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Addi-Data APCI-8001 Commissioning Manual

Positioning and contouring control system
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P
C
OSITIONING AND
ONTOURING
CONTROL SYSTEM
APCI-8001
APCI-8008
AND
C
M
/ CM
OMMISSIONING
ANUAL
Manual revision: 16/112018
www.addi-data.com

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Summary of Contents for Addi-Data APCI-8001

  • Page 1 OSITIONING AND ONTOURING CONTROL SYSTEM APCI-8001 APCI-8008 / CM OMMISSIONING ANUAL Manual revision: 16/112018 www.addi-data.com...
  • Page 2 • The standard software must only be used to set up the ADDI-DATA boards • Reproduction of the software is forbidden (except for back-up and for exchange of faulty data carriers) •...
  • Page 3 The following risks result from the improper implementation of the board and from use contrary to the regulations: Personal injury Damage to the board, the PC and peripherals Pollution of the environment. Protect yourself, others and the environment! Read the safety precautions (yellow leaflet) carefully! If this leaflet is not enclosed with the documentation, please contact us and ask for it.

  • Page 5: Table Of Contents

    ONTENTS Warning! ................................3 1 Introduction ..............................8 2 Intended use ..............................9 Special notes for the APCI-8001 and APCI-8008 ................9 Special notes for the APCI-8008-STP-EVAI .................. 9 Limits of use ..........................10 Users ............................10 2.4.1 Qualification ........................10 2.4.2...
  • Page 6 Counting for the 78-pin SUB-D female connector X1 ............. 35 5.2.5 Setpoint value channels ....................36 5.2.5.1 Setpoint value channel for servo motor axes APCI-8001 / APCI-8008 ..37 5.2.5.1.1 Pin assignment for connector X1, axis channel 1 ......37 5.2.5.1.2 Pin assignment for connector X1, axis channel 2 ......
  • Page 7 ONTENTS Basic wiring diagram of xPCI-800x digital inputs I14 … I16 ......43 5.2.7.2 5.2.8 Pin assignment connector X1, digital outputs (APCI-8001 / APCI-8008) ......44 5.2.8.1 Basic wiring diagram of the xPCI-800x digital outputs O1..O8 ....... 44 5.2.9 APCI-8001 pin assignment connector P5, release relay ..........44 5.2.10 Connection and wiring instructions ..................

  • Page 8: Introduction

    Manual) and PM (Programming and Reference Manual). What devices The xPCI-800x range of products are third-generation positioning and contouring belong to the control systems. At present, these include the APCI-8001 and APCI-8008 xPCI-800x range? positioning and contouring control systems. Other remarks Where the functions described in this manual do not apply for all xPCI-800x products, this is marked clearly.

  • Page 9: Intended Use

    This cable must be connected to the 50-pin SUB-D male connector of the APCI-8001 or APCI-8008. The APCI-8001 or APCI-8008 also has digital outputs for processing 24 V signals. An external 24 V supply voltage is required to operate these outputs.

  • Page 10: Limits Of Use

    CM / C OMMISSIONING ANUAL The scope of software is more or less identical to that of the other xPCI-800x boards. However, an interpolation is only possible with the first 4 axes. The SMLA and SMLR commands can be called up for axes 5 and 6 as well, but only as single-axis traversing commands.

  • Page 11: Handling The Board

    CM / C OMMISSIONING ANUAL 2.5 Handling the board Fig. 2.1: How to handle the board correctly Please note: The following procedures must be observed during commissioning: • Installing the xPCI-800x TOOLSET software [section 3] – Installing the board [section 4] •...

  • Page 12: Installing And Configuring The Xpci-800X Toolset Software

    CM / C OMMISSIONING ANUAL 3 Installing and configuring the xPCI-800x TOOLSET software 3.1 Scope of delivery of the xPCI-800x TOOLSET software The xPCI-800x TOOLSET software [TSW] is delivered on a CD. This essentially contains the following parts: • INF file with Miniport device driver •...

