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Addi-Data CPCI-8004 Commissioning Manual

Positioning and contouring control system
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P
C
OSITIONING AND
ONTOURING
CONTROL SYSTEM
APCI-8001, APCI-8008
AND
CPCI-8004
C
M
/ CM
OMMISSIONING
ANUAL
Manual revision: 15/092015
www.addi-data.com

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Summary of Contents for Addi-Data CPCI-8004

  • Page 1 OSITIONING AND ONTOURING CONTROL SYSTEM APCI-8001, APCI-8008 CPCI-8004 / CM OMMISSIONING ANUAL Manual revision: 15/092015 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: Warning

    Warning! 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

    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 Special notes for the CPCI-8004 ....................10 Limits of use ..........................10 USERS ............................10 2.5.1 Qualification ..........................10 2.5.2 Personal protection equipment ....................10 Handling the board........................11...
  • Page 6 5.2.1 Connector X1: 50-pin SUB-D male connector APCI-8001 / APCI-8008........31 5.2.2 Counting for the 50-pin SUB-D male connector X1 ..............32 5.2.3 Connector X1: 78-pin SUB-D female connector CPCI-8004 ............33 5.2.4 Connector X1: 78-pin SUB-D female connector APCI-8008-STP-EVAI........35 5.2.5 Counting for the 78-pin SUB-D female connector X1 ..............36 5.2.6 Setpoint value channels .......................37...
  • Page 7 ONTENTS 5.2.11 CPCI-8004 pin assignment connector P1, release relay .............46 5.2.12 Connection and wiring instructions ....................46 5.2.12.1 Earth and current supplies....................46 5.2.12.2 Potential equalisation....................46 5.2.12.3 Fitting shields ........................47 Using several xPCI-800x controllers in a PC ................47 APCI-8001 component mounting diagram...................48 APCI-8001 component mounting diagram (bottom side).............49...

  • Page 8: Introduction

    CM / C OMMISSIONING ANUAL Introduction What is this This manual describes how to commission all the necessary system components for manual for? using the xPCI-800x positioning and contouring control system. The complete manual is made up of three parts: OM (Operating Manual), CM (Commissioning Manual) and PM (Programming and Reference Manual).

  • Page 9: Intended Use

    ANUAL Intended use The xPCI-800x motion control boards (APCI-8001, APCI-8008 and CPCI-8004) form the interface between industrial process, automation and drive technology and a personal computer (PC). The board is suitable for use in a PC that has been fitted with free PCI slots. The PC is subject to EU directive 898/336/EEC and must satisfy the corresponding EMC protection requirements.

  • Page 10: Special Notes For The Cpci-8004

    Data exchange between the CPCI-8004 boards and peripherals takes place via a shielded cable. This cable should be connected to the 78-pin SUB-D connector on the CPCI-8004. The CPCI-8004 also has digital outputs for processing 24 V signals. An external 24 V supply voltage is required to operate these outputs.

  • Page 11: Handling The Board

    CM / C OMMISSIONING ANUAL 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] Configuring and wiring the xPCI-800x board [section 5] Settings and planning as described in section 6 and section [OM / section 4.2].

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

    CM / C OMMISSIONING ANUAL Installing and configuring the xPCI-800x TOOLSET software 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 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 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 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)

    CM / C OMMISSIONING ANUAL Value Name Description Customer-specific special version with actual value acquisition through pulse duration measurement ANA_SIGN_SSI Axis with analog manipulated variable output and actual value acquisition through SSI absolute encoder. The analog output signal is always positive; the directional information is output through the digital output.

  • Page 22: Stepper Ndx Motor Type (6)

    CM / C OMMISSIONING ANUAL 3.12.1.5 STEPPER NDX motor type (6) For this motor type, the directional signal is not given to the RS422 outputs Sign+ and Sign- but through the digital output. This digital output must be configured in mcfg (from the version V2.5.3.3) by selecting the option „SIGN SPEC“.

