. COMPONENT REPLACEMENT Components which may require replacement on the MSC-250 include the battery and the firmware. The battery which protects the non-volatile memory must be replaced whenever the battery voltage drops below 2.6 V. This battery is located at the upper right of the MSC-250 circuit board (refer to Figure 4.1).
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Gently lift the spring clip and replace with a similar type battery. Make sure the contacts are properly oriented. Figure 4.1 - Battery Holder 4.1.2 FIRMWARE REPLACEMENT Each firmware EPROM is located in a 40-pin LIF (Low Insertion-Force) socket on the controller circuit board (refer to Figure 4.2).
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Carefully remove the old processor chip by pulling straight up out of the socket so all sides of the chip move away from the socket evenly. Use of a properly- sized chip removal tool is recommended.
A prerequisite to the use of this troubleshooting guide is a thorough knowledge of the MSC-250 controller. When a problem occurs, first read the appropriate sections of this manual to make sure that the controller is installed properly and that it is being operated correctly.
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Figure 4.3 - Controller Circuit Board Test Points System voltage between the +15 VDC and GND test points should read +15 ±0.15 VDC. System voltage between the -15 VDC and GND test points should read - 15 ±0.15 VDC.
IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 4.2.2 SYSTEM TESTS The tests in this section are designed to be followed sequentially until the problem is found. 4.2.2.1 Velocity Loop Test The velocity loop test removes the controller from the loop for the purpose of testing the motor, drive, and power supply.
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE NOTE Since this is a feedback system, there will always be some slight drift to the motor shaft when it is tested in this manner. However, the motor will not be free to be turned by hand.
NOTE The Position Loop Test assumes a 1024 line encoder. The position loop test is used to verify that the MSC-250 controller and encoder are functioning properly. The controller and encoder are placed in a condition where the encoder signals are fed back to the controller. As the encoder is rotated, a corresponding voltage can be measured at the test points on the controller.
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Continue to turn the motor shaft in a counterclockwise direction. The voltage should increase negatively to -10.0 VDC ±1 VDC. When the motor has been turned 180 degrees from the starting point, the voltage will suddenly change polarity to +10 VDC.
4.2.2.4 Encoder and Power Supply Test This test is used when the INT-810 Interface module is used with the MSC-250 controller. Remove controller and system power. Open the controller cover and set the MODE selector switch to position 3. Close the cover.
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE Move the encoder shaft to find two different voltages. The greater voltage should be no less than +2.5 VDC. The lesser voltage should be no more than -2.5 VDC. If the readings are out of specification, replace the encoder.
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IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Figure 4.5 - Typical System Interconnections 4 - 12 MAINTENANCE AUGUST 1998...
INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE 4.2.2.5 Fiber Optic Light Transmission Test Remove the fiber optic transmission line from the fiber optic receiver. Visually check for the presence of light at the end of the fiber optic cable.
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE APPENDIX A - GLOSSARY Actuator: 1. A device used to supply a signal causing the controller to initiate the specified sequences. A device (such as a motor) which creates mechanical motion by converting various forms of energy to mechanical energy.
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Input/Output. (Pertaining to all equipment and activity that transfers information into or out of a computer or similar device ⎯ such as the MSC-250 controller.) Least Significant Bit: The bit that carries the lowest value or weight in the binary notation for a numeral.
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A multi-axis, programmable, servo motion controller capable of synchronously controlling from 1 to 8 axes. Mode: The way in which the MSC-250 executes instructions. It is determined by the position of a 16-position selector switch. Most Significant Bit: The bit that carries the greatest value or weight in the binary notation for a numeral.
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IB-11B012 INDUSTRIAL INDEXING SYSTEMS, INC. USER'S GUIDE MOTION CONTROL SYSTEM, MSC-250 Programmable Logic Controller: An electronic device that scans on/off type inputs and controls on/off type outputs. The relationship between the inputs and outputs are programmable by the user. Quadrature: When relating to a shaft encoder, indicates that there are two oscillating outputs whose frequencies are 90°...
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INDUSTRIAL INDEXING SYSTEMS, INC. IB-11B012 MOTION CONTROL SYSTEM, MSC-250 USER'S GUIDE APPENDIX B - MACROPROGRAM COMMANDS COMMAND PARAMETERS analog_in controller#,channel#,variable analog_out controller#,channel#,value analog_rt controller#,channel#,value analog_zo controller#,channel#,value begin_cam begin_data blk_io_in input_flag#,variable blk_io_out output_flag#,variable calc_cam_sum controller#,starting element,ending element calc_unit_cam controller#,starting element,ending element value,value,etc.