  • Page 13: Starting Fwsetup

    CM / C OMMISSIONING ANUAL 3.5 Starting FWSETUP Start the fwsetup.exe application. The following screen output or any identical one should be displayed on the "Monitor" page: The header line of the fwsetup application includes information on the number of identified xPCI-800x controllers and the board type, among other things.

  • Page 14: Setting Up The Mcfg Project Environment

    CM / C OMMISSIONING ANUAL Important note: The RWMOS.ELF and SYSTEM.DAT files are specifically configured for the various module types. The SYSTEM.DAT file can be converted where required. The RWMOS.ELF file requires the right type to be selected from the Toolset software. This also applies to the SYSTEM.DAT file, but where applicable, this file may as well be adapted through conversion using sysconv.exe.

  • Page 15: Booting The Xpci-800X Controller

    CM / C OMMISSIONING ANUAL 3.8 Booting the xPCI-800x controller • Open the dialogue box [Tools][System Boot] • Press the [Boot System] button • After a few seconds, the [System Booted] check box must be marked and the [Online Mode] entry should appear in the header line of the mcfg application.

  • Page 16: Configuration Errors

    CM / C OMMISSIONING ANUAL 3.9 Configuration errors If the following error message is displayed on the screen after you have booted the control system, this is caused by the following: The system file (system.dat) and system data selected in the project, which are stored residually in the flash memory of the xPCI-800x controller control system, are different.

  • Page 17: New Calling Of Fwsetup.exe

    CM / C OMMISSIONING ANUAL 3.10 New calling of fwsetup.exe By calling the program fwsetup again an output identical to the following examples is displayed in the monitor page: In addition to the screen displayed in section 3.5 the footer indicates that rwMos is running. In the monitor window data about the started operating system variant RWMOS.ELF are listed.

  • Page 18: Entering And Storing System Data

    CM / C OMMISSIONING ANUAL 3.11 Entering and storing system data In the next step, you should edit the system data for the axis channel being used in the programm mcfg. To do this, proceed as follows: • The control system must be booted [Online Mode in the header line of the mcfg.exe application] •...

  • Page 19: Control System Hardware Environment Variables

    CM / C OMMISSIONING ANUAL 3.12 Control system hardware environment variables Environment variables can be set in the control system hardware environment, to configure the control system hardware or software. These environment variables are set and reset using the fwsetup.exe configuration program when the system is not booted.

  • Page 20: The Environment Variable Mt (Motortype)

    CM / C OMMISSIONING ANUAL 3.12.1 The environment variable MT (MotorType) This environment variable can adapt the control system to different axis systems. The axis allocation occurs by attaching the axis index to MT (z.B. MT0). The different configurations possible are listed in the table below.

  • Page 21: Ssi Motor Type (2)

    (PWM) as command value. The PWM output has a basic frequency of 20 kHz and a resolution of 3500 steps with the APCI-8001 (3333 steps with the APCI-8008) plus sign and is available as RS422 signal at the pins servo/puls+ and AGND/puls-. For this option a specific firmware RWMOS.ELF is necessary.

  • Page 22: Stepper Ssi Motor Type (4)

    (PWM) as a manipulated variable. The PWM output has a basic frequency of 20 kHz and a resolution of 3500 steps with the APCI-8001 (3333 steps with the APCI-8008) plus sign. For this option a specific firmware RWMOS.ELF is necessary. In mcfg, this axis has to be set as SERVO.

  • Page 23: Endat Motor Type (11+16)

    CM / C OMMISSIONING ANUAL 3.12.1.10 ENDAT motor type (11+16) For this motor type, an ENDAT absolute value encoder or an incremental encoder for the actual value acquisition can be used. Here you have to distinguish between the Endat versions 2.1 and 2.2 (MT = 11 or MT = 16).