  • Page 23: Virtual Motor Type (13)

    CM / C OMMISSIONING ANUAL The setting of the bearing controller must be done according to the same criteria as with a speed-controlled system. Note: An axis configuration on this motor type can be done only if in RWMOS the resources incremental encoder evaluation and pulse output are available for the specific axis.

  • Page 24: Etm Motor Type (23)

    CM / C OMMISSIONING ANUAL 3.12.1.18 ETM motor type (23) Application-specific motor type with pulse duration measurement for actual value acquisition 3.12.1.19 ANA_SIGN_SSI motor type (24) Axis with analog manipulated variable output and actual value acquisition through SSI absolute encoder (similar to SSI type 2 and ANA_SIGN type 19).

  • Page 25: The Environment Variable Sztsk

    CM / C OMMISSIONING ANUAL If this setting is required for the application, it should also be checked in the application program to avoid faults when the system is reproduced or serviced. This setting is a device option, which is stored in the flash memory of the PCI board.

  • Page 26: The Environment Variable Fbch

    CM / C OMMISSIONING ANUAL Value Oversampling factor Conversion time / µs No oversampling If other values are programmed, oversampling will be deactivated. The default value is 0. Example: set AD7606OS 6 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”...

  • Page 27: 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 28: How To Install The Motion Control Board In The Pc

    (1st LED on the side facing away from the board holder). Must flash when the PC is switched on. CPCI-8004 PC supply voltage 5 V (1st LED seen from the board holder). Must be lit up. PC supply voltage 3.3 V (2nd LED seen from the board holder).

  • Page 29: Installation Under W98

    CM / C OMMISSIONING ANUAL 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: Configuring And Wiring The Motion Control Board

    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 PX8000 screw terminal board can also be used optionally. The CPCI-8004 is connected via a 78-pin SUB-D connector.

  • Page 31: 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+ CHA1- / CLKSSI1- / Actual value 1 ENDATCLK1-...

  • Page 32: 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 33: Connector X1: 78-Pin Sub-D Female Connector Cpci-8004

    CM / C OMMISSIONING ANUAL 5.2.3 Connector X1: 78-pin SUB-D female connector CPCI-8004 Pin Name Group SERVO1 / PULSE1+ Setpoint value 1 / Stepper 1 AGND1 / PULSE1- Setpoint value 1 / Stepper 1 SIGN1+ stepper 1 SIGN1- stepper 1...
  • Page 34 CM / C OMMISSIONING ANUAL Pin Name Group CHB3+ / DATSSI3+ / Actual value 3 ENDAT_Data3+ CHB3- / DATSSI3- / Actual value 3 ENDAT_Data3- NDX3+ Actual value 3 NDX3- Actual value 3 Digital inputs 13-18 (24V) Assignment to axis channels 1, 2, 3 and 4 Digital outputs 7..9 (24V) Assignment to axis channels 1, 2, 3 and 4 GND-D...

  • Page 35: Connector X1: 78-Pin Sub-D Female Connector Apci-8008-Stp-Evai

    CM / C OMMISSIONING ANUAL 5.2.4 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 36: Counting For The 78-Pin Sub-D Female Connector X1

    CM / C OMMISSIONING ANUAL 5.2.5 Counting for the 78-pin SUB-D female connector X1 Bottom / interlocking...

  • Page 37: Setpoint Value Channels

    CM / C OMMISSIONING ANUAL 5.2.6 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 38: Setpoint Value Channel For Servo Motor Axes Apci-8001 / Apci-8008

    CM / C OMMISSIONING ANUAL 5.2.6.1 Setpoint value channel for servo motor axes APCI-8001 / APCI-8008 The analog output signal is used to control a power amplifier, which is activated as a speed or moment controller (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.

  • Page 39: A) Pin Assignment For Connector X1, Axis Channel 1

    CM / C OMMISSIONING ANUAL a) 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 40: Setpoint Value Channels For Cpci-8004

    Reference potential for analog output AGND3 Reference potential for analog output 5.2.6.4 Setpoint value channels for CPCI-8004 On the CPCI-8004 there are four setpoint value channels available. The settings shown above are applied to jumpers J1 to J8. Channel Name Function...

  • Page 41: Endat Absolute Encoder

    CM / C OMMISSIONING ANUAL Furthermore, for the application of SSI absolute encoders, an operating system version (RWMOS.ELF) with the option “option SSI” must be used. The available RWMOS.ELF options can be verified in the “fwsetup” program, on the “Monitor” tab when the control unit is booted. Example: Info: running »...

  • Page 42: Incremental Encoders Without Inverted Signals (Asymmetrical Circuitry)

    CM / C OMMISSIONING ANUAL 5.2.7.4 Incremental encoders without inverted signals (asymmetrical circuitry) It is also possible to process incremental encoders without inverted pulse trains. However, these should only be used in environments that are not subject to severe electromagnetic interference, e.g. in laboratory applications.

  • Page 43: Optical Decoupling Of The Pulse Acquisition Channels

    Incremental signal track B with 90° electrical phase shift to track A CHB3- Inverted incremental signal track B NDX3+ Reference signal track 0 NDX3- Inverted reference signal track 0 5.2.7.7 Pulse acquisition with the CPCI-8004 With the CPCI-8004, four pulse acquisition channels are available. For the assignment, see Chapter 5.2.3...

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

    CM / C OMMISSIONING ANUAL 5.2.8 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 5.2.8.1] and inputs I14…I16 are printed in [section 5.2.8.2]. Name Function Digital input 1 Digital input 2...

  • Page 45: Pin Assignment Connector X1, Digital Outputs (Apci-8001 / Apci-8008)

    The signal assignment is described here for the FB-RELAIS-3000 adapter (SUB-D 9-pin), which is connected to P5 (X6). With the CPCI-8004 it is connected to P1. If there are more than 3 axis channels, the connections might be made via a 25-pin SUB-D connector (see Options Manual).

  • Page 46: Cpci-8004 Pin Assignment Connector P1, Release Relay

    The release relay is activated for the respective selected axis channel by using the cl() command for PCAP and the CL() command for SAP. Note: Depending on the configuration level of the CPCI-8004, 1 to 4 relay outputs are available. The connections could be made via a 25-pin SUB-D connector (see Options Manual).

  • Page 47: Fitting Shields

    CM / C OMMISSIONING ANUAL 5.2.12.3 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 48: Apci-8001 Component Mounting Diagram

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

  • Page 49: Apci-8001 Component Mounting Diagram (Bottom Side)

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

  • Page 50: Apci-8008 Component Mounting Diagram

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

  • Page 51: Apci-8008 Component Mounting Diagram (Bottom Side)

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

  • Page 52: Cpci-8004 Component Mounting Diagram

    CM / C OMMISSIONING ANUAL CPCI-8004 component mounting diagram...

  • Page 53: Apci-8008-Stp-Evai Component Mounting Diagram

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

  • Page 54: Apci-8008-Stp-Evai Component Mounting Diagram (Bottom Side)

    CM / C OMMISSIONING ANUAL 5.10 APCI-8008-STP-EVAI component mounting diagram (bottom side)

  • Page 55: Technical Data Of Apci-8001 / Cpci-8004

    CM / C OMMISSIONING ANUAL 5.11 Technical data of APCI-8001 / CPCI-8004 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...
  • Page 56 24 V power consumption depending on load of the digital outputs Design: Short plug-in boards, x8 multi-layer, 1 slot required CPCI-8004: CompactPCI 100 x 160 (3 HE) PC power supply: 3.3 V/0.8 A, Note: 3.3 V supply voltage is sometimes not provided by older motherboards.

  • Page 57: Settings And Plans

    CM / C OMMISSIONING ANUAL 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 58: Current Amplifier

    CM / C OMMISSIONING ANUAL 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 59: Determining The Coefficients

    CM / C OMMISSIONING ANUAL 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.

This manual is also suitable for:

Apci-8008Apci-8001

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