  • Page 24: Ci / Analog And Cd / Analog Motor Types (20+21)

    CM / C OMMISSIONING ANUAL Example: axis, positive manipulated value = output 4, negative manipulated value display is not required set MT1 19 set SIGNOUTPOS1 8 set SIGNOUTNEG1 0 In this case, SIGNOUTNEG1 can also remain undefined. 3.12.1.16 CI / ANALOG and CD / ANALOG motor types (20+21) Motor type with analog manipulated variable output and actual value acquisition through CI (MT 20) or CD (MT 21) variable.

  • Page 25: Ssi_Pulse Motor Type (26)

    CM / C OMMISSIONING ANUAL Example: axis, positive manipulated value = output 4, negative manipulated value display is not required set MT1 24 set SIGNOUTPOS1 8 set SIGNOUTNEG1 0 In this case, SIGNOUTNEG1 can also remain undefined. 3.12.1.21 SSI_PULSE motor type (26) With this motor type, a position control is carried out in the same way as with default servo systems, but with a step direction output.

  • Page 26: Apci-8001: Configuration Of The Analog Input Voltage Ranges

    With the environment variable AD7606RNG, the input voltage range of the available analog inputs can be configured. Here, the configuration cannot be set individually for each channel but for all analog inputs together. Unlike the APCI-8001, there is no longer a unipolar operating mode with the APCI-8008. Instead, the analog inputs have a 16-bit resolution.

  • Page 27: The Environment Variable Fbch

    CM / C OMMISSIONING ANUAL 3.12.7 The environment variable FBCH? Feedback channel: An available analog input can be allocated to an analog actual value channel. This variable is only significant for axes with motor types “ANALOG PWM” (Section 3.12.1.4), “ANALOG / ANALOG”...

  • Page 28: Additional Installation Information For Windows Nt

    PMON.ELF file. • Please note any error messages during programming. • Select the [Monitor] page. • Press the [Soft Reset] button. The monitor should immediately display new screen messages. 3.16 Trouble-shooting E-mail: info@addi-data.com Phone: +49 7229 1847-0...

  • Page 29: How To Install The Motion Control Board In The Pc

    For most PC systems, the results of the PCI plug and play bios are displayed during the boot process. An xPCI-800x controller with the following identity (APCI-8001) should be listed there: Vendor ID: 11AB (hex) and Device ID: 4611 (hex) Windows 95, 98, Me and Windows 2000 automatically recognises the xPCI-800x board.

  • Page 30: Installation Under W98

    CM / C OMMISSIONING ANUAL Sub-component insertion diagram (soldered side) of the APCI-8001 Must flash when the PC is switched on. Freely programmable Freely programmable Freely programmable 4.1.1 Installation under W98 If the board is displayed in the device manager with an exclamation mark: - Select it with the right mouse key and select properties : Driver –...

  • Page 31: Configuring And Wiring The Motion Control Board

    Hardware interfaces, connection assignments Depending on the level of completion, the peripheral electronics are connected to the APCI-8001 / APCI-8008 via a 50-pin SUB-D connector (X1). For rapid and simple wiring, an ST8001 connection cable and...

  • Page 32: Connector X1: 50-Pin Sub-D Male Connector Apci-8001 / Apci-8008

    CM / C OMMISSIONING ANUAL 5.2.1 Connector X1: 50-pin SUB-D male connector APCI-8001 / APCI-8008 Pin Name Group SERVO1 / PULSE1+ Setpoint value 1/stepper 1 AGND1 / PULSE1- Setpoint value 1/stepper 1 CHA1+ / CLKSSI1+ / Actual value 1 ENDATCLK1+...

  • Page 33: Counting For The 50-Pin Sub-D Male Connector X1

    CM / C OMMISSIONING ANUAL Pin Name Group Digital inputs 9-16 (24V) Assignment to axis channel 1, 2 and 3 Faster latch input axis channel 1 Faster latch input axis channel 2 Faster latch input axis channel 3 GND-D Reference potential for all signal sources. These include digital inputs and outputs and the transmitter actual value.

  • Page 34: Connector X1: 78-Pin Sub-D Female Connector Apci-8008-Stp-Evai

    CM / C OMMISSIONING ANUAL 5.2.3 Connector X1: 78-pin SUB-D female connector APCI-8008-STP-EVAI Row 1 Pins 1-20 Row 2 Pins 21–39 Row 3 Pins 40–59 Row 4 Pins 60–78 Puls+ CH1 21 Puls– CH1 40 Sign+ CH1 60 Sign– CH1 CHA+ CH1 22 CHA–...

  • Page 35: Counting For The 78-Pin Sub-D Female Connector X1

    CM / C OMMISSIONING ANUAL 5.2.4 Counting for the 78-pin SUB-D female connector X1 ▪ 59 ▪ 20 ▪ 78 ▪ 39 ▪ 58 ▪ 19 ▪ 77 ▪ 38 ▪ 57 ▪ 18 ▪ 76 ▪ 37 ▪ 56 ▪...

  • Page 36: Setpoint Value Channels

    ANUAL 5.2.5 Setpoint value channels Each axis channel of the APCI-8001 or APCI-8008 can be operated as a servo or stepper motor channel. The following configuration table, or the following component insertion diagram, can be used to determine the jumper configuration.

  • Page 37: Setpoint Value Channel For Servo Motor Axes Apci-8001 / Apci-8008

    (current amplifier). The offset of this setpoint value channel is stored in the factory in the non- volatile flash memory of the APCI-8001 and is taken into consideration by the software during output. The analog value output is only supported for SERVO planned axes.

  • Page 38: Pin Assignment For Connector X1, Axis Channel 1

    CM / C OMMISSIONING ANUAL 5.2.5.2.1 Pin assignment for connector X1, axis channel 1 Name Group Description PULSE1+ Stepper 1 Pulse signal PULSE1- Stepper 1 Inverted pulse signal SIGN1+ Stepper 1 Directional signal SIGN1- Stepper 1 Inverted directional signal Note: Jumpers J1 and J2 must be bridged in position 1-2, in order for the above-mentioned signals to be available at connector X1.

  • Page 39: Pulse Acquisition Channels

    Reference potential for analog output 5.2.6 Pulse acquisition channels The APCI-8001 / APCI-8008 is fitted with up to three pulse acquisition channels, to which various encoder types, such as linear scales or incremental or absolute encoders can be connected. Two 90° phase-shifted quadrature signals are processed as input signals, with a maximum pulse frequency of 2.0 MHz (optionally...

  • Page 40: Endat Absolute Encoder

    The evaluation electronics on the APCI-8001 / APCI-8008 are based on the RS422 standard and form a signal difference between the inverted and non-inverted input signals. Interference that is linked with transmission lines can thus effectively be suppressed.

  • Page 41: Incremental Encoders Without Inverted Signals (Asymmetrical Circuitry)

    Do not connect pin 41 / X1 Connect pin 41 / X1 Note: The solder jumpers listed in the table are located on the top right-hand corner of the solder side of the APCI-8001 / APCI-8008 board. Component mounting diagram (soldered side) of the APCI-8001...

  • Page 42: Optical Decoupling Of The Pulse Acquisition Channels

    ANUAL 5.2.6.5 Optical decoupling of the pulse acquisition channels All pulse acquisition channels of the APCI-8001 / APCI-8008 are optically decoupled. This is advantageous particularly in an environment that is subject to severe electromagnetic interference. 5.2.6.6 Pin assignment for the pulse acquisition channels with incremental encoders 5.2.6.6.1 Pin assignment X1, channel 1...

  • Page 43: Pin Assignment Connector X1, Digital Inputs (Apci-8001 / Apci-8008)

    CM / C OMMISSIONING ANUAL 5.2.7 Pin assignment connector X1, Digital inputs (APCI-8001 / APCI-8008) The basic wiring diagram of the digital inputs I1..I13 listed below are printed in [section 5.2.7.1] and inputs I14…I16 are printed in [section 5.2.7.2]. Name...

  • Page 44: Pin Assignment Connector X1, Digital Outputs (Apci-8001 / Apci-8008)

    5.2.9 APCI-8001 pin assignment connector P5, release relay At connector P5 of the APCI-8001 (corresponds to X6 on the APCI-8008), relay points are provided for the CNC-ready request and amplifier release. These are ‘normally open’ contacts. After the PC is switched on, all relays are switched off after a reset action or an error.

  • Page 45: Connection And Wiring Instructions

    5.2.10.4 Fitting shields All connections to the APCI-8001 / APCI-8008 must be shielded. The shields must be fitted on both sides on the casing earth wire (not on an internal earth wire, such as pin 50 on X1). Therefore, for SUB-D connectors, massive metal caps (not insulating plastic caps) must be used.

  • Page 46: Using Several Xpci-800X Controllers In A Pc

    Be very cautious at multi-thread-applications because due to a thread-change, the execution of the program codes can be switched at any time. A thread-switch during access to the APCI-8001 / APCI-8008 must be avoided, if after a thread-switch an other than the currently selected device shall be called.

  • Page 47: Apci-8001 Component Mounting Diagram

    CM / C OMMISSIONING ANUAL 5.4 APCI-8001 component mounting diagram...

  • Page 48: Apci-8001 Component Mounting Diagram (Bottom Side)

    CM / C OMMISSIONING ANUAL 5.5 APCI-8001 component mounting diagram (bottom side)

  • Page 49: Apci-8008 Component Mounting Diagram

    CM / C OMMISSIONING ANUAL 5.6 APCI-8008 component mounting diagram...

  • Page 50: Apci-8008 Component Mounting Diagram (Bottom Side)

    CM / C OMMISSIONING ANUAL 5.7 APCI-8008 component mounting diagram (bottom side)

  • Page 51: Apci-8008-Stp-Evai Component Mounting Diagram

    CM / C OMMISSIONING ANUAL 5.8 APCI-8008-STP-EVAI component mounting diagram...

  • Page 52: Apci-8008-Stp-Evai Component Mounting Diagram (Bottom Side)

    CM / C OMMISSIONING ANUAL 5.9 APCI-8008-STP-EVAI component mounting diagram (bottom side)

  • Page 53: Technical Data Of Apci-8001

    CM / C OMMISSIONING ANUAL 5.10 Technical data of APCI-8001 Axes: 1, 2, or 3. extension up to 8 axes with option print OPMF Mixed operation of servo or stepper motors possible Axis processor: RISC, MIPS R5K range Elementary frequency: 150 MHz (250 MHz Option), word length: 64 Bit Peak instruction rate: 325 Dhrystone 2.1 Mips and 500 MFlops...
  • Page 54 Note: 3.3 V supply voltage is sometimes not provided by older motherboards. 5V/1.0A, Cascading: APCI-8001: up to a total of 8 axes with OPMF option Controller software: PIDF (PID controller with forward compensation) Control times: 1.28 ms (idle time approx. 0.05 ms) Optional approx.

  • Page 55: Settings And Plans

    IHB / I NBETRIEBNAHME ANDBUCH 6 Settings and plans After the xPCI-800x hardware and software components have been installed correctly, the axis and motor- specific settings and plans can be made using the mcfg.exe TSW program, as described in the following sections.

  • Page 56: Current Amplifier

    IHB / I NBETRIEBNAHME ANDBUCH 6.2.2 Current amplifier When using a power module that has been designed as a current amplifier, a PD controller (kp, kd, kpl) is required. To prevent the contouring error during traversing and in the event of static loading of the motor shaft, an additional integral component can also be used here.

  • Page 57: Determining The Coefficients

    IHB / I NBETRIEBNAHME ANDBUCH 6.2.5.1 Determining the coefficients To determine the pre-control coefficients experimentally, first run a short trapezoidal profile, and use the graphical system analysis to assess it, in order to set suitable profile data and scaling parameters. Run the profile with medium acceleration and velocity.

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